Power converter with segmented windings

Abstract

A power converter with segmented windings is provided. The transformer or autotransformer comprises a magnetic core (3) and at least one primary winding (51) and at least one secondary winding (52) arranged around the magnetic core (3). The primary winding and / or the secondary winding has at least one full turn, the at least one full turn comprising at least one power switch (10) and at least one capacitor (12) connected in series and arranged opposite to each other and facing opposite sides of the magnetic core, thereby defining a unit (4) divided into four sections, a first section (23) comprising the at least one switch, a second opposite section (24) comprising the at least one capacitor, and two other connecting sections (21, 22) providing electrical connection between the first section and the second section, and each of the two other connecting sections having opposite electrical polarities.

Description

Technical Field

[0001] The present invention belongs to the field of power converters, which power converters include a transformer or an autotransformer, which is intended to connect a primary port with a secondary port, the primary port including a DC energy source or an AC energy source, and the secondary port including a DC load or an AC load, wherein power can flow bidirectionally, only the energy source and the load are exchanged.

[0002] The invention is based on the integration in at least one turn of a winding wound around the magnetic core of a transformer or autotransformer, of at least one switch and at least one capacitor arranged oppositely, thereby dividing or splitting the at least one turn into four distinguishable segments, i.e. providing a segmented winding.

[0003] The load is further integrated and housed within a magnetic core surrounded by a segmented winding having at least one switch and at least one capacitor on opposite sides.

[0004] In the present invention, the term "cell" is used to refer to a complete / full turn of a winding / coil of a transformer or autotransformer, which includes embedded at least one power switch and at least one capacitor, which are connected in series and arranged opposite to each other and facing opposite sides of the magnetic core. The winding can be a primary winding or a secondary winding.

[0005] In the present invention, the conductor element can be any kind of conductive material, such as copper (Cu), copper alloy, etc. Background Art

[0006] EP1536435A1 discloses a circuit board with holes. Each of the individual magnetic flux paths forms a closed loop that passes through at least one hole and surrounds an interior space. The path includes a portion located within a magnetically permeable core. At least two paths are oriented so that there is a straight line in the circuit board that passes through the interior spaces of the two paths without passing through any holes included in the path. The conductive primary winding has a first section and a second section, the first section passing through the interior space of the permeable path, and the second section being located outside the interior space. There are two or more conductive secondary windings.

[0007] Ionel Dan Jitaru of Rompower Energy Systems Inc. discloses several switching topologies in the technical document "GaN Technology as an enabler for higher efficiency magnetics" and on page 9 mentions leakage inductance in the transformer indicating: "In some applications, additional inductive elements are placed in series with the primary winding to increase the leakage inductance," but does not provide any suggestion about including switches or capacitors within the turns of the primary or secondary windings.

[0008] US20200350117A1 relates to a transformer, comprising: a magnetic core including a plurality of core legs and a leakage core leg, the leakage core leg being positioned among the plurality of core legs to control the leakage inductance of the transformer; and a planar winding structure including a primary winding and a plurality of secondary windings, the primary winding and the plurality of secondary windings having a plurality of turns around the plurality of core legs, and no turns extending around the leakage core leg, to further control the leakage inductance of the matrix transformer. Figure 2 In an example of FIG. 1 , a matrix transformer that can be integrated into a single magnetic core includes a basic transformer in which each of the windings on the secondary side includes a synchronous rectifier and a capacitor connected in series.

[0009] US20150256087A1 discloses a soft switching converter having a dual transformer and at least two primary switching devices, and at least two synchronous rectifiers in the secondary, wherein each of the primary switching devices is turned off when the corresponding synchronous rectifier is turned on. The use of large leakage inductance in the zero voltage switch of the prior art topology is avoided, and it also has soft switches in the primary and secondary, which will turn off the rectifier device at zero current and turn on the primary switch at zero voltage without any additional magnetic elements. The secondary winding of one of the transformers arranged around the magnetic core includes a switch and a capacitor connected in series (see Figure 3 B).

[0010] US201827817A1 discloses a power conversion device, comprising: a first primary circuit having a first primary winding; a second primary circuit having a second primary winding; an inductor having an inductor winding coupled in series with the first primary winding and the second primary winding; a first secondary circuit corresponding to the first primary circuit and having a first secondary winding and a second secondary winding coupled in series; a second secondary circuit corresponding to the second primary circuit and having a third secondary winding and a fourth secondary winding coupled in series; and a magnetic core structure. A flat conductor winding (see Fig.11) of the secondary winding (see Figure 2 ) comprises a switch (which may be, for example, a transistor) operated according to a corresponding switch control signal and an output capacitor connected in series to divide a turn into at least two sections (see Fig.11 ). Summary of the invention

[0011] The invention proposes the segmentation of a winding around a magnetic core, the winding being part of a transformer or autotransformer of a power converter and comprising at least one full turn defining a cell, wherein the at least one cell comprises at least one embedded switch and at least one capacitor, the at least one switch and the at least one capacitor being connected in series and being arranged opposite to each other and facing opposite sides of the magnetic core, respectively. In this way, the cell is divided into four sections, two of which are arranged opposite to each other and integrate the at least one embedded switch and the at least one capacitor, respectively, and the other two sections have opposite electrical polarities and serve as electrical connection elements of the sections with embedded components.

[0012] This arrangement in a cell, with one or more switches and one or more capacitors connected in series, respectively, on opposite sides, and with two connection sections with opposite electrical polarity facing each other around the magnetic core, allows:

[0013] - inserting a load in a hole of a core surrounded by at least one cell and feeding the load from the sections of opposite polarity of the at least one cell;

[0014] - Generate compact 2D or 3D spatial structures consisting of multiple interconnected units;

[0015] - Producing a compact 2D or 3D spatial structure comprising a plurality of interconnected cells, wherein at least some of the cells share a magnetic circuit or a primary winding that powers the cell.

[0016] The winding according to the invention can comprise several units, each of which comprises at least one switch and at least one capacitor, and furthermore, the units are connected in parallel, whereby the current capacity of the power converter can be adjusted, ie is adjustable.

[0017] In a particularly preferred embodiment, the power converter comprises a core grid associated with a plurality of interconnected cells, wherein different cells receive different magnetic circuits. The core grid comprises a plurality of holes, some of which have a capacitor belonging to one of the interconnected cells, and the capacitor is arranged on the side of the hole (the hole can contain one or more capacitors), and these holes with (one or more) capacitors further accommodate a load. The core grid further comprises a power switch of the cell with the capacitor in other adjacent holes, the power switch being arranged on the side of the other adjacent holes.

[0018] The cited load, which is accommodated in the hole and has at least one capacitor on one of the sides of the hole, receives energy from conductive plates arranged above and below the magnetic grid core.

[0019] The invention also relates to several constructive embodiments of at least a portion of a power converter. In an exemplary embodiment, one section of the at least one unit comprising at least one switch is integrated in a first electronic board, and the second section of the unit comprising at least one capacitor is integrated in a second electronic board, and the section of the unit providing the electrical connection of the two sections cited is at least partially arranged in any or separate components of the electronic board.

[0020] Other features of the present invention will be described in the subsequent description of the invention with reference to specific embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 A magnetic core with a flux path indication according to the prior art is schematically shown.

[0022] Figure 2 Schematically shows Figure 1 A magnetic core with an indication of the magnetic flux and a number of cells (each cell comprising a full turn) arranged around the core, around a portion of the magnetic circuit.

[0023] Figure 3 An embodiment with a magnetic core is shown, comprising two windings according to the teaching of the present invention, each of the windings comprising at least one cell with an oppositely arranged power switch and capacitor, and two other windings without or without power switches and capacitors. One of the windings comprising a cell of the present invention receives one of the windings without power switches and capacitors.

[0024] Figure 4 An embodiment of a power converter with a planar winding structure is schematically shown, wherein a winding, such as a transformer, is surrounded by an E-shaped magnetic core. The winding including a segment with an integrated switch is arranged on one side of the magnetic core, and the segment including a capacitor is arranged on the opposite side of the magnetic core, and the connecting segment provides an electrical connection between the segments including switches and capacitors, respectively.

[0025] Figure 5 An embodiment of a unit A consisting of four connecting sections is schematically shown, having a first lateral section including at least one switch, a top section consisting of a conductor element, a second lateral section opposite to the first lateral section including at least one capacitor and a bottom section consisting of a conductor element, and each of the top connecting section and the bottom connecting section has a conductor element having opposite electrical polarities.

[0026] Figure 6 A further unit embodiment is schematically shown, in which the second unit simultaneously accommodates the magnetic circuit and, for example, the previous unit A.

[0027] Figure 7 Schematically shows a similar Figure 5 Another unit embodiment of the unit embodiment further includes a conductor element that enables connection between adjacent units, and the unit embodiment accommodates the conductor element and the magnetic circuit.

[0028] Figure 8 A magnetic core surrounded by a winding in the form of a coil is schematically shown, which core relates to a primary winding and several cells connected in parallel by electrical conductor elements and to a secondary winding of a power converter.

[0029] Fig. 9A A prior art circuit of a power converter is schematically shown.

[0030] Fig. 9B It is schematically shown how, when starting from the circuit of the prior art state of the art on the right, the proposal of the invention is implemented by dividing the secondary winding of the transformer in two connected sections and having switches and capacitors oppositely and directly facing each other in the two remaining sections.

[0031] Fig. 9C schematically shows the unit associated with the load around the magnetic core, and Fig.9D Two cells are shown connected in parallel by means of a conducting plate as in the previous embodiment.

[0032] Fig.10 An embodiment with only one unit 4 is schematically shown, which includes four connecting sections: a first lateral section including a switch, a connecting section consisting of a conductor element, a second lateral section opposite to the first lateral section including a capacitor, and a connecting section consisting of a conductor element, and each of the connecting sections has opposite electrical polarity.

[0033] Fig.11 An arrangement implementing the principles of the invention is schematically shown, forming a spatial structure with a plurality of switches and capacitors, and with conductor elements which in this embodiment are implemented by conductive plates at the top and bottom.

[0034] Fig.12 The simplified perspective view shows the Fig.10 An embodiment similar to the embodiment disclosed in .

[0035] Fig.13 Schematically shows the use of Fig.11An embodiment of the structure of an embodiment has multiple cells wrapped around a magnetic core, and the cells are connected by means of conductive plates with opposite electrical polarities.

[0036] Fig.14 Another embodiment of a winding of a transformer of a power converter of the present invention has several cells around a magnetic core and a winding without switches and capacitors.

[0037] Figures 15A to 15E Several parts of an embodiment are shown in perspective and schematic manner, wherein a magnetic core surrounds conductor elements providing connecting sections sharing a central portion.

[0038] Fig.16A is a perspective view of a magnetic core in the form of a magnetic core grid.

[0039] Fig. 16B The referenced core grid is shown with a number of cells which surround some sides of the holes of the core grid and provide at least one capacitor or at least one switch at these hole sides.

[0040] Fig. 16C Corresponds to an indication having a number of loads accommodated in some holes of the core grid (not all holes accommodate the loads) Fig. 16B , and further includes conductive plates on the upper and bottom sides to enable electrical connection between components (units and loads).

[0041] Fig.16D Corresponding to the indication of a further arrangement with a plurality of switches and capacitors Fig. 16C , and an enlarged portion of the core grid shows the relationship between the load, switches, and capacitors, which surround the load.

[0042] Fig.17A and 17B A possible constructive structure for a power converter comprising a cell (eg a secondary winding and an output of the converter) is shown in perspective, wherein the cell is powered by a primary winding with multiple turns received by the cell. The cell comprises multiple switches and another multiple capacitors.

[0043] Fig. 17C A possible constructive structure for a power converter is shown in a perspective view, the power converter comprising Fig.17A and 17B Two separate setups as described in .

[0044] Fig.17D The perspective view shows Fig. 17C A possible constructive arrangement is described in which the primary winding is shared by two arrangements and therefore there is a common primary current which supplies both arrangements simultaneously.

[0045] Fig.17E The perspective view shows FIG. 17A to FIG. 17D The possibility is given of multiple setups as described in , wherein said setups with shared primary windings may be arranged in a 2D matrix, and even in a 3D cube, and thus be powered by the same common current. DETAILED DESCRIPTION

[0046] refer to Fig.10 , 11 and 12 to better understand the principles of the present invention, Fig.10 , 11 12 shows the primary winding 51 or the secondary winding 52 of the power converter 2 (in the implementation of its Fig. 9B A possible circuit arrangement of such a power converter 2 is shown in ). One such power converter comprises a transformer or autotransformer, comprising a magnetic core 3, a primary winding 51 and a secondary winding 52 arranged around the magnetic core 3, said at least primary winding 51 and said at least secondary winding 52 both having at least one cell 4 comprising one full turn. According to the present invention, at least one cell 4 of the primary winding 51 and / or the secondary winding 52 comprises at least one power switch 10 and at least one capacitor 12, said at least one power switch 10 and said at least one capacitor 12 being arranged opposite to each other and facing opposite sides of the magnetic core 3, respectively. Thus, the cell 4 is divided into four sections: a first section 23 comprising said at least one switch 10, a second directly opposite section 24 comprising said at least one capacitor 12 and two further connecting sections 21, 22, which are intended to provide an electrical connection between the first section 23 and the second section 24, and each of said two further connecting sections 21, 22 has opposite electrical polarity (see Fig.10 ).

[0047] In a general embodiment of the invention, the primary winding 51 and / or the secondary winding 52 of the transformer or autotransformer of the power converter 2 comprises several units 4 (see Figure 2 ), each unit 4 comprises one or several switches 10 and one or more capacitors 12 arranged in space as indicated, and the units 4 involving the same winding 51, 52 are connected in parallel, whereby the current capacity of the power converter 2 is adjustable. The number of switches 10 or capacitors 12 integrated in one unit 4 can be any number and does not have to be equal.

[0048] This arrangement of the switch 10 and the capacitor 12 opposite and facing each other on both sides of the core 3 allows a load 41 to be inserted between them and adjacent to the core 3 and fed from the connection sections 21 , 22 having different electrical polarities.

[0049] like Figures 17A to 17C As shown, the magnetic core 3 may adopt different configurations, so that in the embodiment shown, the magnetic core 3 surrounds a section 23 including several switches 10 .

[0050] In an alternative embodiment, the magnetic core extends around a section 24 including several capacitors 12 .

[0051] In another embodiment, as will be described below Figures 15A to 15E In an embodiment of the present invention, a magnetic core can surround the connecting sections 21 , 22 , providing an electrical connection between the sections 23 and 24 comprising the switch 10 and the capacitor 12 , respectively.

[0052] exist Figure 3 In the illustrated embodiment, the magnetic core 3 further comprises an additional winding 60 without the power switch 10 and the capacitor 12 .

[0053] Figure 4 An embodiment of a power converter 2 having a segment 23 and a segment 24 is shown, wherein the segment 23 includes a switch 10 surrounded by an E-type magnetic core 3, and the segment 24 includes a capacitor 12 arranged opposite to the switch 10 and also surrounded by the E-type magnetic core 3, wherein the segment 23 having the switch 10 and the segment 24 having the capacitor 12 are connected to a conductor passing through the space of each window of the magnetic core 3.

[0054] Figure 5 An embodiment of a unit 4 is schematically shown, the unit 4 consisting of four sections 21, 22, 23 and 24, including a first side section 23 integrating at least one switch 10, a second side section 24 integrating at least one capacitor 12, the two sections 23, 24 facing each other and located on opposite sides of the magnetic core 3, and a top section 21 and a bottom section 22 consisting of a conductor element providing an electrical connection between the first section 23 and the second section 24.

[0055] Figure 6 A specific spatial arrangement is schematically shown, in which a cell 4 associated with either the primary winding 51 or the secondary winding 52 of the power converter 2 receives a cell 4 of the other winding, whereby the leakage energy and leakage inductance of the magnetic assembly are adjustable.

[0056] Figure 7 Schematically shows a similar Figure 5 Another embodiment of the unit 4 of the unit embodiment further comprises a conductor element 11 (see Figure 8 ), the unit 4 embodiment accommodates the conductor element 11 and the magnetic circuit of the magnetic core 3.

[0057] Figure 8Schematically shown is a magnetic core 3 surrounded by primary cells 4 and windings 60 (in the form of coils) of several cells 4 connected in parallel and forming a secondary part 52 of a transformer or autotransformer of a power converter 2. The cells 4 are connected by means of conductor elements 11 (e.g. Figure 7 In this embodiment, the turns of the different windings 60 and 52 are interleaved, whereby the leakage energy and leakage inductance of the magnetic assembly are adjustable.

[0058] Fig. 9B An embodiment of the present invention is shown, compared with the previous technology ( Fig. 9A ), the secondary winding 52 of the transformer is divided into two parts, and the switch 10 and the capacitor 12 of the circuit are arranged oppositely, providing the unit 4 and the load 41 fed from the two separate windings. Fig. 9C In the embodiment, the core 3 is surrounded by four sections 21, 22, 23 and 24 of the unit 4. A further improvement of the structure occurs in Fig.9D In the embodiment, two units 4 are connected in parallel via two conductive plates 42 and 43.

[0059] Fig. 15B and 15C The different parts of the embodiment are shown in perspective view, wherein the magnetic core 3 (see Fig.15A ) are arranged around an inner elongated connection section providing two attached connection sections 22, each of which is opposite to a corresponding outer connection section 21 also formed by an elongated connection section. Each of said cited elongated sections comprises a through-channel 75 through which an electrical connection 76 extends, thereby forming a winding 51, 52 comprising a relative switch 10 and a capacitor 12 according to the invention (see Fig.15E ).

[0060] Figures 16A to 16D An embodiment is shown in which several interconnected units 4 accommodate different magnetic circuits. Fig.16D , see the enlarged part, the magnetic core 3 includes a magnetic core grid 13 with a plurality of holes 40, some holes include a capacitor 12 belonging to one of the interconnected units 4, the capacitor 12 is arranged on the side of the hole 40 (it may include one or more capacitors 12). The hole 40 with the capacitor 12 further accommodates a load 41 (which may be an electronic semiconductor circuit), and the magnetic core grid 13 further includes a power switch 10 of the interconnected unit 4 arranged on the side of the other adjacent holes 40. As shown Fig.16DAs shown, the load 41 receives energy from conductive plates 42, 43 of opposite electrical polarity, forming a core grid 13 assembly sandwiched between the conductive plates 42, 43. The core grid 13 assembly is integrated in an electronic board or in a multi-layer electronic stack. In an alternative embodiment, the core grid 13 assembly is integrated in an electronic semiconductor circuit.

[0061] Fig.17A and 17B In perspective and schematic diagram is shown a constructive embodiment in which a plurality of switches 10 of a cell 4 are integrated in a first electronic board 71 and a plurality of capacitors 12 of the same cell 4 are integrated in a second electronic board 72 and in which the cell 4 of windings receives a further independent winding 60 included in one of the electronic boards 71, 72 or between them (as previously described in Figure 6 shown in ).

[0062] Fig. 17C and 17D Part of a power converter 2 is shown in perspective, which comprises several cells 4 of secondary windings connected in parallel, which are arranged in a structure in which some or all of the cells 4 are powered by a primary winding (indicated by reference numeral 60) of each cell.

[0063] exist Fig.17D In an alternative embodiment, some or all of the cells 4 or all of them are powered simultaneously by a common current from a single primary winding (indicated by reference numeral 60 ) which creates a current loop perpendicular or parallel to the induced current in the secondary windings of the cells 4 .

[0064] Fig.17E Another embodiment of multiple units 4 with secondary windings is shown, which are connected in parallel in a 3D structure arrangement at several relative spatial positions. Fig.17D In the previous embodiments, the units 4 can be powered by a primary winding associated with each of them, or simultaneously by a common current of a single primary winding (indicated by the reference numeral 60) which creates a current loop perpendicular or parallel to the induced current in the secondary windings of the units 4.

Claims

1. A power converter (2) comprising a transformer or an autotransformer, the transformer or the autotransformer comprising a magnetic core (3) and at least one primary winding (51) and at least one secondary winding (52) arranged around the magnetic core (3), characterized in that: The primary winding (51) and / or the secondary winding (52) has at least one full turn, the full turn comprising at least one power switch (10) and at least one capacitor (12), the at least one power switch (10) and the at least one capacitor (12) being connected in series and respectively arranged opposite to each other and facing opposite sides of the magnetic core (3), defining a unit (4); The defining unit (4) is divided into four sections: a first section (23) including the at least one power switch (10), a second relative section (24) including the at least one capacitor (12), and two other connecting sections (21, 22), referred to as a first connecting section (21) and a second connecting section (22), wherein the first connecting section (21) and the second connecting section (22) provide an electrical connection between the first section (23) and the second relative section (24), and the first connecting section (21) and the second connecting section (22) have opposite electrical polarities.

2. The power converter (2) according to claim 1, wherein the magnetic core (3) surrounds the first section (23), the second opposing section (24), the first connecting section (21) or the second connecting section (22).

3. The power converter (2) according to claim 1, wherein the primary winding (51) and / or the secondary winding (52) comprises a plurality of cells (4), wherein each of the cells (4) comprises at least one power switch (10) and at least one capacitor (12), and wherein the cells (4) belonging to the same primary winding (51) or secondary winding (52) are connected in parallel.

4. The power converter (2) of claim 1, wherein the magnetic core (3) further comprises at least one other winding (60) without a power switch (10) and a capacitor (12).

5. The power converter (2) according to claim 3, wherein the at least one power switch (10) and the at least one capacitor (12) of the plurality of units (4) are connected by means of at least two conductive plates (42, 43) receiving the magnetic core (3), the conductive plates (42, 43) providing the first connection section (21) or the second connection section (22).

6. The power converter (2) according to claim 1, wherein: It is implemented as a DC / DC or AC / DC or AC / AC or AC / DC power converter.

7. The power converter (2) according to claim 4, wherein the turns of the primary winding (51), the secondary winding (52) and the further winding (60) are interleaved, whereby the leakage energy and the leakage inductance of the magnetic core (3) are adjustable.

8. The power converter (2) according to claim 3, wherein a cell (4) of any one of the primary winding (51) or the secondary winding (52) receives a cell (4) of another primary winding (51) or secondary winding (52), whereby the leakage energy and leakage inductance of the magnetic core (3) are adjustable.

9. The power converter (2) according to claim 5, further comprising a plurality of interconnected cells (4), wherein different cells (4) receive different magnetic circuits (7).

10. A power converter (2) according to claim 9, wherein the magnetic core (3) comprises a magnetic core grid (13) having a plurality of holes (40), some of the plurality of holes (40) comprising a capacitor (12) belonging to one of the interconnected cells (4), the capacitor (12) being arranged on the side of the hole (40), and these holes (40) with the capacitors (12) further accommodate a load (41) comprising an electronic semiconductor circuit, and the magnetic core grid (13) further comprises a power switch (10) of the cell (4) with the capacitor (12) in other adjacent holes (40), the power switch (10) being arranged on the side of the other adjacent holes (40).

11. A power converter (2) according to claim 10, wherein the load (41) is configured to receive energy from the conductive plates (42, 43) having opposite electrical polarities, forming a core grid (13) assembly sandwiched between the conductive plates (42, 43).

12. The power converter (2) according to claim 11, wherein the core-grid (13) assembly is integrated in an electronic board or in a multi-layer electronic stack.

13. The power converter (2) according to claim 11, wherein the magnetic core grid (13) assembly is integrated in an electronic semiconductor circuit.

14. An electric power converter (2) according to any one of the preceding claims 1 to 5, wherein the first section (23) is integrated in a first electronic board (71), and the second relative section (24) is integrated in a second electronic board (72), and the first connecting section (21) and the second connecting section (22) are at least partially arranged on the first electronic board (71) or the second electronic board (72), or as independent parts.

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