Power conversion module

Abstract

A power conversion module is disclosed. The power conversion module includes a printed circuit board and a first primary power unit disposed on the printed circuit board. The first primary power unit includes a magnetic assembly, a primary side switching circuit, a first secondary side rectifying circuit, and a first positive output terminal pin. The primary side switching circuit, the first secondary side rectifying circuit, the magnetic assembly, and the first positive output terminal pin are sequentially arranged along a first direction of the printed circuit board.

Description

Technical Field

[0001] This invention relates to the field of power electronic equipment technology, and more particularly to a power conversion module. Background Technology

[0002] Modern power electronic devices, as a crucial component of power conversion, are widely used in the power, electronics, motor, and energy industries. Ensuring the long-term stable operation of power electronic devices and improving their power conversion efficiency have always been important goals pursued by those skilled in the art.

[0003] With the rapid development of technologies such as mobile communication and cloud computing, high-power DC / DC power conversion modules have been widely used in communication products. The increasing power and miniaturization of these products present new challenges to power conversion modules in terms of conversion efficiency and size.

[0004] Power conversion modules are divided into two-stage power conversion structures and single-stage power conversion structures. Two-stage structures suffer from low efficiency and complex applications. In contrast, single-stage structures offer higher efficiency and are simpler and more flexible in application, making them commonly used in power conversion modules.

[0005] However, in traditional power conversion modules with a single-stage conversion structure, the size of the modules is limited due to the layout of the circuit components. When traditional power conversion modules are intended to be used in long and dense electronic devices, such as display cards or ASIC cards, the very narrow distance between the two opposite sides of multiple electronic devices prevents them from being effectively applied to such devices.

[0006] In addition, traditional power conversion modules typically contain magnetic components to form inductors or transformers. However, due to the structure of the magnetic core and the winding method, the magnetic components of traditional power conversion modules have high losses, which is not conducive to improving the performance of the power conversion module. Furthermore, the magnetic components of traditional power conversion modules also have the disadvantages of large AC current ripple and poor resistance to current saturation of the magnetic core.

[0007] Therefore, how to develop a power conversion module and its magnetic components to solve the problems faced by the existing technology and achieve the goal of optimizing the power conversion module is a topic that urgently needs to be addressed in this field. Summary of the Invention

[0008] The main objective of this invention is to provide a power conversion module that addresses the shortcomings of traditional power conversion modules, which are ineffective in long and dense electronic devices. It also addresses the issue that the high losses in the magnetic components of traditional power conversion modules hinder performance improvement. Furthermore, it resolves the deficiencies of traditional power conversion modules, such as large AC current ripple and poor current saturation resistance in the magnetic components.

[0009] To achieve the aforementioned objectives, the present invention provides a power conversion module, comprising: a printed circuit board; and a first basic power unit disposed on the printed circuit board and including a magnetic component; a primary-side switching circuit; a first secondary-side rectifier circuit; and a first positive output terminal pin; wherein the primary-side switching circuit, the first secondary-side rectifier circuit, the magnetic component, and the first positive output terminal pin are arranged sequentially along a first direction of the printed circuit board.

[0010] The beneficial effects of the present invention are that it provides a power conversion module in which the magnetic reluctance of the second and fourth magnetic pillars of the magnetic core assembly of the power conversion module is greater than that of the first and third magnetic pillars, and the primary winding and secondary winding are arranged in a cross configuration, so that the magnetic component of the power conversion module has the advantages of small AC current ripple and strong anti-current saturation capability of the magnetic core. Attached Figure Description

[0011] Figure 1A and Figure 1B These are three-dimensional structural diagrams of the power conversion module of the first preferred embodiment of the present invention from different perspectives.

[0012] Figure 2 for Figure 1A The circuit topology diagram corresponding to the power conversion module shown is shown below;

[0013] Figure 3 for Figure 2 The voltage timing diagram of the circuit topology shown;

[0014] Figure 3 for Figure 2 The voltage timing diagram of the circuit topology shown;

[0015] Figure 4 for Figure 1A The diagram shows an exploded view of the magnetic core assembly.

[0016] Figure 5 for Figure 1A The diagram shown illustrates the structure of the magnetic component after the first magnetic cover has been removed.

[0017] Figure 6A , Figure 6BThese are three-dimensional structural diagrams of the power conversion module of the second preferred embodiment of the present invention from different perspectives.

[0018] Figure 7 for Figure 6A The circuit topology diagram corresponding to the power conversion module shown is shown below;

[0019] Figure 8 for Figure 6A The diagram shows the structure of the two magnetic components after the first magnetic cover has been removed.

[0020] Figure 9 This is a schematic diagram of the structure of another variation of the magnetic component of the present invention after the first magnetic cover has been removed;

[0021] Figure 10A , Figure 10B These are three-dimensional structural diagrams of the power conversion module of the third preferred embodiment of the present invention from different perspectives;

[0022] Figure 10C for Figure 10A The diagram shows an exploded view of the power conversion module.

[0023] Figure 11 for Figure 10A The diagram shows a structural schematic of the first magnetic component in another variation.

[0024] Figure 12 This is a schematic diagram of the circuit topology corresponding to the power conversion module of the fourth preferred embodiment of the present invention;

[0025] Figure 13 for Figure 12 The diagram shows the structure of the magnetic components of the power conversion module after the first magnetic cover has been removed.

[0026] Figure 14 This is a schematic diagram of the circuit topology corresponding to the power conversion module of the fifth preferred embodiment of the present invention;

[0027] Figure 15 for Figure 14 The diagram shows the structure of the two magnetic components after the first magnetic cover has been removed.

[0028] Figure 16 for Figure 14 Another variation of the two magnetic components shown is a schematic diagram of the structure after the first magnetic cover has been removed.

[0029] The attached figures are labeled as follows:

[0030] 1a, 1b, 1c, 1d, 1e: Power conversion modules

[0031] Vin+: Positive input terminal

[0032] Vin-: Negative input terminal

[0033] Vin: Input voltage

[0034] Vo+: Positive output terminal

[0035] Vo-: Negative output terminal

[0036] Vo: Output voltage

[0037] 1: Primary-side switching circuit

[0038] 2: First magnetic component

[0039] 3: First secondary rectifier circuit

[0040] Q1: First switch

[0041] Q2: Second switch

[0042] A, B: Midpoint of bridge arm

[0043] Lin: Input inductance

[0044] C1: First capacitor

[0045] C2: Second capacitor

[0046] 20: Magnetic core assembly

[0047] Np1: Primary winding

[0048] Ns1: First secondary winding

[0049] Ns2: Second secondary winding

[0050] S1: First rectifier component

[0051] S2: Second rectifier assembly

[0052] Co: Output capacitor

[0053] VQ1, VQ2, VS1, VS2: Drive signals

[0054] VAB: Bridge voltage

[0055] D: Duty Cycle

[0056] 21: First magnetic cover

[0057] 22, 22a: Second magnetic cover

[0058] 23, 23a: First magnetic column

[0059] 24, 24a: Second magnetic column

[0060] 25, 25a: Third magnetic column

[0061] 26: Fourth magnetic column

[0062] 27: Connected Parts

[0063] D1, D2: Diodes

[0064] 4: Printed Circuit Board

[0065] To1+: First positive output pin

[0066] X, Y: Direction

[0067] S11, S21: First rectifier element

[0068] S12, S22: Second rectifier elements

[0069] 40: First Page

[0070] 41: Second page

[0071] Tin: Input pin

[0072] To-: Negative output pin

[0073] Ts: Signal control and detection signal pin

[0074] 2a: Second magnetic component

[0075] 3a: Secondary rectifier circuit

[0076] To2+: Second positive output pin

[0077] 10: Drive

[0078] 2b: Third magnetic component

[0079] Na Na1, Na2: Additional windings

[0080] La: Additional Inductance Detailed Implementation

[0081] Some typical embodiments embodying the features and advantages of the present invention will be described in detail in the following description. It should be understood that the present invention can be varied in different ways without departing from the scope of the invention, and the description and drawings herein are for illustrative purposes only and are not intended to limit the invention.

[0082] Figure 1A and Figure 1B These are three-dimensional structural diagrams of the power conversion module of the first preferred embodiment of the present invention from different perspectives. Figure 2 for Figure 1AThe circuit topology diagram corresponding to the power conversion module shown is as follows: Figure 3 for Figure 2 The voltage timing diagram of the circuit topology shown is as follows. Figure 4 for Figure 1A The diagram shown is an exploded view of the magnetic core assembly. Figure 5 for Figure 1A The diagram shows the structure of the magnetic component after the first magnetic cover has been removed. The circuit topology of the power conversion module 1a in this embodiment can be similar to... Figure 2 As shown, the power conversion module 1a is a single-stage power conversion circuit structure. The power conversion module 1a receives the input voltage Vin via the positive input terminal Vin+ and the negative input terminal Vin-, and outputs the output voltage Vo via the positive output terminal Vo+ and the negative output terminal Vo-. Furthermore, the power conversion module 1a includes a primary-side switching circuit 1, a first magnetic component 2, and a first secondary-side rectifier circuit 3. The primary-side switching circuit 1 includes a switching bridge arm to form a half-bridge switching structure. The switching bridge arm includes a first switch Q1 and a second switch Q2, which are connected in series and form the midpoint A of the bridge arm between the first switch Q1 and the second switch Q2.

[0083] In some embodiments, the primary-side switching circuit 1 may further include a capacitor bridge arm, and the power conversion module 1a may further include an input inductor Lin. The capacitor bridge arm is connected in parallel with the switching bridge arm and includes a first capacitor C1 and a second capacitor C2. The first capacitor C1 and the second capacitor C2 are connected in series and form the midpoint B of the bridge arm between the first capacitor C1 and the second capacitor C2. The input inductor Lin is electrically connected between the positive input terminal Vin+ of the power conversion module 1a, the first end of the switching bridge arm, and the first end of the capacitor bridge arm. In addition, the negative input terminal Vin- of the power conversion module 1a is electrically connected to the second end of the switching bridge arm and the second end of the capacitor bridge arm.

[0084] The first magnetic component 2 includes a magnetic core component 20, a primary winding Np1, a first secondary winding Ns1, and a second secondary winding Ns2. The first end of the primary winding Np1 is electrically connected to the midpoint A of the bridge arm, and the second end of the primary winding Np1 is electrically connected to the midpoint B of the bridge arm. The first secondary winding Ns1 and the second secondary winding Ns2 are electromagnetically coupled to the primary winding Np1, and each of the first secondary winding Ns1 and the second secondary winding Ns2 has a first end and a second end. The second end of the first secondary winding Ns1, the first end of the second secondary winding Ns2, and the first end of the primary winding Np1 are terminals of the same name, while the second ends of the first secondary winding Ns1 and the second secondary winding Ns2 are terminals of different names, and are electrically connected to form a center tap. The first secondary rectifier circuit 3 includes a first rectifier component S1, a second rectifier component S2, and an output capacitor Co. The first rectifier component S1 and the second rectifier component S2 may each be composed of at least one rectifier element, such as a metal-oxide-semiconductor field-effect transistor (hereinafter referred to as MOSFET) or a diode. Furthermore, the first rectifier component S1 and the second rectifier component S2 may each be composed of multiple rectifier elements composed of MOSFETs connected in parallel. The first rectifier component S1 and the second rectifier component S2 mentioned below are all exemplarily described as being composed of multiple rectifier elements composed of MOSFETs connected in parallel. Furthermore, the first terminal of the first rectifier component S1 is electrically connected to the first terminal of the second rectifier component S2, wherein the first terminals of the first rectifier component S1 and the first terminals of the second rectifier component S2 are the same electrode, such as the source. The second terminal of the first rectifier component S1, such as the drain, is electrically connected to the first terminal of the first secondary winding Ns1, and the second terminal of the second rectifier component S2, such as the drain, is electrically connected to the first terminal of the second secondary winding Ns2. Therefore, the first rectifier component S1, the second rectifier component S2, the first secondary winding Ns1, and the second secondary winding Ns2 can form a closed loop. The first terminal of the output capacitor Co is electrically connected to the center tap point and forms the positive output terminal Vo+ of the power conversion module 1a. The second terminal of the output capacitor Co is electrically connected to the first terminals of the first rectifier component S1 and the first terminals of the second rectifier component S2 and forms the negative output terminal Vo- of the power conversion module 1a.

[0085] In some embodiments, such as Figure 3 As shown, the drive signal VQ1 received by the first switch Q1 and the drive signal VQ2 received by the second switch Q2 are 180° out of phase, while the duty cycles of the drive signals VQ1 and VQ2 are nearly equal (in Figure 3In this context, symbol D represents the duty cycle of drive signals VQ1 and VQ2. Furthermore, the drive signals VS1 and VQ2 received by the first rectifier component S1 are complementary, and the drive signals VS2 and VQ1 received by the second rectifier component S2 are complementary. The bridging voltage VAB (or the bridging voltage between the midpoint A and midpoint B of the bridge arm) between the first and second terminals of the primary winding Np1 is a three-level alternating voltage, meaning it has three voltage levels: a positive input voltage Vin, 0, and a negative input voltage Vin. In other embodiments, when the duty cycles of drive signals VQ1 and VQ2 are close to or equal to 50%, the bridging voltage VAB becomes a two-level alternating voltage, meaning it has two voltage levels: half the positive input voltage Vin (i.e., +Vin / 2) and half the negative input voltage Vin (i.e., -Vin / 2).

[0086] Of course, in some embodiments, the capacitor bridge arm can be replaced by another switch bridge arm (not shown), making the primary-side switching circuit 1 a full-bridge switching structure, wherein the other switch bridge arm includes another first switch and another second switch. The control method of the two switches in each of the two switch bridge arms is not limited, as long as the bridging voltage VAB can be a two-level or three-level alternating voltage.

[0087] In this embodiment, as Figure 4 and Figure 5 As shown, the magnetic core assembly 20 includes a first magnetic cover 21, a second magnetic cover 22, a first magnetic post 23, a second magnetic post 24, a third magnetic post 25, and a fourth magnetic post 26. The first magnetic post 23 and the third magnetic post 25 are disposed opposite each other between the first magnetic cover 21 and the second magnetic cover 22, and the second magnetic post 24 and the fourth magnetic post 26 are disposed opposite each other between the first magnetic cover 21 and the second magnetic cover 22. The first magnetic post 23 and the third magnetic post 25 are located between the second magnetic post 24 and the fourth magnetic post 26. The magnetic reluctance of the second magnetic post 24 and the fourth magnetic post 26 is greater than that of the first magnetic post 23 and the third magnetic post 25, respectively. The first magnetic post 23, the second magnetic post 24, the third magnetic post 25, and the fourth magnetic post 26 together define a connected region 27. Furthermore, possible variations of the magnetic core assembly will be mentioned later, and since the magnetic core assemblies mentioned later are all similar... Figure 4 The magnetic core assembly 20 shown includes a first magnetic cover and a second magnetic cover, with only variations in the number, position, and winding method of the magnetic pillars. Therefore, the magnetic core assembly shown in the following figures only shows one of the first and second magnetic covers so that the variations in the number, position, and winding method of the magnetic pillars can be clearly displayed.

[0088] Furthermore, the primary winding Np1 is wound around the first magnetic post 23 and the third magnetic post 25 via the connecting region 27, and the magnetic flux directions on the first magnetic post 23 and the third magnetic post 25 are opposite. The first end of the first secondary winding Ns1 passes between the first magnetic post 23 and the second magnetic post 24, and the second end of the first secondary winding Ns1 passes between the third magnetic post 25 and the fourth magnetic post 26. The first end of the second secondary winding Ns2 passes between the first magnetic post 23 and the fourth magnetic post 26, and the second end of the second secondary winding Ns2 passes between the second magnetic post 24 and the third magnetic post 25.

[0089] As can be seen from the above, since the magnetic reluctance of the second magnetic post 24 and the fourth magnetic post 26 of the magnetic core assembly 20 of the power conversion module 1a in this embodiment is greater than that of the first magnetic post 23 and the third magnetic post 25, and the primary winding Np1 is wound around the first magnetic post 23 and the third magnetic post 25 via the connecting region 27, the first end of the first secondary winding Ns1 passes between the first magnetic post 23 and the second magnetic post 24, the second end of the first secondary winding Ns1 passes between the third magnetic post 25 and the fourth magnetic post 26, the first end of the second secondary winding Ns2 passes between the first magnetic post 23 and the fourth magnetic post 26, and the second end of the second secondary winding Ns2 passes between the second magnetic post 24 and the third magnetic post 25, that is, the windings are arranged in a cross configuration, so that the magnetic component of the power conversion module 1a has a flow through the primary winding Np1 and the first secondary winding Ns1. It has the advantages of low AC current ripple in the second secondary winding Ns2 and strong resistance to current saturation of the magnetic core.

[0090] In some embodiments, the second magnetic post 24 and the fourth magnetic post 26 include air gaps, while the first magnetic post 23 and the third magnetic post 25 may not include air gaps. However, this is not a limitation. In other embodiments, the first magnetic post 23 and the third magnetic post 25 may also include air gaps. However, the lengths of the air gaps in the second magnetic post 24 and the fourth magnetic post 26 are respectively greater than the lengths of the air gaps in the first magnetic post 23 and the third magnetic post 25. Furthermore, the air gap of each magnetic post may be located in the upper region of the corresponding magnetic post and adjacent to the first magnetic cover 21, but this is not a limitation. The air gap of each magnetic post may also be located in the lower region of the corresponding magnetic post and adjacent to the second magnetic cover 22, or the air gap of each magnetic post may be located in the middle region of the corresponding magnetic post.

[0091] In some embodiments, the primary winding Np1 is wound alternately on the first magnetic post 23 and the third magnetic post 25 in a figure-eight pattern via the connecting region 27, such that the magnetic flux directions on the first magnetic post 23 and the third magnetic post 25 are opposite. To further explain, the primary winding Np1 enters between the first magnetic post 23 and the fourth magnetic post 26, passes through the connecting region 27, exits between the second magnetic post 24 and the third magnetic post 25, and surrounds the third magnetic post 25. Then, it enters between the third magnetic post 25 and the fourth magnetic post 26, passes through the connecting region 27, and finally exits between the first magnetic post 23 and the second magnetic post 24, and surrounds the first magnetic post 23. Therefore, the first end of the primary winding Np1 is located between the first magnetic post 23 and the fourth magnetic post 26, and the second end of the primary winding Np1 is located between the first magnetic post 23 and the second magnetic post 24. The first and second ends of the primary winding Np1 are located on the same side of the magnetic core assembly 20. Of course, in other embodiments, the winding method of the primary winding Np1 can also be changed to first partially winding the primary winding Np1 onto the first magnetic post 23, and then the remaining part of the primary winding Np1 is wound onto the third magnetic post 25 via the connecting region 27.

[0092] Furthermore, portions of the first secondary winding Ns1 and the second secondary winding Ns2 can be located within the connecting region 27, forming an alternating top-bottom configuration. Additionally, the first ends of the first secondary winding Ns1 and the second secondary winding Ns2 are electrically connected via rectifier components (S1 and S2) on the same side of the core assembly 20 and adjacent to the first magnetic post 23. Moreover, the first ends of the primary winding Np1, the first secondary winding Ns1, and the second secondary winding Ns2 are located on the same side of the magnetic assembly 2.

[0093] For example Figure 2 As shown, the first rectifier component S1 restricts the current direction of the first secondary winding Ns1, and the second rectifier component S2 restricts the current direction of the second secondary winding Ns2, so that the current direction of the current flowing through the first secondary winding Ns1 and the current direction of the current flowing through the second secondary winding Ns2 are the same, both flowing from the first end of the corresponding secondary winding to the second end of the corresponding secondary winding.

[0094] The first rectifier component S1 and the second rectifier component S2 can be switching transistors (such as MOSFETs or IGBTs) or diodes. Figure 5 The diagram below illustrates the structure of a magnetic assembly, with diodes D1 and D2 representing the first rectifier assembly S1 and the second rectifier assembly S2, respectively. The arrows on the first secondary winding Ns1 and the second secondary winding Ns2 indicate the direction of the current, which flows in from the first end of the secondary winding and out from the second end.

[0095] Furthermore, the first voltage connected across the first and second terminals of the first secondary winding Ns1 is 180° out of phase with the second voltage connected across the first and second terminals of the second secondary winding Ns2. The current flowing through the first secondary winding Ns1 and the current flowing through the second secondary winding Ns2 generate alternating magnetic flux on the first magnetic post 23 and the third magnetic post 25, respectively. The directions of the alternating magnetic flux on the first magnetic post 23 and the third magnetic post 25 are opposite, and the alternating magnetic flux of the first magnetic post 23 and the alternating magnetic flux of the third magnetic post 25 are approximately equal. Each alternating magnetic flux is the alternating magnetic flux generated on the magnetic post by the current flowing through the first secondary winding Ns1 and the alternating magnetic flux generated on the magnetic post by the current flowing through the second secondary winding Ns2, subtracted by phase. Furthermore, the AC magnetic flux generated by the first secondary winding Ns1 and the second secondary winding Ns2 are distributed approximately evenly to the second magnetic post 24 and the fourth magnetic post 26, respectively, by means of phase superposition. The AC magnetic fluxes on the second magnetic post 24 and the fourth magnetic post 26 are in opposite directions. In addition, the DC magnetic flux generated on the first magnetic post 23 by the DC current flowing through the first secondary winding Ns1 is subtracted from the DC magnetic flux generated on the first magnetic post 23 by the DC current flowing through the second secondary winding Ns2. Simultaneously, the DC magnetic flux generated on the third magnetic post 25 by the DC current flowing through the first secondary winding Ns1 is also subtracted from the DC magnetic flux generated on the third magnetic post 25 by the DC current flowing through the second secondary winding Ns2. Due to the presence of the capacitor bridge arm in the primary-side switching circuit 1, the capacitor bridge arm has the function of blocking DC current. Therefore, the DC component of the current flowing through the first secondary winding Ns1 (hereinafter referred to as DC current) and the DC component of the current flowing through the second secondary winding Ns2 (hereinafter referred to as DC current) can be made approximately equal through the capacitor bridge arm, making the DC magnetic flux of the first magnetic post 23 and the third magnetic post 25 approximately zero. Furthermore, the DC magnetic voltage generated by the DC current flowing through the first secondary winding Ns1 and the DC magnetic voltage generated by the DC current flowing through the second secondary winding Ns2 are connected in series in the same direction, bridging the second magnetic post 24 and the fourth magnetic post 26. The air gap between the second magnetic post 24 and the fourth magnetic post 26 is used to prevent the saturation of the second magnetic post 24 and the fourth magnetic post 26. Using the capacitor bridge arm in the primary-side switching circuit 1, the DC current flowing through the first secondary winding Ns1 and the DC current flowing through the second secondary winding Ns2 can be made approximately equal. In some embodiments, in addition to the first method of achieving approximately equal DC current flowing through the first secondary winding Ns1 and the second secondary winding Ns2 by relying on the current sharing of the capacitor bridge arm in the primary-side switching circuit 1, a second method of current sharing can be used, namely, adding a DC blocking capacitor (not shown) to achieve approximately equal DC current flowing through the first secondary winding Ns1 and the second secondary winding Ns2, wherein the DC blocking capacitor is connected in series with the primary winding Np1.Furthermore, a third current-sharing method, namely adding a current-sharing circuit (not shown), can be used to make the DC current flowing through the first secondary winding Ns1 and the DC current flowing through the second secondary winding Ns2 approximately equal. At least one of the aforementioned three current-sharing methods can be applied to the power conversion module 1a.

[0096] Furthermore, when the DC current flowing through the first secondary winding Ns1 and the DC current flowing through the second secondary winding Ns2 are not completely equal, the unequal DC currents will cause the DC magnetic flux of the first magnetic post 23 and the third magnetic post 25 to be non-zero, which will easily lead to the saturation of the first magnetic post 23 and the third magnetic post 25. Therefore, in order to avoid this situation, in other embodiments, air gaps can be provided on the first magnetic post 23 and the third magnetic post 25 respectively to prevent the magnetic flux on the first magnetic post 23 and the third magnetic post 25 from saturating.

[0097] Furthermore, in this embodiment, the first magnetic post 23 has a large AC flux but a small air gap and low magnetic reluctance. In contrast, the second magnetic post 24 has a large air gap and high magnetic reluctance, but a small AC flux. This results in a small AC current ripple in the first secondary winding Ns1 and a large equivalent inductance. Similarly, although the third magnetic post 25 has a large AC flux, it has a small air gap and low magnetic reluctance. In contrast, the fourth magnetic post 26 has a large air gap and high magnetic reluctance, but a small AC flux. This results in a small AC current ripple in the second secondary winding Ns2 and a large equivalent inductance. Correspondingly, the primary winding Np1, coupled with the first and second secondary windings Ns1 and Ns2, also benefits from reduced current ripple. Simultaneously, the current ripple flowing through the switching arm of the primary switching circuit 1 is also reduced, thereby reducing switching losses. Therefore, the magnetic component of the power conversion module 1a of the present invention has the advantages of small AC current ripple and strong anti-current saturation capability of the magnetic core.

[0098] Furthermore, regarding the composition of the magnetic core assembly 20, the entire magnetic core assembly 20 can be made of the same material, such as ferrite or iron powder. However, in other embodiments, the materials of the first magnetic pillar 23 and the third magnetic pillar 25 are different from the materials of the rest of the magnetic core assembly 20. For example, the first magnetic pillar 23 and the third magnetic pillar 25 are made of ferrite, while the rest of the magnetic core assembly 20 is made of iron powder with distributed air gaps. As a result, the core loss of the magnetic core assembly 20 is low, while the equivalent inductance of the first secondary winding Ns1 and the second secondary winding Ns2 is large. In some embodiments, the sum of the cross-sectional areas of the second magnetic pillar 24 and the fourth magnetic pillar 26 is greater than the sum of the cross-sectional areas of the first magnetic pillar 23 and the third magnetic pillar 25. Furthermore, the cross-sectional area of ​​the second magnetic column 24 is approximately equal to the cross-sectional area of ​​the fourth magnetic column 26, with an error within ±20%; the cross-sectional area of ​​the first magnetic column 23 is approximately equal to the cross-sectional area of ​​the third magnetic column 25, with an error within ±20%. The aforementioned error of ±20% means that the difference between the cross-sectional areas of the two magnetic columns and the cross-sectional area of ​​one of the magnetic columns is within ±20%.

[0099] For the three-dimensional structure of power conversion module 1a, please refer to [link / reference]. Figure 1A , Figure 1B In this embodiment, the power conversion module 1a further includes a printed circuit board 4 and a first positive output terminal pin To1+. The printed circuit board 4 may be, but is not limited to, a multilayer structure. The primary-side switching circuit 1, the first secondary-side rectifier circuit 3, the first magnetic component 2, and the first positive output terminal pin To1+ can constitute a basic power unit, which is disposed on the printed circuit board 4. The power conversion module 1a can perform power conversion through at least one basic power unit to output electrical energy. The primary-side switching circuit 1, the first secondary-side rectifier circuit 3, the first magnetic component 2, and the first positive output terminal pin To1+ are along one direction of the printed circuit board 4, for example, along... Figure 1A The X-axis directions shown are arranged in sequence. The first positive output pin To1+ corresponds to the positive output pin Vo+ in Figure 2, and the first positive output pin To1+ can be made of a conductor, such as a copper block.

[0100] As mentioned above, since the primary-side switching circuit 1, the first secondary-side rectifier circuit 3, the first magnetic component 2, and the first positive output terminal pin To1+ are arranged sequentially along the X-axis direction of the printed circuit board 4, the width of the power conversion module 1a in the Y-axis direction perpendicular to the X-axis direction can be reduced. This also helps to expand the output current or output power of the power conversion module 1a, making the size and structure of the power conversion module 1a suitable for rectangular, small-sized, and high-density electronic devices, such as display cards or ASIC cards. Thus, the power conversion module 1a has the advantages of small size and high power density.

[0101] In some embodiments, such as Figure 1A As shown, the primary-side switching circuit 1 is located on one side of the printed circuit board 4. The first switch Q1 and the second switch Q2 of the switching bridge arm of the primary-side switching circuit 1 are disposed on the first surface 40 of the printed circuit board 4, and the first capacitor C1 and the second capacitor C2 of the capacitor bridge arm of the primary-side switching circuit 1 are disposed on the second surface 41 of the printed circuit board 4 opposite to the first surface 40. The positions of the switching bridge arm and the capacitor bridge arm on the printed circuit board 4 correspond. Furthermore, the primary-side switching circuit 1 may also include a driver 10, which is used to drive the actuation of the first switch Q1 and the second switch Q2 of the switching bridge arm. The driver 10 is disposed along the Y-axis on one side of the first switch Q1 and the second switch Q2 of the switching bridge arm, for example... Figure 1A The first switch Q1 and the second switch Q2 are shown above each other. The first positive output pin To1+ can be located on the first side 40 and / or the second side 41 of the printed circuit board 4.

[0102] In other embodiments, the first rectifier assembly S1 and the second rectifier assembly S2 may each be composed of multiple MOSFETs connected in parallel. For example, the first rectifier assembly S1 may be composed of a first rectifier element S11 and a second rectifier element S12 connected in parallel, and the second rectifier assembly S2 may be composed of a first rectifier element S21 and a second rectifier element S22 connected in parallel. The first rectifier element S11 of the first rectifier assembly S1 and the first rectifier element S21 of the second rectifier assembly S2 are disposed on the first surface 4 of the printed circuit board 4. On the first rectifier assembly S1, the second rectifier element S12 and the second rectifier element S22 are disposed on the second surface 41 of the printed circuit board 4. The positions of the first rectifier element S11 and the second rectifier element S12 on the printed circuit board 4 are corresponding, for example, mirror symmetrical to the first surface 40 and the second surface 41 of the printed circuit board 4. The positions of the first rectifier element S21 and the second rectifier element S22 on the printed circuit board 4 are corresponding, for example, mirror symmetrical to the first surface 40 and the second surface 41 of the printed circuit board 4.

[0103] Furthermore, the first magnetic cover 21 and the second magnetic cover 22 of the magnetic core assembly 20 are fastened to the printed circuit board 4 from the first side 40 and the second side 41 of the printed circuit board 4, respectively, and the first magnetic post 23, the second magnetic post 24, the third magnetic post 25 and the fourth magnetic post 26 are respectively inserted through the corresponding through holes (not shown) of the printed circuit board 4 and are at least partially housed in the printed circuit board 4.

[0104] Furthermore, the printed circuit board 4 is a multilayer circuit board, with the primary winding Np1, the first secondary winding Ns1, and the second secondary winding Ns2 sequentially embedded in different layers of the printed circuit board 4, and staggered in the different layers. The second end of the first secondary winding Ns1 and the second end of the second secondary winding Ns2 are electrically connected to the first positive output terminal pin To1+ located on the second surface 41 of the printed circuit board 4.

[0105] In some embodiments, the power conversion module 1a further includes multiple input pins Tin, multiple negative output pins To-, and multiple signal control and detection pins Ts. The multiple input pins Tin, To-, and Ts can be made of conductive materials, such as copper, and are respectively disposed on the second surface 41 of the printed circuit board 4, for example, on two opposite side regions of the second surface 41 along the Y-axis. The multiple negative output pins To- are respectively adjacent to the first rectifier component S1 and the second rectifier component S2 of the first secondary rectifier circuit 3, and the signal control and detection pins Ts are adjacent to the first capacitor C1 and the second capacitor C2 of the capacitor bridge arm. Each input pin Tin is located between the corresponding negative output pin To- and the signal control and detection pin Ts.

[0106] Furthermore, in other embodiments, the tops of the first switch Q1, the second switch Q2, the first rectifier element S11 of the first rectifier assembly S1, the second rectifier element S21 of the second rectifier assembly S2, and the first magnetic cover 21 of the magnetic core assembly 20 on the first surface 40 of the printed circuit board 4 can be located on the same horizontal plane. This allows the power conversion module 1a to easily install heat dissipation devices, such as thermally conductive materials and / or heat dissipation substrates, at the tops of the first rectifier element S11 of the first rectifier assembly S1, the second rectifier element S21 of the second rectifier assembly S2, and the first magnetic cover 21 of the magnetic core assembly 20. This minimizes the thermal resistance between the first rectifier assembly S1, the second rectifier assembly S2, and the magnetic core assembly 20 and the heat dissipation device, thereby achieving side heat dissipation of the power conversion module 1a.

[0107] Figure 6A , Figure 6B These are three-dimensional structural diagrams of the power conversion module of the second preferred embodiment of the present invention from different perspectives. Figure 7 for Figure 6A The circuit topology diagram corresponding to the power conversion module shown is as follows: Figure 8 for Figure 6A The diagram shows the structure of the two magnetic components after the first magnetic cover has been removed. The circuit topology of the single-stage power conversion formed by the power conversion module 1b in this embodiment can be similar to... Figure 7 As shown, compared to Figure 2 The power conversion module 1a shown in this embodiment, and the power conversion module 1b of this embodiment, further include a second magnetic component 2a and a second secondary rectifier circuit 3a. The structure of the second magnetic component 2a is similar to that of the first magnetic component 2, and the structure of the second secondary rectifier circuit 3a is similar to that of the first secondary rectifier circuit 3. Therefore, the same symbols are used here to represent that the components have similar structures and functions. In addition, the primary winding Np1 of the first magnetic component 2 and the primary winding Np1 of the second magnetic component 2a are connected in series between the midpoint A and the midpoint B of the bridge arm. That is, the first end of the primary winding Np1 of the first magnetic component 2 is electrically connected to the midpoint A of the bridge arm, the second end of the primary winding Np1 of the first magnetic component 2 is electrically connected to the first end of the primary winding Np1 of the second magnetic component 2a, and the second end of the primary winding Np1 of the second magnetic component 2a is electrically connected to the midpoint B of the bridge arm.

[0108] The electrical connection between the second secondary rectifier circuit 3a and the second magnetic component 2a is similar to that between the first secondary rectifier circuit 3 and the first magnetic component 2a, and will not be described again here. Furthermore, the second ends of the first secondary winding Ns1 and the second secondary winding Ns2 of the second secondary rectifier circuit 3a, which are opposite-named terminals, are electrically connected to each other and form a center tap. This center tap is electrically connected to the first end of the output capacitor Co. The first ends of the first rectifier component S1 and the first ends of the second rectifier component S2 of the second secondary rectifier circuit 3a are electrically connected to the second end of the output capacitor Co. Also, the drive signal of the first rectifier component S1 of the first secondary rectifier circuit 3 is in phase with the drive signal of the first rectifier component S1 of the second secondary rectifier circuit 3a, and the drive signal of the second rectifier component S2 of the first secondary rectifier circuit 3 is in phase with the drive signal of the second rectifier component S2 of the second secondary rectifier circuit 3a.

[0109] Compared to Figure 2 The circuit topology shown is composed of power conversion module 1a. In this embodiment, power conversion module 1b uses one primary-side switching circuit 1, two magnetic components 2 and 2a, and two secondary-side rectifier circuits 3 and 3a. Therefore, it can not only double the output current and output power, but also has the advantages of fewer components and smaller size of primary-side switching circuit 1. In addition, since the primary windings Np1 of the two magnetic components 3 and 3a are connected in series, the number of turns of the primary winding Np1 of each magnetic component can be reduced from N turns to 0.5*N turns. This halves the number of electrical isolation gaps between different turns of the primary winding Np1 of each magnetic component, greatly improving the copper filling rate of the primary winding Np1 of each magnetic component and reducing the on-resistance of the primary winding Np1 of each magnetic component.

[0110] In addition, such as Figure 8 As shown, the primary winding Np1, the first secondary winding Ns1, and the second secondary winding Ns2 of the second magnetic component 2a are wound around the first magnetic post 23 and the second magnetic post 25 of the second magnetic component 2a in a similar manner to the winding of the primary winding Np1, the first secondary winding Ns1, and the second secondary winding Ns2 of the first magnetic component 2a around the first magnetic post 23 and the second magnetic post 25 of the first magnetic component 2a. That is, the primary winding Np1 of the second magnetic component 2a is wound around the first magnetic post 23 and the third magnetic post 25 of the second magnetic component 2a through the connecting region 27 of the second magnetic component 2a, and the magnetic flux directions on the first magnetic post 23 and the third magnetic post 25 of the second magnetic component 2a are opposite. The first end of the first secondary winding Ns1 of the second magnetic component 2a passes between the first magnetic post 23 and the second magnetic post 24. The second end of the first secondary winding Ns1 of the second magnetic component 2a passes between the third magnetic post 25 and the fourth magnetic post 26 and is electrically connected to the first end of the output capacitor Co. The first end of the second secondary winding Ns2 of the second magnetic component 2a passes between the first magnetic post 23 and the fourth magnetic post 26. The second end of the second secondary winding Ns2 of the second magnetic component 2a passes between the second magnetic post 24 and the third magnetic post 25 and is electrically connected to the first end of the output capacitor Co.

[0111] Furthermore, the primary winding Np1 of the first magnetic component 2 and the primary winding Np1 of the second magnetic component 2a are connected in series. The bridging voltage VAB (or the bridging voltage between the midpoint A and the midpoint B of the bridge arm) between the primary winding Np1 of the first magnetic component 2 and the primary winding Np1 of the second magnetic component 2a can be a three-level alternating voltage, that is, the bridging voltage VAB has three voltage levels: positive input voltage Vin, 0, and negative input voltage Vin. Of course, the bridging voltage VAB can also be a two-level alternating voltage, that is, the bridging voltage VAB has two voltage levels: half of the positive input voltage Vin (i.e., +Vin / 2) and half of the negative input voltage Vin (i.e., -Vin / 2).

[0112] For the three-dimensional structure of power conversion module 1b, please refer to [link / reference]. Figure 6A , Figure 6B In this embodiment, the power conversion module 1b is compared to... Figure 1A , Figure 1B The power conversion module 1a shown also includes a second magnetic component 2a, a second secondary-side rectifier circuit 3a, and a second positive output terminal To2+, wherein the second positive output terminal To2+, the second magnetic component 2a, the second secondary-side rectifier circuit 3a, the primary-side switching circuit 1, the first secondary-side rectifier circuit 3, the first magnetic component 2, and the first positive output terminal To1+ are along one direction of the printed circuit board 4, for example along... Figure 6AThe X-axis directions shown are arranged in sequence. The second positive output pin To2+ corresponds to... Figure 7 The positive output terminal Vo+ and the second positive output terminal To2+ can be made of a conductor, such as a copper block, and can be disposed on the first side 40 and / or the second side 41 of the printed circuit board 4.

[0113] like Figure 6A As shown, the primary-side switching circuit 1 is located in the middle area of ​​the printed circuit board 4. Furthermore, in other embodiments, the first rectifier component S1 and the second rectifier component S2 of the second secondary-side rectifier circuit 3a can each be composed of multiple MOSFETs connected in parallel. For example, the first rectifier component S1 is composed of a first rectifier element S11 and a second rectifier element S12 connected in parallel, and the second rectifier component S2... It is composed of a first rectifier element S21 and a second rectifier element S22 connected in parallel. The first rectifier element S11 of the first rectifier component S1 and the first rectifier element S21 of the second rectifier component S2 of the second secondary rectifier circuit 3a are disposed on the first surface 40 of the printed circuit board 4. The second rectifier element S12 of the first rectifier component S1 and the second rectifier element S22 of the second rectifier component S2 of the second secondary rectifier circuit 3a are disposed on the second surface 41 of the printed circuit board 4. The positions of the first rectifier element S11 and the second rectifier element S12 of the second secondary rectifier circuit 3a on the printed circuit board 4 are corresponding, and the positions of the first rectifier element S21 and the second rectifier element S22 of the second secondary rectifier circuit 3a on the printed circuit board 4 are corresponding, for example, mirror-symmetrical to the first surface 40 and the second surface 41 of the printed circuit board 4.

[0114] Furthermore, the primary-side switching circuit 1 may include a driver 10, which is used to drive the operation of the first switch Q1 and the second switch Q2 of the switching bridge arm. The driver 10 is disposed on one side of the first switch Q1 and the second switch Q2 of the switching bridge arm along the Y-axis direction, for example... Figure 6A The upper side of the first switch Q1 and the second switch Q2 shown.

[0115] Furthermore, the first magnetic cover 21 and the second magnetic cover 22 of the second magnetic component 2a are respectively fastened to the printed circuit board 4 from the first surface 40 and the second surface 41 of the printed circuit board 4, and the first magnetic post 23, the second magnetic post 24, the third magnetic post 25 and the fourth magnetic post 26 of the second magnetic component 2a are respectively inserted through corresponding through holes (not shown) in the printed circuit board 4 and are at least partially housed within the printed circuit board 4. The second end of the first secondary winding Ns1 and the second end of the second secondary winding Ns2 of the magnetic component 2a are electrically connected to the second positive output terminal pin To2+ located on the second surface 41.

[0116] Furthermore, in other embodiments, some of the negative output terminals To- are adjacent to the first rectifier component S1 and the second rectifier component S2 of the second secondary rectifier circuit 3a, and some of the signal control and detection signal terminals Ts are adjacent to the first capacitor C1 and the second capacitor C2 of the capacitor bridge arm. Each input terminal Tin is located between the corresponding negative output terminal To- and the signal control and detection signal terminal Ts.

[0117] Figure 9 This is a schematic diagram of another variation of the magnetic component of the present invention after the first magnetic cover has been removed. Of course, the structures of the first and second magnetic components used in the power conversion module of the present invention are not limited to this. Figure 4 , Figure 5 The implementation methods shown. In some embodiments, Figure 1A The first and second magnetic components used in the power conversion module shown in Figure 6A can also be respectively made from... Figure 9 The third magnetic component 2b shown is used instead, wherein the third magnetic component 2b includes a magnetic core assembly, a primary winding Np1, a first secondary winding Ns1, and a second secondary winding Ns2. The magnetic core assembly includes a first magnetic cover (not shown), a second magnetic cover 22a, a first magnetic post 23a, a second magnetic post 24a, and a third magnetic post 25a. The first magnetic post 23a, the second magnetic post 24a, and the third magnetic post 25a are located between the first magnetic cover and the second magnetic cover 22a, wherein the first magnetic post 23a and the third magnetic post 25a are arranged opposite to each other, and the second magnetic post 24a is located between the first magnetic post 23a and the third magnetic post 25a. In some embodiments, the first magnetic post 23a and the third magnetic post 25a include an air gap, while the second magnetic post 24a may not include an air gap, but this is not a limitation; in other embodiments, the second magnetic post 24a may also include an air gap.

[0118] The primary winding Np1, the first secondary winding Ns1, and the second secondary winding Ns2 of the third magnetic component 2b are sequentially embedded in, for example... Figure 1A or Figure 6A The printed circuit board 4 shown is arranged in different layers, and is staggered vertically within each layer. Furthermore, the first secondary winding Ns1 passes between the first magnetic post 23a and the second magnetic post 24a, and the second secondary winding Ns2 passes between the second magnetic post 24a and the third magnetic post 25a. The first end of the first secondary winding Ns1 is electrically connected to... Figure 2 The second terminal of the first rectifier assembly S1 shown, and the first terminal of the second secondary winding Ns2 are electrically connected as follows: Figure 2The second terminal of the second rectifier assembly S2 shown is electrically connected to the second terminal of the first secondary winding Ns1 and the second terminal of the second secondary winding Ns2, forming a center tap. This center tap is electrically connected to the first terminal of the output capacitor Co. The first rectifier assembly S1 restricts the current direction of the first secondary winding Ns1, and the second rectifier assembly S2 restricts the current direction of the second secondary winding Ns2, so that the current direction flowing through the first secondary winding Ns1 and the current direction flowing through the second secondary winding Ns2 are the same, both flowing from the first terminal of the corresponding secondary winding to the second terminal of the corresponding secondary winding. Wherein... Figure 9 The diagram below shows the structure of the magnetic component, with diodes D1 and D2 representing the first rectifier component S1 and the second rectifier component S2, respectively.

[0119] The first end of the primary winding Np1 of the third magnetic component 2b is electrically connected to, as follows: Figure 2 The switch bridge arm shown has its midpoint A, and passes between the first magnetic post 23a and the second magnetic post 24a, so that the primary winding Np1 surrounds the second magnetic post 24a. The second end of the primary winding Np1 passes between the second magnetic post 24a and the third magnetic post 25a, and is electrically connected as shown. Figure 2 The capacitor bridge arm shown is at midpoint B. The voltage VAB (or the voltage between midpoint A and midpoint B of the bridge arm) between the first and second terminals of the primary winding Np1 is a three-level alternating voltage, meaning it has three voltage levels: a positive input voltage Vin, 0, and a negative input voltage Vin. In other embodiments, when the drive signals and duty cycles of the two switches in the bridge arm circuit driving the primary-side switching circuit 1 are close to or equal to 50%, the voltage VAB becomes a two-level alternating voltage, meaning it has two voltage levels: half a positive input voltage Vin (i.e., +Vin / 2) and half a negative input voltage Vin (i.e., -Vin / 2). Furthermore, the second terminal of the first secondary winding Ns1, the first terminal of the second secondary winding Ns2, and the first terminal of the primary winding Np1 are terminals of the same name.

[0120] Furthermore, the first voltage across the first and second terminals of the first secondary winding Ns1 connected to the third magnetic component 2b is 180° out of phase with the second voltage across the first and second terminals of the second secondary winding Ns2. The alternating current flux generated by the first secondary winding Ns1 is applied to the first magnetic post 23a, and the alternating current flux generated by the second secondary winding Ns2 is applied to the third magnetic post 25a. The alternating current flux generated by the first secondary winding Ns1 and the alternating current flux generated by the second secondary winding Ns2 are subtracted from each other in phase and applied to the second magnetic post 24a. Furthermore, the DC component of the current flowing through the first secondary winding Ns1 (hereinafter referred to as DC current) generates a DC magnetic flux on the second magnetic post 24a, which is subtracted from the DC component of the current flowing through the second secondary winding Ns2 (hereinafter referred to as DC current) generated on the second magnetic post 24a. The DC magnetic pressure generated by the DC current flowing through the first secondary winding Ns1 and the DC magnetic pressure generated by the DC current flowing through the second secondary winding Ns2 are connected in series in the same direction and are connected across the first magnetic post 23a and the third magnetic post 25a. The air gap between the first magnetic post 23a and the third magnetic post 25a is used to resist the series DC magnetic pressure and prevent the first magnetic post 23a and the third magnetic post 25a from saturating.

[0121] Compared to Figure 5 The first magnetic component 2 shown, although Figure 9 The first magnetic post 23a of the third magnetic component 2b shown has a large AC magnetic flux, a large air gap, and high magnetic reluctance, resulting in a large AC current ripple in the first secondary winding Ns1 and a small equivalent inductance. Similarly, although the third magnetic post 25a has a large AC magnetic flux, a large air gap, and high magnetic reluctance, resulting in a large AC current ripple in the first secondary winding Ns1 and a small equivalent inductance, correspondingly, the current ripple in the primary winding Np1, which is coupled to the first secondary winding Ns1 and the second secondary winding Ns2, is also large. However, regardless of... Figure 9 The first secondary winding Ns1 and the second secondary winding Ns2 of the third magnetic component 2b shown are both straight through the magnetic columns of the magnetic component 2b. Therefore, the path of the secondary winding is short, the equivalent parasitic resistance is small, and the conduction loss is small. Thus, it is suitable for high current output applications.

[0122] In addition, regarding Figure 8Regarding the composition of the magnetic core assembly, the entire magnetic core assembly can be made of the same material, such as ferrite or iron powder. However, in other embodiments, the materials of the first magnetic post 23a and the third magnetic post 25a are different from the materials of the rest of the magnetic core assembly 20. For example, the first magnetic post 23a and the third magnetic post 25a are made of ferrite, while the rest of the magnetic core assembly is made of iron powder with distributed air gaps. As a result, the magnetic core assembly 20 has low core loss, while the equivalent inductance of the first secondary winding Ns1 and the second secondary winding Ns2 is large.

[0123] Figure 10A , Figure 10B These are three-dimensional structural diagrams of the power conversion module of the third preferred embodiment of the present invention from different perspectives. Figure 10C for Figure 10A The diagram shown is an exploded view of the power conversion module. Figure 11 for Figure 10A The diagram shows a structural schematic of the first magnetic component in another variation. As shown, the power conversion module 1c of this embodiment is different from... Figure 6A The power conversion module 1b shown differs in that the structures of the first magnetic component 2 and the second magnetic component 2a used in this embodiment are the same as those of the other two components. Figure 9 The structure of the third magnetic component 2b is shown. Furthermore, in this embodiment, the first positive output pin To1+ of the power conversion module 1c is instead disposed on the wall surface of the second magnetic cover 22 of the first magnetic component 2, such as the upper wall surface, the lower wall surface, and the side wall surface between the upper and lower wall surfaces of the second magnetic cover 22. Similarly, the second positive output pin To2+ is instead disposed on the wall surface of the second magnetic cover 22 of the second magnetic component 2a, such as the upper wall surface, the lower wall surface, and the side wall surface between the upper and lower wall surfaces of the second magnetic cover 22. By disposing the first positive output pin To1+ and the second positive output pin To2+ on the wall surface of the second magnetic cover 22 of the first magnetic component 2, the size of the printed circuit board 4 of the power conversion module 1c can be reduced, thereby reducing the size of the power conversion module 1c and increasing its power density.

[0124] In the above embodiments, the first positive output terminal pin To1+ and the second positive output terminal pin To2+ can be electroplated onto the sidewall surface of the second magnetic cover 22 of the first magnetic component 2 and the second magnetic component 2a, and onto two surfaces adjacent to the sidewall surface, respectively, to increase the current conduction capability of the positive output terminal Vo+. However, this is not a limitation; they can also be embedded adjacent to the sidewall surface of the second magnetic cover 22 of the first magnetic component 2 and the second magnetic component 2a. Furthermore, to Figure 11Taking the first magnetic component as an example, the first positive output terminal pin To1+ can also be electroplated on the side wall of the second magnetic cover 22 and on the two surfaces adjacent to the side wall, and the second positive output terminal pin To2+ of the second magnetic component 2a can also be electroplated on the side wall of the second magnetic cover and on the two surfaces adjacent to the side wall.

[0125] Figure 12 This is a schematic diagram of the circuit topology corresponding to the power conversion module of the fourth preferred embodiment of the present invention. Figure 13 for Figure 12 The diagram shows the structure of the magnetic components of the power conversion module after the first magnetic cover has been removed. In some embodiments, in Figure 2 Based on the circuit topology corresponding to the power conversion module 1a shown, an additional winding Na can be added to form a circuit. Figure 12 The power conversion module 1d shown can be a magnetic component 2c used in the power conversion module 1d. Figure 9 The structure of the third magnetic component 2b shown is represented here by the same symbol to indicate that the components have similar structures and functions. Magnetic component 2c also includes an additional winding Na, which is electromagnetically coupled to the primary winding Np1. The additional winding Na is also electrically connected to an external inductor La. The additional winding Na is alternately wound in a figure-eight pattern on the first magnetic post 23a and the third magnetic post 25a. The AC voltage coupled from the additional winding Na on the first magnetic post 23a and the AC voltage coupled from the additional winding Na on the second magnetic post 24a have approximately equal amplitudes but are 180° out of phase. Furthermore, because the additional winding Na is alternately wound in a figure-eight pattern on the first magnetic post 23a and the third magnetic post 25a, the voltage amplitude on the additional winding Na decreases, and the frequency doubles. When the duty cycle of the AC voltage coupled from the additional winding Na on the first magnetic post 23a and the AC voltage coupled from the additional winding Na on the third magnetic post 25a is close to 50%, the additional winding Na can be wound alternately on the first magnetic post 23a and the third magnetic post 25a in an ∞-shaped manner, so that the duty cycle of the AC voltage on the additional winding Na can be close to 100%. Therefore, when this AC voltage is applied to the additional inductor La, the ripple current of the additional inductor La is small.

[0126] When the load driven by power conversion module 1d switches from heavy load to light load, the output voltage Vo of power conversion module 1d will overshoot, causing the controller (not shown) to respond. This causes the drive signals of the first switch Q1 and the second switch Q2 of the primary-side switching circuit 1 to disappear, while the first rectifier element S1 and the second rectifier element S2 of the first secondary-side rectifier circuit 3 remain on. This causes both the first secondary-side winding Ns1 and the second secondary-side winding Ns2 to bear the output voltage Vo. However, due to the additional winding Na... As a result of this configuration, the AC voltage coupled from the additional winding Ns1 to the first magnetic post 23a and the AC voltage coupled from the additional winding Na to the second magnetic post 24a are both proportional to the output voltage Vo. This causes the AC voltage coupled from the additional winding Na to the first magnetic post 23a and the AC voltage coupled from the additional winding Na to the second magnetic post 24a to be superimposed and applied to the additional inductor La. This results in a significant increase in the current of the additional inductor La, which in turn causes a significant decrease in the current of the first secondary winding Ns1 and the second secondary winding Ns2. Consequently, the overshoot of the output voltage Vo is significantly suppressed.

[0127] Of course, the aforementioned technique of using an additional winding Na to achieve dynamic overshoot suppression can also be applied to power conversion modules that contain multiple parallel electrical connections in the basic power unit. Figure 14 This is a schematic diagram of the circuit topology corresponding to the power conversion module of the fifth preferred embodiment of the present invention. Figure 15 for Figure 14 The diagram shows the structure of the two magnetic components after the first magnetic cover has been removed. The circuit topology of the single-stage power conversion circuit formed by the power conversion module 1e in this embodiment can be similar to... Figure 2 As shown, compared to Figure 2 The power conversion module 1a shown contains a single basic power unit. Figure 14 The power conversion module 1e shown also includes two basic power units, namely a first basic power unit and a second basic power unit. The input terminals of the first basic power unit and the second basic power unit are connected in parallel, and the output terminals of the first basic power unit and the second basic power unit are connected in parallel. The first basic power unit includes a primary-side switching circuit 1, a first magnetic component 2, and a first secondary-side rectifier circuit 3. The primary-side switching circuit 1, the first magnetic component 2, and the first secondary-side rectifier circuit 3 are connected in parallel with... Figure 2The primary-side switching circuit 1, the first magnetic component 2, and the first secondary-side rectifier circuit 3 shown are identical in circuit structure and operation, and will not be described again here. The second basic power unit includes a primary-side switching circuit 1a, a first magnetic component 2a, and a first secondary-side rectifier circuit 3a. The circuit structure and operation of the primary-side switching circuit 1a, the first magnetic component 2a, and the first secondary-side rectifier circuit 3a are similar to those of the primary-side switching circuit 1, the first magnetic component 2, and the first secondary-side rectifier circuit 3 of the first basic power unit. Therefore, the same symbols are used here to indicate that the components have similar structures and functions. In addition, in this embodiment, the positive output terminal To1+ of the second basic power unit, the first magnetic component 2a, the first secondary-side rectifier circuit 3a, the primary-side switching circuit 1a, the primary-side switching circuit 1, the first secondary-side rectifier circuit 3, the first magnetic component 2, and the first positive output terminal To1+ are arranged in the same direction along the printed circuit board 4.

[0128] Furthermore, the first basic power unit also includes an additional winding Na1, and the second basic power unit also includes an additional winding Na2, such as... Figure 15 As shown, one end of multiple additional windings passes through the magnetic component 2 of the first basic power unit between the first magnetic post 23 and the fourth magnetic post 26, through the third magnetic post 25 and the fourth magnetic post 26, through the magnetic component 2a between the first magnetic post 23 and the fourth magnetic post 26, and out through the third magnetic post 25 and the fourth magnetic post 26. They are wound around two fourth magnetic posts 26 along the outside of the magnetic component 2a and the magnetic component 2, forming a partial additional winding Na1 and a partial additional winding Na2, which are connected in series to form a series branch. Then, they pass through the magnetic component 2 between the first magnetic post 23 and the second magnetic post 24, through the third magnetic post 25 and the second magnetic post 24, and then through the magnetic component 2a between the first magnetic post 23 and the second magnetic post 25, and out through the third magnetic post 25 and the second magnetic post 24. Two second magnetic pillars 24 are wound around the outer sides of magnetic components 2a and 2, forming partial additional windings Na1 and Na2, which are connected in series to form another series branch. The endpoints of these two series branches with the same polarity are connected in parallel and then connected in series with the additional inductor La to form a closed loop. In this embodiment, the additional windings Na1 and Na2 are wound in a B-shape on the second magnetic pillar 24 and the fourth magnetic pillar 26, respectively, and then connected in parallel and connected in series with the additional inductor La to form a closed loop. In this embodiment, the AC voltage coupled from the additional windings Na1 and Na2 can also be applied to the additional inductor La, resulting in a small ripple current in the additional inductor La.

[0129] In another embodiment, the first basic power unit further includes an additional winding Na1, and the second basic power unit further includes an additional winding Na2, such as... Figure 16As shown, one end of multiple additional windings passes through the space between the first magnetic post 23 and the fourth magnetic post 26 of the magnetic component 2 of the first basic power unit, passes between the third magnetic post 25 and the fourth magnetic post 26, enters between the first magnetic post 23 and the fourth magnetic post 26 of the magnetic component 2a, exits between the third magnetic post 25 and the fourth magnetic post 26, and winds around two fourth magnetic posts 26 along the outside of the magnetic component 2a and the magnetic component 2, forming a partial additional winding Na1 and a partial additional winding Na2, which are connected in series to form a series branch; then, it passes around the outside of the second magnetic post 24 of the magnetic component 2 and the magnetic component 2a, enters between the second magnetic post 24 and the third magnetic post 25 of the magnetic component 2a, passes between the first magnetic post 23 and the second magnetic post 24, and then enters from the second magnetic post 24 of the magnetic component 2. The additional winding Na1 passes between the first magnetic post 23 and the second magnetic post 24, and exits between the third magnetic post 25 and the first magnetic post 23, forming a partial additional winding Na2, which are connected in series to form another series branch. The two ends of these two series branches with different polarities are connected in series and then connected in series with the additional inductor La to form a closed loop. In this embodiment, the additional winding Na is wound in an ∞ shape around the second magnetic post 24 and the fourth magnetic post 26, and after being connected in series, it forms a closed loop with the additional inductor La. In this embodiment, the AC voltage coupled from the additional winding can also be applied to the additional inductor La, resulting in a small ripple current in the additional inductor La. Compared to Figure 15 In the embodiment shown, the voltages across the additional windings Na1 and Na2 are superimposed, causing the voltage across the additional inductor La to double. This halves the current flowing through the additional inductor La, resulting in a reduction in the parasitic conduction losses in the series circuit of the additional windings Na1, Na2, and the additional inductor La.

[0130] The figure-eight and figure-B winding methods of the above-mentioned additional windings can also be applied to a single power conversion unit, and additional windings Na can be obtained to achieve the benefit of dynamic overshoot suppression.

[0131] In some embodiments, the drive signals received by the switching bridge arm of the primary-side switching circuit 1 of the first basic power unit and the switching bridge arm of the primary-side switching circuit 1a of the second power conversion unit are out of phase by 90°. That is, the voltage VAB between the midpoints A and B of the bridge arms of the primary-side switching circuit 1 of the first basic power unit and the capacitor bridge arm is out of phase by 90°.

[0132] In the above embodiments, the two magnetic components 2 and 2a used in the power conversion module 1e can be respectively Figure 5The structure of the magnetic component 2, which includes four magnetic pillars, is shown here. Therefore, the same symbols are used to represent components with similar structures and functions. The additional winding Na1 of the first basic power unit is coupled to the second magnetic pillar 24 and the fourth magnetic pillar 26 of the magnetic component 2, generating a signal at four times the frequency. The additional winding Na2 of the second basic power unit is coupled to the second magnetic pillar 24 and the fourth magnetic pillar 26 of the magnetic component 2a, generating the same signal at four times the frequency. When the duty cycle of the drive signal of the switching arm of the primary-side switching circuit 1 is 25%, the duty cycle of the AC voltage on the additional winding Na1 is close to 100%. When the duty cycle of the drive signal of the switching arm of the primary-side switching circuit 1a is 25%, the duty cycle of the AC voltage on the additional winding Na2 is close to 100%. The AC voltages of the additional windings Na1 and Na2 are applied to the additional inductor La, resulting in a small ripple current in the additional inductor La.

[0133] When the load driven by the power conversion module 1d switches from heavy load to light load, the output voltage Vo of the power conversion module 1d will overshoot, causing the controller (not shown) to respond. This causes the drive signals of the first switch Q1 and the second switch Q2 of the primary-side switching circuit 1, 1a to disappear, while the first rectifier element S1 and the second rectifier element S2 of the first secondary-side rectifier circuit 3, 3a are constantly on. This causes the first secondary winding Ns1 and the second secondary winding Ns2 of the magnetic components 2, 2a in each basic power unit to bear the output voltage Vo. However, due to the setting of the additional windings Na1 and Na2, the additional windings Na1 and Na2 couple out 4 times the output voltage Vo and apply it to the additional inductor La, causing the current of the additional inductor La to increase significantly. As a result, the current of the first secondary winding Ns1 and the second secondary winding Ns2 of each basic power unit decreases significantly, thereby greatly suppressing the overshoot of the output voltage Vo.

[0134] In summary, this invention provides a power conversion module and its magnetic component. Because the reluctance of the second and fourth magnetic pillars of the magnetic core component in the power conversion module is greater than that of the first and third magnetic pillars, and the primary and secondary windings are arranged in a crossed configuration, the magnetic component of the power conversion module has the advantages of low AC current ripple and strong anti-current saturation capability of the magnetic core. Furthermore, since the primary-side switching circuit, the first secondary-side rectifier circuit, the first magnetic component, and the first positive output terminal pin of the power conversion module are arranged sequentially along the same X direction on the printed circuit board, the width of the power conversion module in the Y direction perpendicular to the X direction can be reduced. This facilitates the expansion of the output current or output power of the power conversion module, making its size and structure suitable for applications such as display cards or ASIC cards, thus giving the power conversion module the advantages of small size and high power density.

[0135] This invention may be modified in various ways by those skilled in the art, but all such modifications shall not depart from the protection sought by the appended claims.

Claims

1. A power conversion module, comprising: A printed circuit board; and A first basic power unit is disposed on the printed circuit board and includes: A magnetic component; A primary-side switching circuit; A first secondary rectifier circuit; and The first positive output pin; The primary-side switching circuit, the first secondary-side rectifier circuit, the magnetic component, and the first positive output terminal pin are arranged sequentially along a first direction of the printed circuit board. The magnetic component includes at least one magnetic core assembly, the magnetic core assembly comprising: A first magnetic cover and a second magnetic cover; and A first magnetic post, a second magnetic post, and a third magnetic post are disposed between a first magnetic cover and a second magnetic cover, and the second magnetic post is disposed between the first magnetic post and the third magnetic post. The magnetic resistance of the first magnetic post and the third magnetic post is greater than that of the second magnetic post. A primary winding is wound around the second magnetic post; and A first secondary winding and a second secondary winding are provided. A first end of the first secondary winding passes through the first magnetic post and the second magnetic post, and a second end of the first secondary winding passes through the first magnetic post and the second magnetic post. A first end of the second secondary winding passes through the second magnetic post and the third magnetic post, and a second end of the second secondary winding passes through the second magnetic post and the third magnetic post.

2. The power conversion module as claimed in claim 1, wherein the first magnetic cover and the second magnetic cover are respectively fastened to the printed circuit board from a first side and a second side opposite to each other; The first and second ends of the primary winding are arranged adjacent to the first secondary rectifier circuit, the first end of the secondary winding is arranged adjacent to the first secondary rectifier circuit, and the second end of the secondary winding is arranged adjacent to the first positive output terminal.

3. The power conversion module as claimed in claim 2, wherein the primary-side switching circuit includes a switching bridge arm, the switching bridge arm includes two switches connected in series, the midpoint of a bridge arm between the two switches is electrically connected to a first end of the primary-side winding of the magnetic component, and the two switches are disposed on a first surface of the printed circuit board.

4. The power conversion module of claim 3, wherein the primary-side switching circuit includes at least one capacitor bridge arm, the capacitor bridge arm is connected in parallel with the switching bridge arm and includes two capacitors connected in series, the midpoint of a bridge arm between the two capacitors is connected to a second end of the primary-side winding of the magnetic component, and the two capacitors are disposed on a second surface of the printed circuit board opposite to the first surface.

5. The power conversion module of claim 3, wherein the primary-side switching circuit includes another switching bridge arm, the other switching bridge arm being electrically connected in parallel with the first switching bridge arm and including two switches connected in series, and the midpoint of one bridge arm between the two switches of the first switching bridge arm being electrically connected to a second end of the primary winding of the magnetic component.

6. The power conversion module as claimed in claim 2, wherein the power conversion module further comprises a plurality of input terminal pins, a plurality of negative output terminal pins and a plurality of signal control and detection signal pins, respectively disposed on two opposite side regions of the second surface along a second direction, wherein the first direction is perpendicular to the second direction.

7. The power conversion module of claim 1, wherein the power conversion module further comprises another magnetic component, a second secondary-side rectifier circuit and a second positive output terminal pin, wherein the second positive output terminal pin, the other magnetic component, the second secondary-side rectifier circuit, the primary-side switching circuit, the first secondary-side rectifier circuit, the magnetic component and the first positive output terminal pin are arranged sequentially along the first direction of the printed circuit board.

8. The power conversion module of claim 7, wherein the magnetic component and the other magnetic component have the same structure, and the primary winding of the magnetic component and the primary winding of the other magnetic component are connected in series.

9. The power conversion module of claim 1, wherein the power conversion module further comprises a second basic power unit, the structure of the second basic power unit being the same as that of the first basic power unit, wherein the positive output terminal pin of the second basic power unit, the magnetic component of the second basic power unit, the first secondary-side rectifier circuit of the second basic power unit, the primary-side switching circuit of the second basic power unit, the primary-side switching circuit of the first basic power unit, the first secondary-side rectifier circuit of the first basic power unit, the magnetic component of the first basic power unit, and the positive output terminal pin of the first basic power unit are arranged sequentially along the first direction of the printed circuit board.

10. The power conversion module of claim 9, wherein the magnetic component of the first basic power unit and the magnetic component of the second basic power unit are the same.

11. The power conversion module of claim 1, wherein the first secondary-side rectifier circuit further includes a first rectifier assembly and a second rectifier assembly, the first rectifier assembly being composed of a first rectifier element and a second rectifier element, both of which are metal-oxide-semiconductor field-effect transistors, connected in parallel, and the second rectifier assembly being composed of a first rectifier element and a second rectifier element, both of which are metal-oxide-semiconductor field-effect transistors, connected in parallel. The first rectifier element of the first rectifier assembly and the first rectifier element of the second rectifier assembly are disposed on a first surface of the printed circuit board, and the second rectifier element of the first rectifier assembly and the second rectifier element of the second rectifier assembly are disposed on a second surface of the printed circuit board opposite to the first surface. The positions of the first rectifier element of the first rectifier assembly and the second rectifier element of the second rectifier assembly on the printed circuit board are corresponding, and the positions of the first rectifier element of the second rectifier assembly and the second rectifier element of the second rectifier assembly on the printed circuit board are also corresponding.

12. The power conversion module as claimed in claim 1, wherein the first positive output terminal pin is disposed on the printed circuit board.

13. The power conversion module of claim 2, wherein the first positive output terminal is formed on the second magnetic cover of the magnetic component by electroplating or inlay.

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