Transformer and Switch-Mode Power Supply
20200168389 ยท 2020-05-28
Inventors
- Hongbo Zhang (Dongguan, CN)
- Yongjun Dai (Wuhan, CN)
- Xiaosong Liu (Shenzhen, CN)
- Qinghai Wang (Dongguan, CN)
Cpc classification
H01F27/324
ELECTRICITY
International classification
Abstract
A transformer and a switch-mode power supply are provided. The transformer includes: a magnetic core structure; several windings that surround a same magnetic cylinder in the magnetic core structure in a stacked manner, where the several windings include at least one primary-side winding and at least one secondary-side winding; and an electromagnetic shielding layer that is disposed between at least two adjacent windings, where the two adjacent windings are a primary-side winding and a secondary-side winding, and the electromagnetic shielding layer is made of a magnetic material. The electromagnetic shielding layer of the transformer can suppress a noise current of the winding, to reduce noise.
Claims
1. A transformer, comprising: a magnetic core structure: a magnetic cylinder in the core structure, wherein the magnetic cylinder is surrounded by several windings in a stacked manner, and wherein the several windings comprise a primary-side winding and a secondary-side winding; and a first electromagnetic shielding layer coupled to the magnetic cylinder that is disposed between at least two adjacent windings, wherein the at least two adjacent windings are the primary-side winding and the secondary-side winding, and wherein the first electromagnetic shielding layer is made of a magnetic material and is an insulator.
2. The transformer of claim 1, further comprising a second electromagnetic shielding layer that is disposed between every two of the at least two adjacent windings.
3. The transformer of claim 1, further comprising a second electromagnetic shielding layer that is disposed on a surface of a framework and that is wrapped around the magnetic cylinder.
4. The transformer of claim 1, further comprising a second electromagnetic shielding layer that is disposed on a surface of an outermost winding, wherein the outermost winding is the primary-side winding or the secondary-side winding away from the magnetic cylinder.
5. The transformer of claim 1, wherein the primary-side winding and the secondary-side winding alternately surround the magnetic cylinder in the stacked manner.
6. The transformer of claim 1, wherein the several windings further comprise an auxiliary winding, wherein the auxiliary winding surrounds the magnetic cylinder in the magnetic core structure in the stacked manner, and wherein the auxiliary winding is located between the primary-side winding and the secondary-side winding.
7. The transformer of claim 6, further comprising a second electromagnetic shielding layer that is disposed between either the primary-side winding and the auxiliary winding, or the secondary-side winding and the auxiliary winding.
8. The transformer of claim 6, wherein the primary-side winding, the auxiliary winding, and the secondary-side winding alternately surround the magnetic cylinder in the stacked manner.
9. The transformer of claim 1, wherein the magnetic core structure comprises an upper part and a lower part, wherein each part is an E-shaped structure, and wherein the magnetic cylinder is a middle magnetic cylinder in the E-shaped structure.
10. The transformer of claim 1, wherein the first electromagnetic shielding layer is disposed on a winding surface using a pasting process or a coating process.
11. The transformer of claim 1, wherein a first magnetic permeability of the first electromagnetic shielding layer is greater than two.
12. The transformer of claim 11, wherein the first magnetic permeability of the first electromagnetic shielding layer further meets a preset magnetic permeability change curve, and wherein the preset magnetic permeability change curve is configured to reduce a second magnetic permeability of the transformer in an operating frequency band and increase a third magnetic permeability of an electromagnetic interference (EMI) frequency band.
13. The transformer of claim 11, wherein a material of the first electromagnetic shielding layer is ferrite.
14. The transformer of claim 1, wherein the transformer further comprises a metal electromagnetic shielding strip that surrounds a surface of the magnetic core structure in a head-to-tail manner.
15. A switch-mode power supply, comprising: a transformer comprising: a magnetic core structure; a magnetic cylinder coupled to the magnetic core structure, wherein the magnetic cylinder is surrounded by several windings in a stacked manner, and wherein the several windings comprise a primary-side winding and a secondary-side winding; and a first electromagnetic shielding layer disposed between at least two adjacent windings, wherein the at least two adjacent windings are the primary-side winding and the secondary-side winding, and wherein the first electromagnetic shielding layer is made of a magnetic material and is an insulator; wherein the switch-mode power supply does not comprise a Y capacitor.
16. The switch-mode power supply of claim 15, wherein a magnetic permeability of the first electromagnetic shielding layer meets a preset magnetic permeability change curve, wherein the preset magnetic permeability change curve is configured to reduce a second magnetic permeability of the transformer in an operating frequency band and increase a third magnetic permeability of an electromagnetic interference (EMI) frequency band.
17. The switch-mode power supply of claim 15, wherein a material of the first electromagnetic shielding layer is ferrite.
18. A charger, configured to perform terminal power fast charging, wherein the charger comprises: a transformer comprising: a magnetic core structure; a magnetic cylinder coupled to the magnetic core structure, wherein the magnetic cylinder is surrounded by several windings in a stacked manner, wherein the several windings comprise a primary-side winding and a secondary-side winding; and a first electromagnetic shielding layer disposed between at least two adjacent windings, wherein the at least two adjacent windings are the primary-side winding and the secondary-side winding, and wherein the first electromagnetic shielding layer is made of a magnetic material and is an insulator; wherein the charger does not comprise a Y capacitor.
19. The charger of claim 18, wherein a magnetic permeability of the first electromagnetic shielding layer meets a preset magnetic permeability change curve, and wherein the preset magnetic permeability change curve is configured to reduce a second magnetic permeability of the transformer in an operating frequency band and increase a third magnetic permeability of an electromagnetic interference (EMI) frequency band.
20. The charger of claim 18, wherein a material of the first electromagnetic shielding layer is ferrite.
Description
BRIEF DESCRIPTION OF DRAWINGS
[0015]
[0016]
[0017]
[0018]
[0019]
[0020]
[0021]
DESCRIPTION OF EMBODIMENTS
[0022] The following further describes embodiments of this application in detail with reference to accompanying drawings.
[0023] A transformer works by using an electromagnetic induction principle.
[0024] In the foregoing formula, a punctuation indicates that the induced electromotive force always hinders a change of the magnetic flux, N.sub.1 is a quantity of turns of the primary-side winding, and N.sub.2 is a quantity of turns of the secondary-side winding.
[0025] It can be learned that, if the load is connected to the secondary-side winding 103, a current I.sub.2 flows through the load under the action of the electromotive force E.sub.2, to transfer electric energy. It can be learned from the foregoing formulas that values of the induced electromotive forces in the primary-side winding 102 and the secondary-side winding 103 are proportional to a quantity of turns of the windings. Therefore, a voltage can be changed provided that the quantity of turns of the primary-side winding 102 and the quantity of turns of the secondary-side winding 103 are changed. This is a basic working principle of the transformer.
[0026] A coil of the transformer is usually referred to as a winding, and is a circuit part of the transformer. A small transformer usually formed by winding an enameled round copper wire that is insulated, and a transformer with a slightly larger capacity is formed by winding a flat copper wire or a flat aluminum wire. In the transformer, a winding connected to a high-voltage grid is referred to as a high-voltage winding, and a winding connected to a low-voltage grid is referred to as a low-voltage winding. The windings may be classified into two types: a concentric winding and an overlapping winding based on different mutual positions and shapes of the high-voltage winding and the low-voltage winding.
[0027] The concentric winding is a winding that is sleeved around a magnetic core cylinder by using a same cylindrical line on any transverse profile of the magnetic core cylinder. For ease of insulation from a magnetic core structure, the low-voltage winding is always placed inside and is close to the magnetic core cylinder, and the high-voltage winding is placed outside. A specified insulation gap needs to be reserved between the high-voltage winding and the low-voltage winding and between the low-voltage winding and an iron core cylinder. When the low-voltage winding is placed inside and is close to the magnetic core cylinder, because an insulation distance required between the low-voltage winding and the magnetic core cylinder is relatively small, a size of the winding can be reduced, and an external size of the entire transformer is also reduced simultaneously. In addition, both the primary-side winding and the secondary-side winding are wound around a same magnetic cylinder. In comparison with a winding manner shown in
[0028] Concentric windings may be classified into a plurality of types such as a cylindrical winding, a spiral winging, and a continuous winding according to different winding methods. The concentric winding has a simple structure and is easy to manufacture, and a transformer with the concentric winding has a small size. Therefore, the concentric winding is usually used in a transformer of a switch-mode power supply.
[0029] A noise transmission mechanism of a conventional transformer with a concentric winding is shown in
[0030] Based on the working principle and the noise transmission mechanism of the transformer, this embodiment of this application provides a transformer. The transformer is obtained by mainly adding an electromagnetic shielding layer to an existing transformer structure, and the electromagnetic shielding layer may be mounted between different adjacent windings. Because the electromagnetic shielding layer is made of a magnetic material, inductive reactance on a winding surface can be changed, and noise generation on the winding surface is suppressed. Specifically, a main structure of the transformer includes a magnetic core structure, and a primary-side winding and a secondary-side winding that surround a same magnetic cylinder in the magnetic core structure in a stacked manner. There may be one or more primary-side windings and secondary-side windings. The primary-side winding and the secondary-side winding usually alternatively surround a same magnetic cylinder in the electromagnetic structure in the stacked manner. The electromagnetic shielding layer is located between the primary-side winding and the auxiliary winding. The electromagnetic shielding layer may be located between only some adjacent primary-side windings and auxiliary windings, or the electromagnetic shielding layer may be disposed between every two adjacent windings. Certainly, the electromagnetic shielding layer is disposed between every two adjacent windings to reduce noise to a greatest extend.
[0031] The magnetic core structure of the transformer needs to be a magnet loop. A possible design of the magnetic core structure is a conventional hollow-shaped structure, and another possible design is an E-shaped structure. The magnetic core structure is usually a high-frequency magnetic core, and a material may be ferrite, for example, MnZn ferrite, silicon-aluminum ferrite, or an amorphous alloy. In this embodiment of this application, an E-shaped structure is preferably used. As shown in
[0032] With reference to
[0033] In addition, in addition to being mounted between different windings, the electromagnetic shielding layer may also be mounted on an outer surface of an outermost winding, or on an outer surface of an innermost framework. That is, an electromagnetic shielding layer is wrapped around the outer surface of the framework of the innermost winding, and if the outermost winding is a primary-side winding, an electromagnetic shielding layer is mounted on the outer surface of the outermost winding. In this case, noise can be reduced, because the transformer works in the high-frequency environment, and the framework and the outermost winding become conductors in the high-frequency environment. Therefore, a current is generated on the surface of the transformer. Current generation may be suppressed by pasting the electromagnetic shielding layer to the outer surface of the outermost winging or the outer surface of the framework, to implement noise reduction.
[0034] To make the EMI of the transformer meet a standard, a designer tests the magnetic permeability curve of the electromagnetic shielding layer in advance, to obtain a magnetic permeability change curve that can enable the EMI of the transformer to meet a standard. Then, a material provider modulates the electromagnetic shielding material based on the magnetic permeability change curve. The electromagnetic shielding material is mainly a soft magnetic material, and the soft magnetic material is mainly used for magnetic conduction and electromagnetic energy conversion and transmission. Therefore, relatively high magnetic permeability and magnetic induction intensity are required for such materials, and an area and a magnetic loss of a magnetic hysteresis loop are relatively small. Generally, soft magnetic materials can be classified into four categories: (1) an alloy thin band or sheet such as FeNi; (2) an amorphous alloy thin band such as Fe base or Co base; (3) a magnetic medium (also referred to as iron powder core), for example, powers such as FeNi (Mo), FeSiAl, a carbonyl iron powder, and ferrite that are wrapped and bonded by using an electrical insulating medium and then are pressed to form the magnetic medium based on a requirement; and (4) ferrite that includes spinel typeMo.Fe.sub.2o.sub.3; (M represents NiZn/MnZn/MgZ, or the like) and magneto plumbite typeBa.sub.3Me.sub.2Fe.sub.24O.sub.41 (Me represents Co/Ni/Mg/Zn/Cu, and composite parts). Currently, ferrite is commonly used mainly because raw materials are rich and have low costs, and the magnetic permeability change curve is relatively stable.
[0035] The designer may mount, on a winding/framework surface by using a pasting process or a coating process, the electromagnetic shielding material that meets the requirement and that is provided by the material provider. The electromagnetic shielding material may be insulated or may be a conductor. If the electromagnetic shielding material is a conductor, an adhesive tape needs to be pasted first before the conductor is mounted on the winding surface, to ensure that the winding and the electromagnetic shielding material are insulated. Otherwise, there is an electrical connection between the electromagnetic shielding layer and the winding, and a short circuit is caused. If the electromagnetic shielding material is insulated, the electromagnetic shielding material may be processed to be in an adhesive tape form that has adhesiveness. In this way, not only insulation can be implemented, but also a winding coil can be fastened. It can be learned that the electromagnetic material shielding layer can replace the adhesive tape on the winding. Therefore, a process of pasting the insulation tape can be reduced.
[0036] In consideration that the transformer provided in this embodiment of this application is mainly applicable to the switch-mode power supply and a component on a circuit board of the switch-mode power supply needs to provide a working voltage, the transformer provided in this embodiment of this application further includes at least one auxiliary winding that surrounds a same magnetic cylinder in a stacked manner. The auxiliary winding mainly provides a working voltage for the component on the circuit board of the switch-mode power supply. There may be one or more auxiliary windings. The auxiliary winding may be located between the primary-side winding and the secondary-side winding, or may be located on two sides of the primary-side winding and the secondary-side winding. That is, windings that are wound from inside to outside may be separately the secondary-side winding, the auxiliary winding, and the primary-side winding, or may be the secondary-side winding, the primary-side winding, and the auxiliary winding, or may be the auxiliary winding, the secondary-side winding, and the primary-side winding. In this case, the location of the electromagnetic shielding layer may also be between the primary-side winding and the auxiliary winding, or may be between the secondary-side winding and the auxiliary winding.
[0037] Because windings of the transformer include the primary-side winding, the secondary-side winding, and the auxiliary winding, there may be a plurality of windings, there are a plurality of manners in which the windings are stacked, and there are various locations at which the electromagnetic shielding layer is mounted. Therefore, this embodiment of this application provides schematic diagrams of locations shown in
[0038] In
[0039] In
[0040] In
[0041] In
[0042] In
[0043] In
[0044] It should be noted that
[0045] In addition, a metal electromagnetic shielding strip may further surround, in a head-to-tail manner, an outer surface of the magnetic core structure of the transformer provided in this embodiment of this application. As shown in
[0046] In conclusion, in the transformer provided in this embodiment of this application, the electromagnetic shielding layer is added to a winding or a framework, and a high magnetic conduction characteristic of the electromagnetic shielding layer suppresses noise generated by the transformer in a working process, to resolve a problem that EMI exceeds a limit. The transformer may be applied to a scenario such as a de-Y capacitor with a relatively high noise reduction requirement. In addition, the electromagnetic shielding layer provided in this embodiment of this application has very good EMC consistency, because the electromagnetic shielding layer is mounted on a winding surface, and thickness, a length and a width are all easily controlled. In comparison with an existing winding manner, controllability is strong, and therefore, EMC consistency is very good. In addition, the method helps production and processing, EMC performance is relatively good, and an application prospect is broad.
[0047] In the foregoing specific implementations, the objectives, technical solutions, and beneficial effects of this application are further described in detail. It should be understood that different embodiments may be combined, and the foregoing descriptions are merely specific implementations of this application, but are not intended to limit the protection scope of this application. Any combination, modification, equivalent replacement, or improvement made without departing from the spirit and principle of this application shall fall within the protection scope of this application.