Power supply device and magnetic assembly thereof

Abstract

The application provides a power supply device and a magnetic assembly thereof. The magnetic assembly comprises at least one magnetic core assembly, a first magnetic cover and a second magnetic cover, a first magnetic column, a second magnetic column and a third magnetic column, the first magnetic column, the second magnetic column and the third magnetic column are sequentially arranged in the same direction and are arranged between the first magnetic cover and the second magnetic cover, the second magnetic column is located between the first magnetic column and the third magnetic column, the magnetic resistance of the first magnetic column and the third magnetic column is greater than that of the second magnetic column, a first secondary winding and a second secondary winding, the first secondary winding is arranged between the first magnetic column and the second magnetic column, the second secondary winding is arranged between the second magnetic column and the third magnetic column, and a primary winding, a first end of the primary winding is arranged between the first magnetic column and the second magnetic column, the primary winding surrounds the second magnetic column, and a second end of the primary winding is arranged between the second magnetic column and the third magnetic column.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of power electronic devices, in particular to a power conversion module and a magnetic assembly thereof. BACKGROUND

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

[0003] With the rapid development of mobile communication and cloud computing technologies, high-power DC / DC power conversion modules have also been widely used in communication products. Due to the high power and tendency to miniaturization of products, new challenges are posed to the conversion efficiency and volume of power conversion modules.

[0004] Power conversion modules are divided into two-stage power conversion structures and single-stage power conversion structures. The two-stage conversion structure has the problems of low efficiency and complex application. Compared with the two-stage conversion structure, the single-stage conversion structure has the advantages of high efficiency and simple and flexible application, so it is often used in power conversion modules.

[0005] However, in the traditional power conversion module with a single-stage conversion structure, due to the layout of the circuit elements, the traditional power conversion module has certain size limitations. When the traditional power conversion module is applied to long-size and high-density electronic devices such as display cards or ASIC cards, etc., due to the very narrow distance between the two opposite sides of multiple electronic devices, the traditional power conversion module cannot be effectively applied to long-size and high-density electronic devices.

[0006] In addition, in the traditional power conversion module, there is usually a magnetic assembly to form an inductor or a transformer, etc. through the magnetic assembly. However, due to the structure of the magnetic core and the winding method of the winding, the magnetic assembly of the traditional power conversion module has large loss, which is not conducive to the improvement of the performance of the power conversion module. In addition, the magnetic assembly of the traditional power conversion module also has the disadvantages of large alternating current ripple and poor current saturation resistance of the magnetic core.

[0007] Therefore, how to develop a power conversion module and a magnetic assembly thereof to solve the problems faced by the prior art and achieve the optimization of the power conversion module is a very important issue in the field. SUMMARY

[0008] The main purpose of the present application is to provide a power conversion module and a magnetic assembly thereof, so as to solve the defects that the conventional power conversion module cannot be effectively applied to the electronic device with long size and high density, and the conventional power conversion module is not conducive to the performance improvement of the power conversion module due to the large loss of the magnetic assembly. In addition, the conventional power conversion module has the defects that the magnetic assembly has large AC current ripple and poor magnetic core current saturation resistance.

[0009] To achieve the foregoing purpose, the present application provides a magnetic assembly, comprising: at least one magnetic core assembly, comprising: a first magnetic cover and a second magnetic cover; and a first magnetic column, a second magnetic column and a third magnetic column, the first magnetic column, the second magnetic column and the third magnetic column are sequentially arranged in the same direction and are arranged between the first magnetic cover and the second magnetic cover, the second magnetic column is located between the first magnetic column and the third magnetic column, and the magnetic resistance of the first magnetic column and the third magnetic column is greater than the magnetic resistance of the second magnetic column; a first secondary winding and a second secondary winding, the first secondary winding is arranged between the first magnetic column and the second magnetic column, and the second secondary winding is arranged between the second magnetic column and the third magnetic column; and a primary winding, the first end of the primary winding is inserted between the first magnetic column and the second magnetic column, so that the primary winding surrounds the second magnetic column, and the second end of the primary winding is inserted between the second magnetic column and the third magnetic column.

[0010] To achieve the foregoing purpose, the present application further provides a power supply device, comprising: a magnetic core assembly comprising at least four magnetic flux channels; at least four secondary windings wound on the magnetic core assembly, wherein the magnetic flux generated by each secondary winding on the magnetic core assembly flows through at least one magnetic flux channel; a primary winding; at least four switching devices; and at least one output capacitor; wherein the magnetic flux channel through which the magnetic flux generated by each secondary winding on the magnetic core assembly flows, the corresponding secondary winding, the corresponding switching device and the corresponding output capacitor constitute a basic component, each secondary winding, the corresponding switching device and the corresponding output capacitor are connected in series to form a closed loop, and the power supply device comprises at least four closed loops; the four closed loops are connected in parallel; wherein the primary winding has two winding directions on the at least four magnetic flux channels, and the number of basic components corresponding to each winding direction is equal. BRIEF DESCRIPTION OF DRAWINGS

[0011] Figure 1A And Figure 1B The perspective structure diagram of the power conversion module of the first preferred embodiment of the present application under different viewing angles;

[0012] Figure 2 For Figure 1A The circuit topology schematic diagram corresponding to the power conversion module shown in the figure;

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

[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 , 6B These 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 , 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 14Structure schematic diagram of two magnetic components shown after removing the first magnetic cover;

[0028] Figure 16 For Figure 14 Another variation of the two magnetic elements shown is a structure schematic diagram after removing the first magnetic cover.

[0029] The reference signs are as follows:

[0030] 1a, 1b, 1c, 1d, 1e: power conversion module

[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 side rectifier circuit

[0040] Q1: first switch

[0041] Q2: second switch

[0042] A, B: bridge arm midpoint

[0043] Lin: input inductor

[0044] C1: first capacitor

[0045] C2: second capacitor

[0046] 20: magnetic core assembly

[0047] Np1: primary side winding

[0048] Ns1: first secondary side winding

[0049] Ns2: second secondary side winding

[0050] S1: first rectifier component

[0051] S2: second rectifier component

[0052] Co: output capacitor

[0053] VQ1, VQ2, VS1, VS2: drive signal

[0054] VAB: across 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: communication region

[0063] D1, D2: diode

[0064] 4: printed circuit board

[0065] To1+: first positive output terminal pin

[0066] X, Y: direction

[0067] S11, S21: first rectifying element

[0068] S12, S22: second rectifying element

[0069] 40: first surface

[0070] 41: second surface

[0071] Tin: input terminal pin

[0072] To-: negative output terminal pin

[0073] Ts: signal control and detection signal pin

[0074] 2a: second magnetic assembly

[0075] 3a: second secondary rectifying circuit

[0076] To2+: second positive output terminal pin

[0077] 10: driver

[0078] 2b: third magnetic assembly

[0079] Na, Na1, Na2: additional winding

[0080] La: additional inductor DETAILED DESCRIPTION

[0081] Some typical embodiments embodying features and advantages of the present application are described in detail below. It should be appreciated that the present application can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and fully convey the scope of the application to those skilled in the art.

[0082] Figure 1A and Figure 1B A perspective view of a power conversion module according to a first preferred embodiment of the present application, Figure 2 A perspective view of a power conversion module according to a first preferred embodiment of the present application, Figure 1A A circuit topology diagram of the power conversion module shown in Figure 3 A circuit topology diagram of the power conversion module shown in Figure 2 A voltage timing diagram of the circuit topology shown in Figure 4 A voltage timing diagram of the circuit topology shown in Figure 1A An exploded view of the magnetic core assembly shown in Figure 5 An exploded view of the magnetic core assembly shown in Figure 1A An exploded view of the magnetic core assembly shown in Figure 2 The power conversion module 1a according to the first preferred embodiment of the present application is a single-stage power conversion circuit, and receives an input voltage Vin via a positive input terminal Vin+ and a negative input terminal Vin-, and outputs an output voltage Vo via a positive output terminal Vo+ and a negative output terminal Vo-. The power conversion module 1a comprises a primary-side switching circuit 1, a first magnetic assembly 2, and a first secondary-side rectification circuit 3. The primary-side switching circuit 1 comprises a switching bridge arm to form a half-bridge switching structure, which comprises a first switch Q1 and a second switch Q2. The first switch Q1 and the second switch Q2 are connected in series, and a bridge arm midpoint A is formed between the first switch Q1 and the second switch Q2.

[0083] In some embodiments, the primary-side switching circuit 1 further comprises a capacitor bridge arm, and the power conversion module 1a further comprises an input inductor Lin. The capacitor bridge arm is connected in parallel with the switching bridge arm, and comprises a first capacitor C1 and a second capacitor C2. The first capacitor C1 and the second capacitor C2 are connected in series, and a bridge arm midpoint B is formed between the first capacitor C1 and the second capacitor C2. The input inductor Lin is connected between the positive input terminal Vin+ of the power conversion module 1a, a first end of the switching bridge arm, and a first end of the capacitor bridge arm. In addition, the negative input terminal Vin- of the power conversion module 1a is connected to a second end of the switching bridge arm and a 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 S1 and the second rectifier 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 S1 and the second rectifier S2 may each be composed of multiple rectifier elements composed of MOSFETs connected in parallel. The first rectifier S1 and the second rectifier 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 switch circuit 1 a full-bridge switch structure, wherein the other switch bridge arm includes another first switch and another second switch. The control method of the two switches of 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] In addition, the primary winding Np1 is wound on the first magnetic leg 23 and the third magnetic leg 25 via the communication region 27, and the magnetic flux directions of the first magnetic leg 23 and the third magnetic leg 25 are opposite. The first end of the first secondary winding Ns1 is threaded between the first magnetic leg 23 and the second magnetic leg 24, the second end of the first secondary winding Ns1 is threaded between the third magnetic leg 25 and the fourth magnetic leg 26, the first end of the second secondary winding Ns2 is threaded between the first magnetic leg 23 and the fourth magnetic leg 26, and the second end of the second secondary winding Ns2 is threaded between the second magnetic leg 24 and the third magnetic leg 25.

[0089] As can be seen from the above, since the magnetic resistances of the second magnetic leg 24 and the fourth magnetic leg 26 of the magnetic core assembly 20 of the power conversion module 1a of the embodiment are greater than those of the first magnetic leg 23 and the third magnetic leg 25, respectively, the primary winding Np1 is wound on the first magnetic leg 23 and the third magnetic leg 25 via the communication region 27, the first end of the first secondary winding Ns1 is threaded between the first magnetic leg 23 and the second magnetic leg 24, the second end of the first secondary winding Ns1 is threaded between the third magnetic leg 25 and the fourth magnetic leg 26, the first end of the second secondary winding Ns2 is threaded between the first magnetic leg 23 and the fourth magnetic leg 26, and the second end of the second secondary winding Ns2 is threaded between the second magnetic leg 24 and the third magnetic leg 25, i.e., the windings are arranged in a cross arrangement, so that the power conversion module 1a has the advantages of small alternating current ripple of the current flowing through the primary winding Np1, the first secondary winding Ns1 and the second secondary winding Ns2 and strong current saturation resistance of the magnetic core.

[0090] In some embodiments, the second magnetic leg 24 and the fourth magnetic leg 26 include air gaps, and the first magnetic leg 23 and the third magnetic leg 25 can not include air gaps, but not limited thereto, in other embodiments, the first magnetic leg 23 and the third magnetic leg 25 can also include air gaps, but the length of the air gap of the second magnetic leg 24 and the length of the air gap of the fourth magnetic leg 26 are greater than the length of the air gap of the first magnetic leg 23 and the length of the air gap of the third magnetic leg 25, respectively. In addition, the air gap of each magnetic leg can be located in the upper region of the corresponding magnetic leg adjacent to the first magnetic cover 21, but not limited thereto, the air gap of each magnetic leg can also be located in the lower region of the corresponding magnetic leg adjacent to the second magnetic cover 22, or the air gap of each magnetic leg can be located in the middle region of the corresponding magnetic leg.

[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, then 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 end and the second end 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 crossover 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] In addition, the first voltage across the first end and the second end of the first secondary winding Ns1 is 180° out of phase with the second voltage across the first end and the second end 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 fluxes on the first magnetic column 23 and the third magnetic column 25, respectively, wherein the alternating magnetic fluxes on the first magnetic column 23 and the third magnetic column 25 are opposite in direction and approximately equal in magnitude, and each of the alternating magnetic fluxes is the phase-difference between the alternating magnetic flux generated by the current flowing through the first secondary winding Ns1 and the alternating magnetic flux generated by the current flowing through the second secondary winding Ns2. Moreover, the alternating magnetic flux generated by the first secondary winding Ns1 and the alternating magnetic flux generated by the second secondary winding Ns2 are approximately equally distributed to the second magnetic column 24 and the fourth magnetic column 26 by phase superposition, and the alternating magnetic fluxes on the second magnetic column 24 and the fourth magnetic column 26 are opposite in direction. Furthermore, the direct current flowing through the first secondary winding Ns1 and the direct current flowing through the second secondary winding Ns2 generate direct magnetic fluxes on the first magnetic column 23, which are subtracted from each other, and the direct current flowing through the first secondary winding Ns1 and the direct current flowing through the second secondary winding Ns2 generate direct magnetic fluxes on the third magnetic column 25, which are also subtracted from each other. Due to the presence of the capacitor bridge arm of the primary side switching circuit 1, the capacitor bridge arm has the function of blocking direct current, so that the direct current flowing through the first secondary winding Ns1 and the direct current flowing through the second secondary winding Ns2 can be approximately equalized by the capacitor bridge arm, so that the direct magnetic fluxes on the first magnetic column 23 and the third magnetic column 25 are approximately equal to zero. Moreover, the direct magnetic flux generated by the direct current flowing through the first secondary winding Ns1 and the direct magnetic flux generated by the direct current flowing through the second secondary winding Ns2 are in the same direction and are connected in series across the second magnetic column 24 and the fourth magnetic column 26, and the air gap of the second magnetic column 24 and the fourth magnetic column 26 is used to prevent the saturation of the second magnetic column 24 and the fourth magnetic column 26. By using the capacitor bridge arm in the primary side switching circuit 1, the direct current flowing through the first secondary winding Ns1 and the direct current flowing through the second secondary winding Ns2 can be approximately equalized. In some embodiments, in addition to the first current equalization method relying on the capacitor bridge arm in the primary side switching circuit 1 to achieve the approximate equalization of the direct current flowing through the first secondary winding Ns1 and the direct current flowing through the second secondary winding Ns2, a second current equalization method can be used to achieve the approximate equalization of the direct current flowing through the first secondary winding Ns1 and the direct current flowing through the second secondary winding Ns2, that is, by adding a direct-current blocking capacitor (not shown) in series with the primary winding Np1. Furthermore, a third current equalization method can also be used to achieve the approximate equalization of the direct current flowing through the first secondary winding Ns1 and the direct current flowing through the second secondary winding Ns2, that is, by adding a current equalization circuit (not shown).The three current sharing methods mentioned above can be applied to the power conversion module la.

[0096] In addition, when the direct current flowing through the first secondary winding Ns1 and the direct current flowing through the second secondary winding Ns2 are not completely equal, the unequal direct currents will make the direct magnetic flux of the first magnetic column 23 and the third magnetic column 25 not equal to zero, resulting in the first magnetic column 23 and the third magnetic column 25 being easily saturated. Therefore, in other embodiments, air gaps can be provided in the first magnetic column 23 and the third magnetic column 25 respectively to prevent the magnetic flux in the first magnetic column 23 and the third magnetic column 25 from being saturated.

[0097] In addition, in the present embodiment, the alternating current of the first magnetic column 23 is large, but the air gap and the magnetic resistance are small, while the air gap and the magnetic resistance of the second magnetic column 24 are large with respect to the first magnetic column 23, but the alternating current of the second magnetic column 24 is small, so that the alternating current ripple of the first secondary winding Ns1 is small, and the equivalent inductance of the first secondary winding Ns1 is large. Similarly, although the alternating current of the third magnetic column 25 is large, but the air gap and the magnetic resistance are small, while the air gap and the magnetic resistance of the fourth magnetic column 26 are large with respect to the third magnetic column 25, but the alternating current of the fourth magnetic column 26 is small, so that the alternating current ripple of the second secondary winding Ns2 is small, and the equivalent inductance of the second secondary winding Ns2 is large. Correspondingly, the primary winding Np1 coupled with the first secondary winding Ns1 and the second secondary winding Ns2 also obtains the benefit of current ripple reduction, and the current ripple of the switching bridge arm flowing through the primary side switching circuit 1 is also reduced, thereby reducing the switching loss. Therefore, the magnetic assembly of the power conversion module la of the present application has the advantages of small alternating current ripple and strong current saturation resistance of the magnetic core.

[0098] In addition, for the composition of the magnetic core assembly 20, the materials of the entire magnetic core assembly 20 can be the same, such as ferrite material or iron powder material. However, in other embodiments, the composition materials of the first magnetic column 23 and the third magnetic column 25 are different from the composition materials of the remaining part of the magnetic core assembly 20, for example, the composition materials of the first magnetic column 23 and the third magnetic column 25 are ferrite materials, and the composition materials of the remaining part of the magnetic core assembly 20 are distributed air gap iron powder materials, thereby the magnetic core loss of the magnetic core assembly 20 is low, and 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 column 24 and the fourth magnetic column 26 is greater than the sum of the cross-sectional areas of the first magnetic column 23 and the third magnetic column 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%, wherein the error within ±20% mentioned above means that the difference between the cross-sectional areas of the two magnetic columns is within ±20% of the cross-sectional area of one of the two magnetic columns.

[0099] For the three-dimensional structure of the power conversion module 1a, please refer to 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 can be, but is not limited to, a multi-layer structure. The primary side switching circuit 1, the first secondary side rectifying circuit 3, the first magnetic assembly 2, and the first positive output terminal pin To1+ can constitute a basic power unit, which is arranged on the printed circuit board 4. The power conversion module 1a can perform power conversion through at least one basic power unit to output electric energy, wherein the primary side switching circuit 1, the first secondary side rectifying circuit 3, the first magnetic assembly 2, and the first positive output terminal pin To1+ are sequentially arranged along a direction of the printed circuit board 4, for example, along the X-axis direction as shown in Figure 1A The first positive output terminal pin To1+ corresponds to the positive output terminal Vo+ in Figure 2 , and the first positive output terminal pin To1+ can be composed of a conductive body, such as a copper block, etc.

[0100] As mentioned above, since the primary side switching circuit 1, the first secondary side rectifying circuit 3, the first magnetic assembly 2, and the first positive output terminal pin To1+ are sequentially arranged 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, and it is helpful to expand the output current or output power of the power conversion module 1a, so that the size structure of the power conversion module 1a is suitable for the application of rectangular small-size and high-density electronic devices, such as display cards or ASIC cards, thereby making the power conversion module 1a have the advantages of small size and high power density.

[0101] In some embodiments, as shown in Figure 1A , the primary side switching circuit 1 is located at a side edge region of the printed circuit board 4, wherein the first switch Q1 and the second switch Q2 of the switch bridge arm of the primary side switching circuit 1 are arranged on the first face 40 of the printed circuit board 4, the first capacitor C1 and the second capacitor C2 of the capacitor bridge arm of the primary side switching circuit 1 are arranged on the second face 41 of the printed circuit board 4 opposite to the first face 40, and the switch bridge arm and the capacitor bridge arm correspond in position on the printed circuit board 4. In addition, the primary side switching circuit 1 can further include a driver 10 for driving the operation of the first switch Q1 and the second switch Q2 of the switch bridge arm, and the driver 10 is arranged along the Y-axis direction at one side of the first switch Q1 and the second switch Q2, for example, the upper side of the first switch Q1 and the second switch Q2 as shown in Figure 1A The first positive output terminal pin To1+ can be arranged on the first face 40 and / or the second face 41 of the printed circuit board 4.

[0102] In other embodiments, the first rectifying assembly S1 and the second rectifying assembly S2 can be respectively formed by a plurality of MOSFETs connected in parallel, for example, the first rectifying assembly S1 is formed by the first rectifying element S11 and the second rectifying element S12 connected in parallel, and the second rectifying assembly S2 is formed by the first rectifying element S21 and the second rectifying element S22 connected in parallel, wherein the first rectifying element S11 of the first rectifying assembly S1 and the first rectifying element S21 of the second rectifying assembly S2 are disposed on the first surface 40 of the printed circuit board 4, the second rectifying element S12 of the first rectifying assembly S1 and the second rectifying element S22 of the second rectifying assembly S2 are disposed on the second surface 41 of the printed circuit board 4, and the positions of the first rectifying element S11 and the second rectifying element S12 on the printed circuit board 4 correspond, for example, are mirror-symmetrical to the first surface 40 and the second surface 41 of the printed circuit board 4, and the positions of the first rectifying element S21 and the second rectifying element S22 on the printed circuit board 4 correspond, for example, are mirror-symmetrical to the first surface 40 and the second surface 41 of the printed circuit board 4.

[0103] Further, the first magnetic cover 21 and the second magnetic cover 22 of the magnetic core assembly 20 are respectively buckled on 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 column 23, the second magnetic column 24, the third magnetic column 25, and the fourth magnetic column 26 are respectively arranged through the corresponding through holes (not shown) of the printed circuit board 4 and at least partially accommodated in the printed circuit board 4.

[0104] In addition, the printed circuit board 4 is a multi-layer circuit board, and the primary winding Np1, the first secondary winding Ns1, and the second secondary winding Ns2 are sequentially embedded in different layers of the printed circuit board 4 and are placed in 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 a plurality of input terminal pins Tin, a plurality of negative output terminal pins To-, and a plurality of signal control and detection signal pins Ts. The plurality of input terminal pins Tin, the plurality of negative output terminal pins To-, and the plurality of signal control and detection signal pins Ts can be respectively formed by conductive bodies, such as copper, and are respectively disposed on the second surface 41 of the printed circuit board 4, for example, on the two opposite side regions of the second surface 41 along the Y-axis direction, wherein the plurality of negative output terminal pins To- are respectively disposed adjacent to the first rectifying assembly S1 and the second rectifying assembly S2 of the first secondary rectifying circuit 3, and the signal control and detection signal pins Ts are disposed adjacent to the first capacitor C1 and the second capacitor C2 of the capacitor bridge arm. Each input terminal pin Tin is located between a corresponding negative output terminal pin To- and a signal control and detection signal pin Ts.

[0106] Furthermore, in other embodiments, the top of the first switch Ql, the top of the second switch Q2, the top of the first rectifying element Sll of the first rectifying assembly S1, the top of the second rectifying element S21 of the second rectifying assembly S2, and the top of the first magnetic cover 21 of the magnetic core assembly 20 can be located at the same horizontal plane on the first surface 40 of the printed circuit board 4, thereby facilitating the installation of a heat dissipation device, such as a heat conducting medium material and / or a heat dissipation substrate, etc., on the top of the first rectifying element Sll of the first rectifying assembly S1, on the top of the second rectifying element S21 of the second rectifying assembly S2, and on the top of the first magnetic cover 21 of the magnetic core assembly 20, so as to minimize the thermal resistance between the first rectifying assembly S1, the second rectifying assembly S2, and the magnetic core assembly 20 and the heat dissipation device, and to achieve one-side edge heat dissipation of the power conversion module la.

[0107] Figure 6A 、 6B a perspective view of the power conversion module according to the second preferred embodiment of the present application from a different viewing angle, Figure 7 a perspective view of the power conversion module according to the second preferred embodiment of the present application from a different viewing angle, Figure 6A a circuit topology diagram of the power conversion module shown in Figure 8 a circuit topology diagram of the power conversion module shown in Figure 6A a structural diagram of the two magnetic assemblies after the first magnetic cover is removed. The single-stage electric energy conversion circuit topology of the power conversion module lb according to the present embodiment can be similar to that shown in Figure 7 wherein, compared to the power conversion module la shown in Figure 2 the power conversion module lb according to the present embodiment further comprises a second magnetic assembly 2a and a second auxiliary side rectifying circuit 3a, wherein the structure of the second magnetic assembly 2a is similar to that of the first magnetic assembly 2, and the structure of the second auxiliary side rectifying circuit 3a is similar to that of the first auxiliary side rectifying circuit 3, so the same symbols are used to represent similar structures and functions of the elements. In addition, the primary winding Npl of the first magnetic assembly 2 and the primary winding Npl of the second magnetic assembly 2a are electrically connected in series between the bridge arm midpoint A and the bridge arm midpoint B, i.e., the first end of the primary winding Npl of the first magnetic assembly 2 is electrically connected to the bridge arm midpoint A, the second end of the primary winding Npl of the first magnetic assembly 2 is electrically connected to the first end of the primary winding Npl of the second magnetic assembly 2a, and the second end of the primary winding Npl of the second magnetic assembly 2a is electrically connected to the bridge arm midpoint B.

[0108] The electrical connection between the second secondary side rectifier circuit 3a and the second magnetic assembly 2a is similar to the electrical connection between the first secondary side rectifier circuit 3 and the first magnetic assembly 2, and thus will not be described again. In addition, the second end of the first secondary side winding Ns1 of the second secondary side rectifier circuit 3a and the second end of the second secondary side winding Ns2 are opposite ends and are electrically connected to each other and form a center tap point, which is electrically connected to the first end of the output capacitor Co. The first end of the first rectifier assembly S1 and the first end of the second rectifier assembly S2 of the second secondary side rectifier circuit 3a are electrically connected to the second end of the output capacitor Co. In addition, the driving signal of the first rectifier assembly S1 of the first secondary side rectifier circuit 3 and the driving signal of the first rectifier assembly S1 of the second secondary side rectifier circuit 3a are the same in phase, and the driving signal of the second rectifier assembly S2 of the first secondary side rectifier circuit 3 and the driving signal of the second rectifier assembly S2 of the second secondary side rectifier circuit 3a are the same in phase.

[0109] Compared with Figure 2 As shown in the circuit topology composed of the power conversion module 1a, the power conversion module 1b of the embodiment uses one primary side switching circuit 1, two magnetic assemblies 2, 2a and two secondary side rectifier circuits 3, 3a, so that the output current and the output power can be doubled, the number of components of the primary side switching circuit 1 is small, the volume of the primary side switching circuit 1 is small, and in addition, since the primary side windings Np1 of the two magnetic assemblies 2, 2a are electrically connected in series, the number of turns of the primary side winding Np1 of each magnetic assembly can be reduced from N turns to 0.5*N turns, so that the number of electrical isolation gaps between different turns of the primary side winding Np1 of each magnetic assembly is halved, the copper filling rate of the position of the primary side winding Np1 of each magnetic assembly is greatly improved, and the on-resistance of the primary side winding Np1 of each magnetic assembly is reduced.

[0110] In addition, as Figure 8As 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 , 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 6A The X-axis directions shown are arranged in sequence. The second positive output pin To2+ corresponds to... Figure 7The 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 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-side rectifier circuit 3a are disposed on the printed circuit board 4. On the first surface 40 of the 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] Further, in other embodiments, part of the negative output pins To- of the plurality of negative output pins To- are disposed adjacent to the first rectifying component S1 and the second rectifying component S2 of the second secondary rectifying circuit 3a, and part of the signal control and detection signal pins Ts of the plurality of signal control and detection signal pins Ts are disposed adjacent to the first capacitor C1 and the second capacitor C2 of the capacitor bridge arm. Each of the input pins Tin is then located between the corresponding negative output pin To- and the signal control and detection signal pin Ts.

[0117] Figure 9 Another variation of the magnetic assembly of the present application is shown in a schematic view after the first magnetic cover is removed. Of course, the structure of the first magnetic assembly and the second magnetic assembly used in the power conversion module of the present application is not limited to the embodiments shown in Figure 4 、 Figure 5 . In some embodiments, the first magnetic assembly and the second magnetic assembly used in the power conversion module shown in Figure 1A 、 Figure 6A may also be replaced by a third magnetic assembly 2b shown in Figure 9 , respectively, wherein the third magnetic assembly 2b comprises a magnetic core assembly, a primary winding Np1, a first secondary winding Ns1 and a second secondary winding Ns2. The magnetic core assembly comprises a first magnetic cover (not shown), a second magnetic cover 22a, a first magnetic leg 23a, a second magnetic leg 24a and a third magnetic leg 25a. The first magnetic leg 23a, the second magnetic leg 24a and the third magnetic leg 25a are located between the first magnetic cover and the second magnetic cover 22a, wherein the first magnetic leg 23a and the third magnetic leg 25a are oppositely disposed, and the second magnetic leg 24a is located between the first magnetic leg 23a and the third magnetic leg 25a. In some embodiments, the first magnetic leg 23a and the third magnetic leg 25a comprise an air gap, and the second magnetic leg 24a can not comprise an air gap, but not limited thereto, in other embodiments, the second magnetic leg 24a can also comprise an air gap.

[0118] The primary winding Np1, the first secondary winding Ns1 and the second secondary winding Ns2 of the third magnetic assembly 2b are sequentially built-in in different layers of a printed circuit board 4, for example, as shown in Figure 1A or Figure 6A , and are in a top-bottom staggered state in different layers. In addition, the first secondary winding Ns1 is threaded between the first magnetic leg 23a and the second magnetic leg 24a, and the second secondary winding Ns2 is threaded between the second magnetic leg 24a and the third magnetic leg 25a. The first end of the first secondary winding Ns1 is electrically connected to the second end of the first rectifying component S1, as shown in Figure 2 , and the first end of the second secondary winding Ns2 is electrically connected to the second end of the second rectifying component S2, as shown in Figure 2The second end of the second rectifying component S2 is electrically connected to the second end of the first secondary winding Ns1 and the second end of the second secondary winding Ns2, and forms a center tap point, which is electrically connected to the first end of the output capacitor Co. The first rectifying component S1 limits the current direction of the first secondary winding Ns1, and the second rectifying component S2 limits 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 from the first end of the corresponding secondary winding to the second end of the corresponding secondary winding. Wherein in Figure 9 the structure diagram of the magnetic component is illustrated by taking the first rectifying component S1 and the second rectifying component S2 represented by diodes D1 and D2 respectively as examples.

[0119] The first end of the primary winding Np1 of the third magnetic component 2b is electrically connected to the bridge arm center point A of the switch bridge arm as Figure 2 shown, and passes through between the first magnetic column 23a and the second magnetic column 24a, so that the primary winding Np1 surrounds the second magnetic column 24a. The second end of the primary winding Np1 passes through between the second magnetic column 24a and the third magnetic column 25a, and is electrically connected to the bridge arm center point B of the capacitor bridge arm as Figure 2 shown. In addition, the voltage VAB across the first end and the second end of the primary winding Np1 (or the voltage across the bridge arm center point A and the bridge arm center point B) is a three-level alternating voltage, that is, the voltage VAB has three voltage levels of the positive input voltage Vin, 0 and the negative input voltage Vin. In other embodiments, when the drive signals of the two switches of the bridge arm circuit of the primary side switch circuit 1 and the conduction duty cycle of the drive signals are close to or equal to 50%, the voltage VAB is a two-level alternating voltage, that is, the voltage VAB has two voltage levels of half of the positive input voltage Vin (i.e. +Vin / 2) and half of the negative input voltage Vin (i.e. -Vin / 2). In addition, 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 the same name ends.

[0120] In addition, the first voltage across the first end and the second end of the first secondary winding Ns 1 of the third magnetic assembly 2b is 180° out of phase with the second voltage across the first end and the second end of the second secondary winding Ns 2. The AC flux generated by the first secondary winding Ns 1 is applied to the first magnetic leg 23a, the AC flux generated by the second secondary winding Ns 2 is applied to the third magnetic leg 25a, and the AC flux generated by the first secondary winding Ns 1 and the AC flux generated by the second secondary winding Ns 2 are subtracted in phase and applied to the second magnetic leg 24a. In addition, the DC component (hereinafter referred to as DC current) of the current flowing through the first secondary winding Ns 1 and the DC component (hereinafter referred to as DC current) of the current flowing through the second secondary winding Ns 2 are subtracted in the DC flux generated by the second magnetic leg 24a, and the DC magnetic pressure generated by the DC current flowing through the first secondary winding Ns 1 and the DC magnetic pressure generated by the DC current flowing through the second secondary winding Ns 2 are in the same direction and are connected in series across the first magnetic leg 23a and the third magnetic leg 25a, and the air gap of the first magnetic leg 23a and the third magnetic leg 25a is used to resist the series DC magnetic pressure to prevent the first magnetic leg 23a and the third magnetic leg 25a from being saturated.

[0121] In comparison with Figure 5 the first magnetic assembly 2 shown in FIG. 1, although Figure 9 the AC flux of the first magnetic leg 23a of the third magnetic assembly 2b shown in FIG. 2 is large, and the air gap is large and the magnetic resistance is large, so that the AC current ripple of the first secondary winding Ns 1 is large, and the equivalent inductance of the first secondary winding Ns 1 is small, and for the same reason, although the AC flux of the third magnetic leg 25a is large, and the air gap is large and the magnetic resistance is large, so that the AC current ripple of the first secondary winding Ns 1 is large, and the equivalent inductance of the first secondary winding Ns 1 is small, correspondingly, the current ripple of the primary winding Np 1 coupled with the first secondary winding Ns 1 and the second secondary winding Ns 2 is also large, however, regardless of Figure 9 the first secondary winding Ns 1 or the second secondary winding Ns 2 of the third magnetic assembly 2b shown in FIG. 2, since they both pass straight through the magnetic legs of the magnetic assembly 2b, the path of the secondary winding is short, the equivalent parasitic resistance is small, and the conduction loss is small, so it is suitable for occasions with large current output.

[0122] In addition, for the configuration of the magnetic core assembly of Figure 9 , the entire magnetic core assembly material can be the same, such as ferrite material or iron powder material. In other embodiments, the material of the first magnetic leg 23a and the third magnetic leg 25a is different from the material of the rest of the magnetic core assembly, for example, the material of the first magnetic leg 23a and the third magnetic leg 25a is ferrite material, and the material of the rest of the magnetic core assembly is distributed air gap iron powder material, so that the magnetic core loss of the magnetic core assembly is low, and the equivalent inductance of the first secondary winding Ns 1 and the second secondary winding Ns 2 is large.

[0123] Figure 10A 、 10B is a perspective view of a power conversion module according to a third preferred embodiment of the present application from a different viewing angle, Figure 10C is an exploded view of the power conversion module shown in Figure 10A , and Figure 11 is a schematic view of the structure of the first magnetic assembly shown in Figure 10A . As shown, the power conversion module 1c of the present embodiment differs from the power conversion module 1b shown in Figure 6A in that the structure of the first magnetic assembly 2 and the second magnetic assembly 2a used in the present embodiment are respectively identical to the structure of the third magnetic assembly 2b shown in Figure 9 . In addition, the first positive output terminal pin To1+ of the power conversion module 1c of the present embodiment is arranged on the wall surface of the second magnetic cover 22 of the first magnetic assembly 2, such as the upper wall surface of the second magnetic cover 22, the lower wall surface of the second magnetic cover 22, and the side wall surface between the upper wall surface of the second magnetic cover 22 and the lower wall surface of the second magnetic cover 22, and the second positive output terminal pin To2+ is arranged on the wall surface of the second magnetic cover 22 of the second magnetic assembly 2a, such as the upper wall surface of the second magnetic cover 22, the lower wall surface of the second magnetic cover 22, and the side wall surface between the upper wall surface of the second magnetic cover 22 and the lower wall surface of the second magnetic cover 22. By arranging the first positive output terminal pin To1+ and the second positive output terminal pin To2+ on the wall surface of the second magnetic cover 22 of the first magnetic assembly 2 respectively, 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 improving the power density of the power conversion module 1c.

[0124] In the above embodiments, the first positive output terminal pin To1+ and the second positive output terminal pin To2+ can be respectively arranged on the side wall surface of the second magnetic cover 22 of the first magnetic assembly 2 and the second magnetic assembly 2a and the two surfaces adjacent to the side wall surface by electroplating, so as to increase the current conduction capacity of the positive output terminal Vo+. However, this is not a limitation, and the first positive output terminal pin To1+ and the second positive output terminal pin To2+ can also be respectively arranged adjacent to the side wall surface of the second magnetic cover 22 of the first magnetic assembly 2 and the second magnetic assembly 2a by inlaying. Furthermore, taking the first magnetic assembly shown in Figure 11 as an example, the first positive output terminal pin To1+ can also be electroplated on the side wall surface of the second magnetic cover 22 and the two surfaces adjacent to the side wall surface, and the second positive output terminal pin To2+ of the second magnetic assembly 2a can also be electroplated on the side wall surface of the second magnetic cover and the two surfaces adjacent to the side wall surface.

[0125] Figure 12 is a schematic view of the circuit topology corresponding to a power conversion module according to a fourth preferred embodiment of the present application, Figure 13 is a schematic view of the magnetic assembly of the power conversion module shown in Figure 12 . In some embodiments, after the first magnetic cover is removed,Figure 2 Based on the circuit topology corresponding to the power conversion module 1a shown, an additional winding Na can be added, i.e. to form a power conversion module 1b Figure 12 The power conversion module 1d shown, wherein the magnetic assembly 2c used by the power conversion module 1d can be Figure 9 The structure of the third magnetic assembly 2b shown, so here the same symbol is used to represent the similar structure and function of the elements, and the magnetic assembly 2c also includes an additional winding Na, which is electromagnetically coupled with the primary winding Np1, and the additional winding Na is further electrically connected with an additional inductance La, wherein the additional winding Na is alternately wound on the first magnetic column 23a and the third magnetic column 25a in the form of an ∞ shape, and the amplitude of the alternating voltage coupled out of the additional winding Na on the first magnetic column 23a and the alternating voltage coupled out of the additional winding Na on the second magnetic column 24a are approximately equal, and the phase difference is 180°. Furthermore, since the additional winding Na is alternately wound on the first magnetic column 23a and the third magnetic column 25a in the form of an ∞ shape, the voltage amplitude on the additional winding Na is reduced, and the frequency is doubled. When the duty cycle of the alternating voltage coupled out of the additional winding Na on the first magnetic column 23a and the alternating voltage coupled out of the additional winding Na on the third magnetic column 25a is close to 50%, then the additional winding Na is alternately wound on the first magnetic column 23a and the third magnetic column 25a in the form of an ∞ shape, which can make the duty cycle of the alternating voltage on the additional winding Na close to 100%, so the alternating voltage is applied to the additional inductance La, which makes the ripple current of the additional inductance La small. In addition, the number of turns of the additional winding Na wound on the first magnetic column 25a and the third magnetic column 25a is greater than or equal to 1, respectively.

[0126] When the load driven by the power conversion module 1d jumps from heavy load to light load, the output voltage Vo of the power conversion module 1d will have an overshoot, so that the controller (not shown) responds, so that the driving signals of the first switch Q1 and the second switch Q2 of the switch bridge arm of the primary side switch circuit 1 disappear, and the first rectifier element S1 and the second rectifier element S2 of the first secondary side rectifier circuit 3 are always on, so that the first secondary side winding Ns1 and the second secondary side winding Ns2 both bear the output voltage Vo, but due to the setting of the additional winding Na, the alternating voltage coupled out of the additional winding Na on the first magnetic column 23a and the alternating voltage coupled out of the additional winding Na on the second magnetic column 24a are both proportional to the output voltage Vo, so that the amplitude of the alternating voltage coupled out of the additional winding Na on the first magnetic column 23a and the alternating voltage coupled out of the additional winding Na on the second magnetic column 24a are superimposed and applied to the additional inductance La, resulting in a large increase in the current of the additional inductance La, thereby greatly reducing the current of the first secondary side winding Ns1 and the second secondary side winding Ns2, thereby greatly suppressing the overshoot of the output voltage Vo.

[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 the input terminals of the second basic power unit. Figure 2 The 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 positive output terminal To1+ of the first basic power unit 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 15As 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 partial additional winding Na1 and partial additional winding Na2, which are connected in series to form a series branch; then, the magnetic component 2... The additional winding Na1 passes between the first magnetic post 23 and the second magnetic post 24, then between the third magnetic post 25 and the second magnetic post 24, and then between the first magnetic post 23 and the second magnetic post 25 of the magnetic component 2a, and exits between the third magnetic post 25 and the second magnetic post 24. It winds two second magnetic posts 24 along the outside of the magnetic components 2a and 2, forming a partial additional winding Na1 and a partial additional winding 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 post 24 and the fourth magnetic post 26, respectively, and connected in parallel to form a closed loop with the additional inductor La. This embodiment can also apply an AC voltage coupled from the additional windings Na1 and Na2 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 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 partial additional winding Na1 and partial additional winding Na2, which are connected in series to form a series branch; then they pass around the magnetic component 2. The additional winding Na1 passes between the second and third magnetic pillars 25 of the magnetic component 2a, through the first and second magnetic pillars 23 and 24, and then through the second and third magnetic pillars 25 of the magnetic component 2a, exiting through the first and second magnetic pillars 23 and 24, forming a partial additional winding Na1 and 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 on the second and fourth magnetic pillars 24 and 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 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 none of them shall depart from the protection sought by the appended claims.

Claims

1. A magnetic component comprising: At least one 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 arranged sequentially in the same direction and positioned between the first magnetic cover and the second magnetic cover. The second magnetic post is located 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 first secondary winding and a second secondary winding, the first secondary winding passing between the first magnetic post and the second magnetic post, and the second secondary winding passing between the second magnetic post and the third magnetic post; and A primary winding, wherein a first end of the primary winding passes through the space between the first magnetic post and the second magnetic post, such that the primary winding surrounds the second magnetic post, and a second end of the primary winding passes through the space between the second magnetic post and the third magnetic post.

2. The magnetic component as claimed in claim 1, wherein a first end of the first secondary winding and a first end of the second secondary winding are on a first side of the magnetic component, and a second end of the first secondary winding and a second end of the second secondary winding are on a second side of the magnetic component, wherein the first side and the second side are opposite sides.

3. The magnetic component as claimed in claim 2, wherein the current flowing through the first secondary winding flows into the first end of the first secondary winding and flows out through the second end of the first secondary winding, and the current flowing through the second secondary winding flows into the first end of the second secondary winding and flows out through the second end of the second secondary winding.

4. The magnetic component as claimed in claim 2, wherein the first end and the second end connected across the first secondary winding are a first voltage and the first end and the second end connected across the second secondary winding are a second voltage, the first voltage and the second voltage being 180° out of phase.

5. The magnetic assembly of claim 1, wherein the first end of the primary winding, a first end of the first secondary winding, and a first end of the second secondary winding are located on the same side of the magnetic assembly.

6. The magnetic component as claimed in claim 1, wherein the length of an air gap of the first magnetic post and the length of an air gap of the third magnetic post are respectively greater than the length of an air gap of the second magnetic post.

7. The magnetic assembly of claim 1, wherein the first magnetic post and the third magnetic post are made of materials different from the materials made of the rest of the magnetic core assembly.

8. The magnetic component of claim 1, wherein the sum of the cross-sectional areas of the first magnetic post and the third magnetic post is greater than the sum of the cross-sectional areas of the second magnetic post.

9. The magnetic component of claim 1, wherein the cross-sectional area of ​​the first magnetic post is equal to the cross-sectional area of ​​the third magnetic post.

10. The magnetic assembly of claim 1, wherein the primary winding, the first secondary winding, and the second secondary winding are embedded in a printed circuit board having a multilayer structure and are respectively located in different layers of the printed circuit board.

11. The magnetic assembly of claim 1, wherein the primary winding is electrically connected to an alternating voltage having two or three voltage levels.

12. The magnetic component of claim 1, wherein the first secondary winding and the second secondary winding are electrically connected to a conductor, the conductor constituting an output terminal of a power conversion module.

13. The magnetic assembly of claim 12, wherein the conductor is formed on the wall surface of the second magnetic cover by electroplating or inlay.

14. The magnetic component of claim 1, wherein the magnetic component further comprises an additional winding alternately wound on the first magnetic post and the third magnetic post in a figure-eight pattern.

15. The magnetic component of claim 14, further comprising an additional inductor electrically connected in series with the additional winding.

16. A power supply device, comprising: A magnetic core assembly containing at least four magnetic flux channels; At least four secondary windings are wound on the core assembly, wherein the magnetic flux generated by each of the secondary windings on the core assembly flows through at least one of the magnetic flux channels. One primary winding; At least four switching devices; as well as At least one output capacitor; The magnetic flux channel through which the magnetic flux generated by each secondary winding flows on the magnetic core assembly, the corresponding secondary winding, the corresponding switching device, and the corresponding output capacitor constitute a basic component. Each secondary winding, the corresponding switching device, and the corresponding output capacitor are connected in series to form a closed loop. The power supply device includes at least four closed loops. The four closed loops are connected in parallel. The primary winding has two winding directions on the at least four magnetic flux channels, and the number of basic components corresponding to each winding direction is equal.

17. The power supply device of claim 16, wherein the number of the basic components is even.

18. The power supply device of claim 16, wherein the power supply device further comprises a primary-side switching circuit electrically connected to the primary-side winding.

19. The power supply device of claim 18, wherein the power supply device includes a positive input terminal, a negative input terminal, a positive output terminal, and a negative output terminal, the positive input terminal and the negative input terminal are electrically connected to the primary-side switching circuit, and the positive output terminal and the negative output terminal are electrically connected to the two ends of the at least one output capacitor.

20. The power supply device of claim 18, wherein the primary-side switching circuit includes a switching bridge arm, the switching bridge arm including two switches connected in series, and the midpoint of a bridge arm between the two switches being electrically connected to a first end of the primary-side winding.

21. The power supply device of claim 20, wherein the primary-side switching circuit includes at least one capacitor bridge arm, the capacitor bridge arm being connected in parallel with the first switching bridge arm and including two capacitors connected in series, the midpoint of a bridge arm between the two capacitors being connected to a second end of the primary-side winding.

22. The power supply device of claim 20, wherein the primary-side switching circuit includes another switching arm, the other switching arm being electrically connected in parallel with the first switching arm and including two switches connected in series, and the midpoint of one arm between the two switches of the other switching arm being electrically connected to a second end of the primary winding.

23. The power supply device of claim 19, wherein the negative input terminal and the negative output terminal are electrically connected.

24. The power supply device of claim 21, wherein the power supply device comprises a first secondary-side rectifier circuit and a second secondary-side rectifier circuit, the first secondary-side rectifier circuit, two of the at least four secondary-side windings and the first positive output terminal pin constitute a first rectifier circuit with a center tap, and the second secondary-side rectifier circuit, the remaining two of the at least four secondary-side windings and the first positive output terminal pin constitute a second rectifier circuit with a center tap.

25. The power supply device of claim 24, wherein the currents flowing through the two secondary windings of the first rectifier circuit are in the same direction, and the currents flowing through the two secondary windings of the second rectifier circuit are in the same direction.

26. The power supply device of claim 24, wherein the first secondary-side rectifier circuit further includes two of the at least four switching devices, and the second secondary-side rectifier circuit further includes the remaining two of the at least four switching devices.

27. The power supply device of claim 18, wherein the primary-side switching circuit further includes a DC blocking capacitor connected in series with the primary-side winding.

28. The power supply device of claim 16, wherein each of the at least four secondary windings has one turn.

29. The power supply device of claim 16, wherein the magnetic flux flowing through the four magnetic flux channels is magnetically coupled within the magnetic core assembly.

30. The power supply device of claim 16, wherein the at least four secondary windings and the primary winding are embedded in a substrate, and the primary windings and the at least four secondary windings are arranged overlapping within the substrate.

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