Magnetic element integrated with coupled inductor and transformer

Abstract

Provided in the present invention is a magnetic element integrated with a coupled inductor and a transformer. The magnetic element comprises an upper magnetic core and a lower magnetic core, which are arranged in a fitted manner, wherein the lower magnetic core comprises a magnetic cover, M coupled inductor magnetic columns, N transformer magnetic columns and Q side columns, M, N and Q all being integers greater than or equal to 1; the coupled inductor magnetic columns are used for the winding of coupled inductor windings; the transformer magnetic columns are used for the winding of transformer primary windings and transformer secondary windings; the M coupled inductor magnetic columns and the N transformer magnetic columns are arranged in parallel on the magnetic cover; and the Q side columns are arranged on the magnetic cover. By means of the present invention, a magnetic element integrated with a coupled inductor and a transformer is used, so that the volume and weight of the magnetic element can be reduced, the efficiency and power density of a converter can be improved, and the costs of the converter can be reduced.

Description

Integrated coupled inductor and transformer magnetic components Technical Field

[0001] The present invention relates to the technical field of electronic components, and in particular to a magnetic component integrating a coupled inductor and a transformer. Background Art

[0002] In recent years, with the development of the new energy industry, improving the efficiency and power density of charging piles has become extremely important. Discrete inductors and transformers occupy a large volume, weight, and loss, and the wiring is complex and costly.

[0003] In related technologies, although magnetic integration technology is used to integrate inductors and transformers into a magnetic core, thereby reducing the volume and loss of the overall magnetic components and improving the efficiency and power density of the converter, its effect is not sufficient, so there is still room for further improvement in magnetic integration technology. Technical issues

[0004] In order to solve one of the above technical problems, the present invention proposes the following technical solution. Technical Solutions

[0005] An embodiment of the first aspect of the present invention proposes a magnetic element that integrates a coupled inductor and a transformer, comprising an upper magnetic core and a lower magnetic core that are arranged in cooperation with each other, the lower magnetic core comprising a magnetic cover, M coupled inductor magnetic columns, N transformer magnetic columns and Q side columns, wherein M, N and Q are all integers greater than or equal to 1, the coupled inductor magnetic columns are used to wind the coupled inductor winding, the transformer magnetic columns are used to wind the primary winding and the secondary winding of the transformer, the M coupled inductor magnetic columns and the N transformer magnetic columns are arranged in parallel on the magnetic cover, and the Q side columns are arranged on the magnetic cover.

[0006] In addition, the magnetic component integrating the coupled inductor and the transformer according to the above embodiment of the present invention may further have the following additional technical features.

[0007] According to one embodiment of the present invention, the upper magnetic core and the lower magnetic core have the same structure and are symmetrically arranged.

[0008] According to one embodiment of the present invention, the upper magnetic core and the lower magnetic core have different structures.

[0009] According to one embodiment of the present invention, the upper magnetic core includes a magnetic cover.

[0010] According to an embodiment of the present invention, air gaps are provided on the coupled inductor magnetic column and the transformer magnetic column.

[0011] According to one embodiment of the present invention, the 2X-turn coupled inductor winding is wound as a whole on M of the coupled inductor magnetic columns, and the Y-turn transformer primary winding and the Z-turn transformer secondary winding are wound as a whole on N of the transformer magnetic columns, wherein X, Y and Z are all integers greater than or equal to 1, and the winding directions of the coupled inductor winding and the transformer primary winding are the same or opposite.

[0012] According to one embodiment of the present invention, when the number of turns of the coupled inductor winding and the primary winding of the transformer is the same, a set of windings is wound as a whole around M of the coupled inductor magnetic columns and N of the transformer magnetic columns; when the number of turns of the coupled inductor winding is less than the number of turns of the primary winding of the transformer, a set of 2X-turn windings is wound as a whole around M of the coupled inductor magnetic columns and N of the transformer magnetic columns, and another set of Y-2X-turn windings is wound as a whole around N of the transformer magnetic columns; when the number of turns of the coupled inductor winding is greater than the number of turns of the primary winding of the transformer, a set of Y-turn windings is wound as a whole around M of the coupled inductor magnetic columns and N of the transformer magnetic columns, and another set of 2X-Y-turn windings is wound as a whole around M of the coupled inductor magnetic columns.

[0013] According to one embodiment of the present invention, M coupled inductor magnetic columns and N transformer magnetic columns form a combination, and there are three groups of the combination, which serve as A-phase coupled inductor and transformer, B-phase coupled inductor and transformer, and C-phase coupled inductor and transformer respectively.

[0014] According to an embodiment of the present invention, the A-phase coupled inductor and transformer, the B-phase coupled inductor and transformer, and the C-phase coupled inductor and transformer are arranged horizontally, vertically, or in a herringbone pattern.

[0015] According to one embodiment of the present invention, the Q side columns are arranged around or in the middle of the A-phase coupled inductor and transformer, the B-phase coupled inductor and transformer, and the C-phase coupled inductor and transformer. Beneficial effects

[0016] The technical solution of the embodiment of the present invention uses a magnetic component that integrates a coupled inductor and a transformer, which can reduce the volume and weight of the magnetic component, improve the efficiency and power density of the converter, and reduce the cost of the converter. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG1 is a cross-sectional view of the lower magnetic core of a magnetic component integrating a coupled inductor and a transformer according to an embodiment of the present invention.

[0018] FIG2A is a schematic structural diagram of a magnetic component integrating a coupled inductor and a transformer according to an embodiment of the present invention.

[0019] FIG2B is a schematic structural diagram of a magnetic component integrating a coupled inductor and a transformer according to another embodiment of the present invention.

[0020] FIG3A is a schematic diagram of a 2X-turn coupled inductor winding and a Y-turn transformer primary winding in the same direction according to an embodiment of the present invention.

[0021] FIG3B is a schematic diagram of reverse winding arrangements of a 2X-turn coupled inductor winding and a Y-turn transformer primary winding according to an embodiment of the present invention.

[0022] FIG4 is a schematic diagram of winding arrangement when the number of turns of the coupled inductor winding and the primary winding of the transformer are the same according to an example of the present invention.

[0023] FIG5A is a cross-sectional view of a lower magnetic core for three-phase integration by laterally extending the magnetic core according to an embodiment of the present invention.

[0024] FIG5B is a cross-sectional view of a lower magnetic core for three-phase integration by longitudinally extending the magnetic core according to an embodiment of the present invention.

[0025] FIG5C is a cross-sectional view of a lower magnetic core for three-phase integration through a herringbone-shaped extended magnetic core according to an embodiment of the present invention.

[0026] FIG6 is a schematic structural diagram of a single-phase magnetic element according to a first specific example of the present invention.

[0027] FIG7 is a schematic structural diagram of a single-phase magnetic element according to a second specific example of the present invention.

[0028] FIG8 is a schematic structural diagram of a single-phase magnetic element according to a third specific example of the present invention.

[0029] FIG9 is a schematic structural diagram of a three-phase magnetic element obtained by horizontally expanding FIG6 .

[0030] FIG10 is a schematic structural diagram of a three-phase magnetic element obtained by longitudinally expanding FIG6 .

[0031] Figure markings: 1. Lower magnetic core; 2. Upper magnetic core; 11. Magnetic cover; 12. Coupled inductor magnetic column; 13. Transformer magnetic column; 14. Side column; 15. Coupled inductor winding; 16. Transformer primary winding; 17. Transformer secondary winding; 15A. A-phase coupled inductor winding; 16A. A-phase transformer primary winding; 17A. A-phase transformer secondary winding; 15B. B-phase coupled inductor winding; 16B. B-phase transformer primary winding; 17B. B-phase transformer secondary winding; 15C. C-phase coupled inductor winding; 16C. C-phase transformer primary winding; 17C. C-phase transformer secondary winding. Best Mode for Carrying Out the Invention

[0032] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0033] In order to solve the problems of large volume, large loss and high cost in related technologies, the embodiments of the present invention adopt magnetic integration technology, which can not only integrate the coupled inductor and transformer into a magnetic core, but also flexibly adjust the number of turns and winding direction of the winding, optimize the magnetic density distribution, further reduce the winding loss and core loss, reduce the volume and weight, reduce the cost, and further improve the efficiency and power density of the converter.

[0034] FIG1 is a cross-sectional view of the lower magnetic core of a magnetic component integrating a coupled inductor and a transformer according to an embodiment of the present invention.

[0035] FIG2A is a schematic structural diagram of a magnetic component integrating a coupled inductor and a transformer according to an embodiment of the present invention.

[0036] FIG2B is a schematic structural diagram of a magnetic component integrating a coupled inductor and a transformer according to another embodiment of the present invention.

[0037] As shown in Figures 1, 2A and 2B, the magnetic elements of the integrated coupled inductor and transformer include an upper magnetic core 2 and a lower magnetic core 1 that are arranged in cooperation with each other. The lower magnetic core 1 includes a magnetic cover 11, M coupled inductor magnetic columns 12, N transformer magnetic columns 13 and Q side columns 14, wherein M, N and Q are all integers greater than or equal to 1, the coupled inductor magnetic columns 12 are used to wind the coupled inductor winding, and the transformer magnetic columns 13 are used to wind the primary winding and the secondary winding of the transformer. The M coupled inductor magnetic columns 12 and the N transformer magnetic columns 13 are arranged in parallel on the magnetic cover 11, and the Q side columns 14 are arranged on the magnetic cover 11.

[0038] It should be noted that the coupled inductor magnetic column 12 and the transformer magnetic column 13 can be first set on the magnetic cover 11, and then Q side columns 14 can be set at other positions of the magnetic cover 11. For example, the Q side columns 14 are set around the M coupled inductor magnetic columns 12 and the N transformer magnetic columns 13 as a whole, that is, the Q side columns 14 fully surround or partially surround the M coupled inductor magnetic columns 12 and the N transformer magnetic columns 13. Referring to Figure 1, the side columns 14 are used to provide a freewheeling path; or other positions other than the M coupled inductor magnetic columns 12 and the N transformer magnetic columns, such as the middle, the surrounding, etc., as long as they do not conflict with the position of the magnetic columns, the side columns 14 are used to provide a freewheeling path. Referring to Figures 2A and 2B, the number of side columns can be two, symmetrically arranged on the left and right sides or the front and rear sides of all the magnetic columns as a whole, that is, a side column 14 is set at one end and the other end of the front-to-back direction or the left-to-right direction of the magnetic cover 11.

[0039] 1 , 2A and 2B , M coupled inductor magnetic columns 12 are arranged in one column (with equal or unequal spacing), and N transformer magnetic columns 13 are arranged in another column (with equal or unequal spacing), which are arranged on the surface of the magnetic cover 11 and may be in a matrix structure.

[0040] The cross-section of each magnetic column and side column can be circular, square, polygonal, etc. The shape of the magnetic cover 11 can be a cube, column, etc.

[0041] Specifically, the coupled inductor magnetic column 12 is wound with several turns of coupled inductor windings, and the transformer magnetic column 13 is wound with several turns of transformer primary windings and transformer secondary windings. The lower magnetic core 1 and the upper magnetic core 2 are arranged in cooperation with each other (covering each other up and down) to obtain a magnetic element integrating the coupled inductor and the transformer, wherein M coupled inductor magnetic columns 12 and N transformer magnetic columns 13 form a group of coupled inductors and transformers. When the magnetic element has one group of coupled inductors and transformers, the magnetic element is a single-phase magnetic element; when the magnetic element has three groups of coupled inductors and transformers, the magnetic element is a three-phase magnetic element, wherein the two groups of coupled inductors and transformers are expanded from one group of coupled inductors and transformers.

[0042] If M, N or Q is greater than 1, the eddy current effect of the magnetic flux can be weakened, the utilization rate of the magnetic conductive area of ​​the magnetic column can be improved, and the core loss can be reduced.

[0043] In the converter circuit topology of the embodiment of the present invention, the coupled inductor is connected to the transformer.

[0044] Compared to related technologies, embodiments of the present invention can integrate a single-phase or three-phase coupled inductor and transformer. Compared to separate coupled inductors and transformers, these devices have a smaller size and weight, thereby increasing the power density of the converter. The integrated coupled inductor and transformer design facilitates adjustment of the number and direction of turns in the coupled inductor and transformer windings, optimizing magnetic flux density distribution, reducing winding and core losses, and minimizing size and cost. Core losses can be further reduced by flexibly adjusting the position and number of magnetic columns or side columns (i.e., M, N, or Q).

[0045] Therefore, the magnetic component integrating the coupled inductor and the transformer in the embodiment of the present invention integrates the coupled inductor and the transformer to obtain the magnetic component, which not only has a smaller volume and weight, but also has lower loss and cost.

[0046] In one embodiment of the present invention, the upper magnetic core 2 and the lower magnetic core 1 have the same structure and are symmetrically arranged, that is, the upper magnetic core 2 and the lower magnetic core 1 are symmetrical structures.

[0047] Specifically, referring to Figure 2A, the upper magnetic core 2 and the lower magnetic core 1 both include a magnetic cover 11, M coupled inductor magnetic columns 12, N transformer magnetic columns 13 and two side columns 14 arranged on the left and right sides of the magnetic cover 1. The magnetic columns and side columns arranged on the two magnetic cores have the same height.

[0048] As a result, magnetic integration can be achieved through two completely identical magnetic cores, which can save molds and reduce costs.

[0049] In another embodiment of the present invention, the upper magnetic core 2 and the lower magnetic core 1 have different structures, that is, the upper magnetic core 2 and the lower magnetic core 1 have an asymmetric structure.

[0050] Furthermore, the upper magnetic core 2 includes a magnetic cover.

[0051] Specifically, the structure of the upper magnetic core 2 is different from that of the lower magnetic core 1. For example, referring to FIG. 2B , the upper magnetic core 2 may include only a magnetic cover. In addition, the upper magnetic core 2 may also have other structures that are different from the structure of the lower magnetic core 1. For example, the heights of the magnetic columns of the upper magnetic core 2 and the lower magnetic core 1 are different, and the number and height of the side columns of the upper magnetic core 2 and the lower magnetic core 1 are different. The structure of the upper magnetic core 2 can be specifically determined according to actual needs and is not limited in this embodiment of the present invention.

[0052] In one embodiment of the present invention, air gaps are provided on the coupled inductor magnetic column 12 and the transformer magnetic column 13. These air gaps can be centralized (at the ends of the magnetic columns, as shown in FIG2A ) or distributed (located anywhere along the magnetic columns, such as in the middle). The side columns 14 may not have air gaps.

[0053] Specifically, the magnetizing inductance of the transformer or the inductance of the coupled inductor can be controlled by adjusting the length of the centralized air gap or the distributed air gap. The air gap lengths of the coupled inductor magnetic column 12 and the transformer 13 can be the same or different.

[0054] In one embodiment of the present invention, 2X turns of coupled inductor windings are wound as a whole on M coupled inductor magnetic columns 12, and Y turns of transformer primary windings and Z turns of transformer secondary windings are wound as a whole on N transformer magnetic columns 13, where X, Y and Z are all integers greater than or equal to 1, and the winding directions of the coupled inductor windings and the transformer primary windings are the same or opposite.

[0055] "Entirely wound around an object" means treating the object as a whole magnetic column and winding the winding around the whole column. For example, "entirely wound around M coupled inductor columns" means treating the M coupled inductor columns as a whole and winding the winding around the M coupled inductor columns, rather than winding them separately.

[0056] Specifically, as shown in Figure 3A, all the coupled inductor magnetic columns 12 are regarded as an integral magnetic column, and the 2X-turn coupled inductor winding 15 is wound on the integral magnetic column, that is, the coupled inductor winding 15 surrounds all the coupled inductor magnetic columns 12; all the transformer magnetic columns 13 are regarded as an integral magnetic column, the Y-turn transformer primary winding 16 is wound on the integral magnetic column, and the Z-turn transformer secondary winding 17 is also wound on the integral magnetic column, and the 2X-turn winding 15 has the same winding direction as the Y-turn winding 16.

[0057] As shown in Figure 3B, all the coupled inductor magnetic columns 12 are regarded as an integral magnetic column, and the 2X-turn coupled inductor winding 15 is wound on the integral magnetic column, that is, the coupled inductor winding 15 surrounds all the coupled inductor magnetic columns 12; all the transformer magnetic columns 13 are regarded as an integral magnetic column, the Y-turn transformer primary winding 16 is wound on the integral magnetic column, and the Z-turn transformer secondary winding 17 is also wound on the integral magnetic column, and the winding direction of the 2X-turn winding 15 is opposite to that of the Y-turn winding 16.

[0058] In FIG3A and FIG3B , the magnetic element has two side columns symmetrically arranged on the upper and lower sides of the magnetic cover.

[0059] For example, 2 turns of coupled inductor winding are wound on 3 coupled inductor magnetic columns 12 as a whole, 2 turns of transformer primary winding and 2 turns of transformer secondary winding are wound on 3 transformer magnetic columns as a whole, and the winding direction of 2 turns of transformer primary winding is opposite to that of 2 turns of coupled inductor winding.

[0060] Therefore, the introduction of multiple magnetic columns can fully optimize the magnetic flux path. When the winding directions of the coupled inductor winding and the primary winding of the transformer are opposite, the magnetic fluxes can cancel each other out, thereby reducing the core loss and improving the efficiency of the converter.

[0061] In one example of the present invention, when the number of turns of the coupled inductor winding 15 and the transformer primary winding 16 is the same, one set of windings is wound as a whole around the M coupled inductor magnetic columns 12 and the N transformer magnetic columns 13; when the number of turns of the coupled inductor winding 15 is less than the number of turns of the transformer primary winding 16, one set of 2X-turn windings is wound as a whole around the M coupled inductor magnetic columns 12 and the N transformer magnetic columns 13, and another set of Y-2X (Y minus 2X)-turn windings is wound as a whole around the N transformer magnetic columns 13; when the number of turns of the coupled inductor winding 15 is greater than the number of turns of the transformer primary winding 16, one set of Y-turn windings is wound as a whole around the M coupled inductor magnetic columns 12 and the N transformer magnetic columns 13, and another set of 2X-Y (2X minus Y)-turn windings is wound as a whole around the M coupled inductor magnetic columns 12.

[0062] The overall winding around the M coupled inductor magnetic columns 12 and the N transformer magnetic columns 13 refers to treating the M coupled inductor magnetic columns 12 and the N transformer magnetic columns 13 (ie, all magnetic columns) as a whole magnetic column and winding a set of windings around the whole magnetic column.

[0063] Specifically, for a single-phase magnetic component, according to the size relationship between 2X and Y, it is determined whether to use two sets of windings or three sets of windings. Each set of windings can be realized by Litz wire, multi-strand enameled wire, flat wire, or PCB winding, etc.

[0064] As shown in Figure 4, if 2X = Y, a single set of windings can be used to wind 2X (or Y) turns on all coupled inductor posts 12 and transformer posts 13 as a whole, that is, all coupled inductor posts 12 and transformer posts 13 are regarded as a whole post, and a single set of windings is wound around this whole post to enclose all the posts. Therefore, at this time, only two sets of windings are used, that is, the coupled inductor winding 15 and the primary winding 16 of the transformer share a single set of windings with 2X (or Y) turns, and the secondary winding of the transformer uses another set of windings with Z turns. In Figure 4, the magnetic component has 2 side posts 14, which are symmetrically arranged on the upper and lower sides of the magnetic cover.

[0065] If 2X < Y, a single set of windings can be used to wind 2X turns on all coupled inductor posts 12 and transformer posts 13 as a whole, that is, all coupled inductor posts 12 and transformer posts 13 are regarded as a whole post, and a single set of windings is wound around this whole post to enclose all the posts. Then, another set of windings with Y - 2X turns is wound on all transformer posts 12 to enclose all the transformer posts 12. Therefore, at this time, three sets of windings are used, that is, the coupled inductor winding 15 and the primary winding 16 of the transformer share a single set of windings with 2X turns, the primary winding 16 of the transformer also uses another set of windings with Y - 2X turns, and the secondary winding of the transformer uses another set of windings with Z turns.

[0066] If 2X > Y, a single set of windings can be used to wind Y turns on all coupled inductor posts 12 and transformer posts 13 as a whole, that is, all coupled inductor posts 12 and transformer posts 13 are regarded as a whole post, and a single set of windings is wound around this whole post to enclose all the posts. Then, another set of windings with 2X - Y turns is wound on all coupled inductor posts 12 to enclose all the coupled inductor posts 12. Therefore, at this time, three sets of windings are used, that is, the coupled inductor winding 15 and the primary winding 16 of the transformer share a single set of windings with Y turns, the coupled inductor winding 15 also uses another set of windings with 2X - Y turns, and the secondary winding of the transformer uses another set of windings with Z turns.

[0067] When 2X = Y, using a single winding to realize the primary side of the transformer and the coupled inductor completely can reduce the winding length by about 30% compared with other methods such as winding separately, thereby reducing the winding loss and improving the efficiency of the converter. When 2X ≠ Y, using a single winding to partially realize the primary side of the transformer and the coupled inductor can reduce the winding length by about 20% compared with other methods such as winding separately, thereby reducing the winding loss and improving the efficiency of the converter.

[0068] Therefore, the coupled inductor winding and the transformer primary winding share a set of windings, which can reduce the winding length, reduce the winding loss, and improve the efficiency of the converter.

[0069] The above magnetic integration solution is for single-phase magnetic components. For three-phase magnetic components, M coupled inductor magnetic columns 12 and N transformer magnetic columns 13 can be expanded as a group of expansion objects to obtain three groups of M coupled inductor magnetic columns 12 and N transformer magnetic columns 13 to obtain a three-phase magnetic component.

[0070] That is, in one embodiment of the present invention, M coupled inductor magnetic columns and N transformer magnetic columns form a combination, and there are three groups of combinations, which serve as A-phase coupled inductor and transformer, B-phase coupled inductor and transformer, and C-phase coupled inductor and transformer respectively.

[0071] Furthermore, as shown in FIG5A , FIG5B and FIG5C , the A-phase coupled inductor and transformer, the B-phase coupled inductor and transformer, and the C-phase coupled inductor and transformer are arranged horizontally, vertically or in a herringbone shape.

[0072] Specifically, to obtain a three-phase magnetic component, the single-phase magnetic component can be expanded to obtain three groups of M coupled inductor magnetic columns 12 and N transformer magnetic columns 13, namely a three-phase coupled inductor and transformer, with each phase of the coupled inductor and transformer including M coupled inductor magnetic columns and N transformer magnetic columns. The three-phase magnetic integration expansion method can be horizontal expansion as shown in Figure 5A, vertical expansion as shown in Figure 5B, or herringbone expansion as shown in Figure 5C. The winding method for each phase in the three-phase magnetic integration solution is the same as that of the single-phase magnetic integration solution.

[0073] During expansion, the position and number of the Q side columns 14 can be kept unchanged, or the number and / or position of the Q side columns 14 can be changed according to actual needs. For example, when horizontal expansion is performed and the single-phase magnetic element includes two side columns 14 arranged on the left and right sides of the magnetic cover, referring to Figure 5A, the three-phase magnetic element may also include two side columns 14 arranged on the left and right sides of the magnetic cover; when vertical expansion is performed and the single-phase magnetic element includes two side columns 14 arranged on the upper and lower sides of the magnetic cover, referring to Figure 5B, the three-phase magnetic element may also include two side columns 14 arranged on the upper and lower sides of the magnetic cover.

[0074] In one example of the present invention, Q side columns 14 are arranged around or in the middle of the A-phase coupled inductor and transformer, the B-phase coupled inductor and transformer, and the C-phase coupled inductor and transformer.

[0075] Specifically, Q side columns 14 are arranged at other positions on the magnetic cover except for the A-phase coupled inductor and transformer, the B-phase coupled inductor and transformer, and the C-phase coupled inductor and transformer. For example, they can be located around all coupled inductors and transformers, that is, the Q side columns surround all coupled inductors and transformers, or they can be located in the middle of all coupled inductors and transformers.

[0076] Furthermore, when the A-phase coupled inductor and transformer, the B-phase coupled inductor and transformer, and the C-phase coupled inductor and transformer are arranged in a herringbone shape, Q side columns are provided in the middle of the magnetic cover 11 .

[0077] Specifically, when performing the herringbone expansion, several side columns without air gaps can be placed around or in the middle of each magnetic column. Referring to Figure 5C, a cylindrical side column can be set in the middle position of the magnetic cover 11, that is, Q=1 at this time to provide a freewheeling path.

[0078] Therefore, when the three-phase magnetic components are arranged in a herringbone shape, a side column is set in the middle of the herringbone shape, which can fully utilize the space and reduce the volume of the three-phase magnetic components, thereby reducing losses and improving the efficiency of the converter.

[0079] The following describes the structure of an embodiment of the present invention using a coupled inductor (having one coupled inductor magnetic column) and a center-tapped transformer (having one transformer magnetic column) as examples. Figures 6 through 8 are schematic diagrams of the structure of a single-phase magnetic component, while Figures 9 and 10 are schematic diagrams of the structure of a three-phase magnetic component.

[0080] As shown in Figure 6, the upper magnetic core 2 and the lower magnetic core 1 are identical. The two side legs 14 on the left and right sides have no air gap, while the two magnetic legs 12 and 13 have air gaps. The number of turns of the coupled inductor winding (2X) equals the number of turns of the transformer primary winding (Y). Winding 17 is the transformer secondary winding, with a total of Z turns. Winding 15 (or 16) is a common winding for the coupled inductor and the transformer primary, with a total of 2X (or Y) turns.

[0081] As shown in Figure 7, the upper core 2 and lower core 1 are identical, with two side legs without air gaps and two legs with air gaps. The number of turns in the coupled inductor winding (2X) is greater than the number of turns in the transformer primary winding (Y). Winding 17 is the transformer secondary winding, with a total of Z turns. One set of windings 15 (or 16) is shared between the coupled inductor and the transformer primary, with a total of Y turns. Another set of windings 15 is the coupled inductor winding, with a total of 2X-Y turns. The difference from Figure 6 is that the number of turns in the coupled inductor (2X) is greater than the number of turns in the transformer primary (Y), requiring an additional 2X-Y turns to be wound around the coupled inductor legs.

[0082] As shown in Figure 8, the upper core 2 and lower core 1 are identical, with two side legs without air gaps and two legs with air gaps. The number of turns of the coupled inductor winding (2X) is less than the number of turns of the transformer primary winding (Y). Winding 17 is the transformer secondary winding, with a total of Z turns. One set of windings 15 (or 16) is shared by the coupled inductor and the transformer primary, with a total of 2X turns. Another set of windings 16 is the transformer primary winding, with a total of Y-2X turns. The difference from Figure 6 is that the number of turns of the coupled inductor (2X) is less than the number of turns of the transformer primary (Y), requiring Y-2X additional turns of winding on the transformer legs.

[0083] As shown in Figure 9, the upper core 2 and lower core 1 are identical, with two side legs ungapped and six legs gapped. The number of turns (2X) of each phase's coupled inductor winding equals the number of turns (Y) of the transformer's primary winding. Winding 17A is the secondary winding of the phase A transformer, with a total of Z turns. Winding 15A (or 16A) is a shared winding between the phase A coupled inductor and the transformer primary, with a total of 2X (or Y) turns. Winding 17B is the secondary winding of the phase B transformer, with a total of Z turns. Winding 15B (or 16B) is a shared winding between the phase B coupled inductor and the transformer primary, with a total of 2X (or Y) turns. Winding 17C is the secondary winding of the phase C transformer, with a total of Z turns. Winding 15C (or 16C) is a shared winding between the phase C coupled inductor and the transformer primary, with a total of 2X (or Y) turns. The magnetic core of this embodiment is obtained by lateral expansion of the magnetic core shown in FIG6 , and the winding method is similar to that in FIG6 .

[0084] As shown in Figure 10, the upper core 2 and lower core 1 are identical cores, with two side legs ungapped and six legs gapped. The number of turns (2X) of each phase's coupled inductor winding is equal to the number of turns (Y) of the transformer's primary winding. Winding 17A is the secondary winding of the phase A transformer, with a total of Z turns. Winding 15A (or 16A) is a common winding for the phase A coupled inductor and the transformer primary, with a total of 2X (or Y) turns. Winding 17B is the secondary winding of the phase B transformer, with a total of Z turns. Winding 15B (or 16B) is a common winding for the phase B coupled inductor and the transformer primary, with a total of 2X (or Y) turns. Winding 17C is the secondary winding of the phase C transformer, with a total of Z turns. Winding 15C (or 16C) is a common winding for the phase C coupled inductor and the transformer primary, with a total of 2X (or Y) turns. The difference from FIG. 9 is that the magnetic core is different. The magnetic core of this embodiment is obtained by longitudinally extending the magnetic core shown in FIG. 6 , and the winding method is similar to that of FIG. 6 .

[0085] FIG9 corresponds to FIG5A , and has two side posts disposed on the left and right sides of the magnetic cover; FIG10 corresponds to FIG5B , and has two side posts disposed on the upper and lower sides of the magnetic cover.

[0086] In summary, the embodiments of the present invention can not only integrate the coupled inductor and the transformer into one magnetic core, but also flexibly adjust the number of turns and winding direction of the winding, optimize the magnetic flux distribution, reduce the winding loss and the core loss, reduce the volume, and reduce the cost; it can integrate single-phase or three-phase coupled inductors and transformers, which have a smaller volume and weight than discrete magnetic components, and improve the power density of the converter; it can be achieved through two completely identical magnetic cores, saving molds and reducing costs; it can reduce the winding length, reduce the winding loss, and improve the efficiency of the converter; it can reduce the core loss through magnetic flux cancellation and improve the efficiency of the converter.

[0087] In the description of this specification, the reference terms "one embodiment", "some embodiments", "examples", "specific examples", or "some examples" and the like are intended to mean that the specific features, structures, materials, or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Although the embodiments of the present invention have been shown and described above, it will be understood that the above embodiments are exemplary and are not to be construed as limiting the present invention. Those skilled in the art may make changes, modifications, substitutions, and variations to the above embodiments within the scope of the present invention.

Claims

1. A magnetic component integrating a coupled inductor and a transformer, characterized in that: It comprises an upper magnetic core and a lower magnetic core which are arranged in cooperation with each other, the lower magnetic core comprises a magnetic cover, M coupled inductor magnetic columns, N transformer magnetic columns and Q side columns, wherein M, N and Q are integers greater than or equal to 1, the coupled inductor magnetic columns are used to wind coupled inductor windings, the transformer magnetic columns are used to wind transformer primary windings and transformer secondary windings, the M coupled inductor magnetic columns and the N transformer magnetic columns are arranged in parallel on the magnetic cover, and the Q side columns are arranged on the magnetic cover.

2. The magnetic component of the integrated coupled inductor and transformer according to claim 1, characterized in that: The upper magnetic core and the lower magnetic core have the same structure and are symmetrically arranged.

3. The magnetic component of the integrated coupled inductor and transformer according to claim 1, characterized in that: The upper magnetic core and the lower magnetic core have different structures.

4. The magnetic component integrating coupled inductor and transformer according to claim 3, characterized in that: The upper magnetic core includes a magnetic cover.

5. The magnetic component integrating coupled inductor and transformer according to claim 1, characterized in that: Air gaps are provided on the coupled inductor magnetic column and the transformer magnetic column.

6. The magnetic component integrating coupled inductor and transformer according to claim 1, characterized in that: The 2X turns of coupled inductor winding are wound as a whole on the M coupled inductor magnetic columns, the Y turns of transformer primary winding and the Z turns of transformer secondary winding are wound as a whole on the N transformer magnetic columns, wherein X, Y and Z are all integers greater than or equal to 1, and the winding directions of the coupled inductor winding and the transformer primary winding are the same or opposite.

7. The magnetic component integrating coupled inductor and transformer according to claim 6, characterized in that: When the number of turns of the coupled inductor winding and the primary winding of the transformer is the same, a set of windings is wound around M coupled inductor magnetic columns and N transformer magnetic columns as a whole; When the number of turns of the coupled inductor winding is less than the number of turns of the primary winding of the transformer, a set of 2X turns of winding is wound around M magnetic columns of the coupled inductor and N magnetic columns of the transformer as a whole, and another set of Y-2X turns of winding is wound around N magnetic columns of the transformer as a whole; When the number of turns of the coupled inductor winding is greater than the number of turns of the primary winding of the transformer, a set of Y-turn windings is wound around M coupled inductor magnetic columns and N transformer magnetic columns, and another set of 2X-Y-turn windings is wound around M coupled inductor magnetic columns.

8. The magnetic component integrating a coupled inductor and a transformer according to any one of claims 1 to 7, characterized in that: M of the coupled inductor magnetic columns and N of the transformer magnetic columns form a combination, and there are three groups of the combination, which are respectively used as A-phase coupled inductor and transformer, B-phase coupled inductor and transformer, and C-phase coupled inductor and transformer.

9. The magnetic component integrating a coupled inductor and a transformer according to claim 8, characterized in that: The A-phase coupled inductor and transformer, the B-phase coupled inductor and transformer, and the C-phase coupled inductor and transformer are arranged horizontally, vertically, or in a herringbone shape.

10. The magnetic component integrating coupled inductor and transformer according to claim 9, characterized in that: The Q side columns are arranged around or in the middle of the A-phase coupled inductor and transformer, the B-phase coupled inductor and transformer, and the C-phase coupled inductor and transformer.

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