Integrated magnetic assembly and switched mode power converter

Abstract

The subject of this invention is "Integrated Magnetic Assembly and Switching Mode Power Converter". This invention relates to an integrated magnetic assembly for a switching mode power converter. The integrated magnetic assembly includes a single-core structure formed of core elements, wherein at least one of the core elements is a leg core element having a flange and one or more legs arranged on one side of the flange. The core elements of the single-core structure are linearly stacked. The integrated magnetic assembly also includes an isolation transformer, wherein a higher current transformer winding is arranged on at least one leg of the core element, a lower current transformer winding is arranged on at least one leg of the core element, and a first filter inductor includes a first filter winding arranged on at least one leg of the core element. Here, the higher current transformer winding and the filter winding include winding portions wound at least along the edges. This invention also relates to a switching mode power converter.

Description

[0001] This application is a divisional application of patent application filed on January 12, 2018, with application number 201810031946.2 and invention title "Integrated Magnetic Components and Switching Mode Power Converter". Technical Field

[0002] This invention relates to an integrated magnetic assembly for a switching mode power converter, comprising a single-core structure formed of core elements, wherein at least one of the core elements is a leg-core element (having a flange and one or more legs disposed on one side of the flange), and wherein the core elements are linearly stacked. The integrated magnetic assembly also includes an isolation transformer, wherein a higher current transformer winding is disposed on at least one leg of the core element, and a lower current transformer winding is disposed on at least one leg of the core element, and a first filter inductor includes a first filter winding disposed on at least one leg of the core element. Background Technology

[0003] As a key component of telecommunications and commercial systems, switching mode power supplies typically have specified size and electrical performance, as well as reliability and cost. With increasing demands for power density and efficiency—critical characteristics of power converters—the need for these evaluation characteristics is particularly strong for inductive components. One way to increase power density and efficiency is to integrate inductive components. Transformers and inductors can be integrated into a single-magnetic structure, which can reduce cost and increase power density and power efficiency.

[0004] One circuit with strongly recommended integrated magnetic components is the current multiplier rectifier, which can be used with various two-terminal master topologies, such as forward, two-transistor-forward, push-pull, half-bridge, or full-bridge converters. Current multiplier rectifier circuits, conventionally used for low-voltage and high-current outputs, employ a simple two-winding transformer and two output inductors. Current multiplier rectifiers exhibit lower conduction losses compared to conventional center-tapped rectifiers. This construction typically results in a higher number of discrete magnetic components, leading to greater size and cost across three high-current windings, as well as some high interconnect losses, negatively impacting efficiency.

[0005] US Patent No. 6784644 (Virginia Tech Intellectual Properties) describes an integrated magnetic structure for a current multiplier rectifier, in which the transformer secondary winding and secondary inductor winding are integrated, thereby eliminating the need for a secondary inductor winding while maintaining rectifier functionality. Due to the introduced gap, the secondary winding not only transforms but also stores energy. The integration of the core and winding reduces cost and increases power density. The reduced number of secondary windings and high-current interconnects results in lower winding losses. The tight coupling between the primary and secondary windings produces minimized leakage inductance.

[0006] Another integrated magnetic structure for current multiplier rectifiers is disclosed in EP 2299456A1 (DET International Holding Limited). Using both standard U / UR cores and bobbinless U / UR cores, it can be manufactured with high quality and therefore at a reduced cost. Tight core winding coupling results in lower leakage, minimized copper power losses and inductance losses, and minimized overall thermal resistance. Furthermore, without bobbins, power density increases while cost decreases with reduced cost per unit.

[0007] The integrated magnetic structure shown in Patent No. 6549436 (Innovative Technology Licensing LLC), U.S. Patent No. 6163466 (Davila, Jr. et al.), and U.S. Patent No. 7034647 (Northeastern University) includes four windings: a primary winding, two secondary windings, and an additional filter winding, which is introduced to further increase the effective inductance and reduce current ripple in the output of the current multiplier rectifier circuit.

[0008] They primarily use retail E-cores, or sometimes complex core structures such as those described in U.S. Patent No. 6980077 (ColdWatt Corporation).

[0009] While the described patent addresses some of the proposed improvements, there are also some setbacks. These cores are not flexible enough in terms of mounting and adjusting the magnetizing and filtering inductance via gaps. Furthermore, conventional inductors (round wire and stranded wire) are unsuitable for high-current secondary windings. Summary of the Invention

[0010] The objective of this invention is to create an integrated magnetic component belonging to the initially mentioned technical field, wherein losses are further reduced, thereby generating higher power density, while on the other hand, production costs should be reduced.

[0011] The solution of the present invention is specified by the features of independent claim 1. According to the present invention, the higher current transformer winding and the filter winding include a winding portion wound at least along the edge.

[0012] An edge-wound is a winding that uses a conductor with a substantially rectangular cross-section (with a shorter edge and a longer edge), wherein the conductor is wound around the shorter edge, but not the longer edge. The substantially rectangular cross-section allows for a general description of the shape of the cross-section, distinguishing it particularly from a circular cross-section. Therefore, a substantially rectangular cross-section can have rounded corners between the shorter and longer edges. The conductor can be, for example, a flat wire.

[0013] The outer shape of the edge winding can be circular, but it can also be non-circular, such as a rectangular shape including curved portions. The conductor of the edge winding is preferably wound in a helical shape, wherein one or more layers of conductor are stacked along the winding axis. However, in some cases, it is advantageous to wind the conductor in a coiled shape, resulting in a flat winding.

[0014] The winding portion along the edge includes at least one turn of rectangular wire. This turn defines an orifice with a minimum extension, preferably not less than twice the width of the wire, wherein the width of the wire is defined by the shorter edge of the wire. The first turn may not be completely closed, but in any case encloses an angle of at least approximately 180°.

[0015] A magnetic core element is a component made of a highly permeable material. Core elements can be used as building blocks, arranged to construct a core structure, thereby forming a common magnetic circuit. A core element may be a legged core element or an I-core. A legged core element includes a flange and at least one leg disposed on a side of the flange, wherein the legs are preferably arranged perpendicularly to the flange. Conversely, an I-core includes only a single flange and no legs. A multi-legged core is a legged core having at least two legs, wherein the legs are disposed on the same side of the flange. The flange of a legged core element or an I-core includes preferably two parallel surfaces, wherein one of the two surfaces forms a side in which at least one leg is disposed. If the legged core element is a multi-legged core element, its legs will be disposed on the side defined by said surface.

[0016] Magnetic core elements may be considered as abstract building blocks, but they preferably represent building blocks constructed from a single piece (preferably of the same material). However, they can be assembled from different sub-building blocks (like I-cores). For example, a building core element (e.g., a U-shaped core element) can be assembled by means of three I-cores, where the first I-core represents the flange of the U-core, and the two other I-cores represent the two legs of the U-shaped core element, arranged on the same side of the first I-core. Similarly, an E-shaped core element may be assembled from four I-cores, or a U-shaped core element and an I-core (forming inner legs). Assembling sub-building blocks to the magnetic core element can be achieved using gluing.

[0017] In the context of this application, linear stacking means that the core elements are arranged in series in a row.

[0018] Higher current transformer windings can be arranged on the primary side or the secondary side of the isolation transformer, thereby allowing the isolation transformer to transfer energy from the primary side to the secondary side due to electromagnetic induction.

[0019] By using edge windings, a very high fill factor and / or winding factor of the core winding window can be achieved. The integrated magnetic assembly can therefore be compact, and compactness and high power density can be achieved by means of the integrated magnetic assembly of the invention.

[0020] The invented integrated magnetic components not only reduce I²R losses (also known as copper losses), but also result in reduced stray inductance and electromagnetic interference due to the compact design. The edge windings also enable higher levels of automation, allowing for lower production costs.

[0021] Integrated magnetic components are generally suitable for use in DC-DC, AC-DC, and DC-AC switching mode power converters. They are particularly suitable for use in switching mode DC-DC power converters. DC-DC power converters have a converter stage at the input. The converter stage preferably has a two-terminal master topology, such as forward, two-transistor-forward, push-pull, and half-bridge or full-bridge converter topologies. Integrated magnetic components also have a rectifier stage at the output.

[0022] The DC input power can be applied to the DC input of the converter stage of a DC-DC voltage converter. The converter stage converts the DC input power to AC input power, which is supplied to an integrated magnetic component and associated with a switching signal and therefore with the switching steps of the converter stage. The AC input power is, for example, accompanied by a rectangular input voltage. The integrated magnetic component receives the AC input power and transfers it via an isolation transformer to the rectifier stage at the output of the DC-DC switching mode power converter. The rectifier stage can be partially or entirely integrated into the integrated magnetic component and is adapted to generate DC output power at the output of the switching mode power converter. The DC output power preferably provides a DC output voltage.

[0023] The AC input power to be applied to the integrated magnetic component can also be provided directly by a direct AC-AC converter stage. Alternatively, an additional AC-DC converter stage can be used upstream of the aforementioned converter stage, supplying DC input power to the converter stage as intermediate DC input power. This intermediate DC input power can be provided by an AC-DC converter stage, such as a simple passive rectifier circuit or an active rectifier circuit, such as AC-DC power factor correction (PFC). The DC-AC converter stage can be positioned downstream of the rectifier stage to provide AC power output. Therefore, the integrated magnetic component is suitable for AC-AC, DC-AC, and AC-DC power conversion.

[0024] In a preferred embodiment of the present invention, the core element of the integrated magnetic assembly is a leg core element or an I-core, wherein the I-core includes a single flange.

[0025] Leg core elements and I-cores are not only convenient for mass production; they are particularly well-suited for linear stacking in such a way that the core elements are preferably arranged in series in rows with the flanges of the core elements arranged in parallel. Here, preferably, the legs of the leg core elements form at least one row of legs. In this row, two proximal legs are directly adjacent to each other, or separated by flanges and arranged on opposite sides of said flanges. The legs of said row are preferably arranged along a single axis. It is also preferred that the sides of the flanges have flat and / or parallel surfaces. If a gap exists between adjacent portions in the flux path, a portion of the core element is considered to be adjacent to another portion. However, this is when the gap is relatively small compared to the distance between the flanges of adjacent core elements. In this context, relatively small is considered to be less than 25% of the distance between the flanges of adjacent core elements. Preferably, the core elements are arranged such that the flanges of the core are positioned parallel to each other. It is also preferred that one or more legs of the leg core element abut the flange of an adjacent core element, or abut one or more legs of an adjacent core element at right angles.

[0026] In another preferred embodiment, the magnetic core element includes a first transformer core element, a second transformer core element, and a first filter core element. The transformer core elements are stacked such that their flanges and legs form at least one transformer winding window for receiving turns of the transformer winding. Furthermore, the first filter core element is stacked on top of the first transformer core element such that the flanges and legs of the first transformer core element and the filter core element form at least one first filter winding window adapted to receive turns of the first filter winding.

[0027] This arrangement is very convenient because it allows for the construction of magnetic circuits comprising at least two independent magnetic loops, reducing the number of core elements required. Here, the core structure surrounding the two winding windows defines two independent flux loops that share the flange of the first filter core element or the first transformer core element as a common flux path. This reduces the core material required for integrated magnetic components.

[0028] The lower current transformer winding and the higher current transformer winding are preferably arranged on the leg in such a way that their turns pass through the transformer winding window, while the first filter winding is preferably arranged in such a way that its turns pass through the first filter winding window.

[0029] It is worth noting that in this application, if the gap is arranged in the flux path defined by two magnetic core elements, the winding window formed by the two magnetic core elements is still considered a window.

[0030] In another preferred embodiment, a first filter gap is provided in the magnetic flux path between the filter core element and the first transformer core element.

[0031] The arrangement of the first filter gap between the filter core element and the first transformer core element is highly suitable for manufacturing. In the case of multi-leg core elements, the gap can be obtained by adapting the length of the legs relative to another leg and / or other legs of the same multi-leg core element. This is typically achieved by grinding the legs at their free ends. In some cases, an additive method can also be advantageously applied. The first filter gap can be provided by inserting a piece of material with low or lower permeability between the first transformer core element and the first filter core element.

[0032] If a single-leg core element is used, the magnetic flux generated by the filter winding causes its forward path to pass through the single leg, and its return path to pass through the filter gap. The distance can be defined by the length of the single leg, which also defines the distance between the flanges of adjacent core elements.

[0033] Alternatively, in addition to providing the first filter gap in the flux path between the filter core element and the first transformer core element, it can also be integrated into the respective core element, which may include regions with lower permeability. This region may, for example, comprise discrete layers of low-permeability material or a large area of ​​this material. Multiple smaller air gaps and / or micro-voids can also be included in the core element to achieve so-called distributed voids. The entire core element can also be manufactured as a single piece of this magnetic material. For example, an iron powder core can be manufactured from iron powder.

[0034] Optionally, the gap can also be arranged between the first transformer core element and the second transformer core element, which allows magnetic saturation of the transformer core element to be avoided.

[0035] In a particularly preferred embodiment, the integrated magnetic component includes the features mentioned above in combination as follows:

[0036] a) The core element of the integrated magnetic assembly is a leg core element or an I-core, wherein the I-core includes a single flange.

[0037] b) Wherein the magnetic core elements include a first transformer core element, a second transformer core element, and a first filter core element, the core elements being stacked in such a way that their flanges and legs form at least one transformer winding window and a first filter winding window, and

[0038] c) Wherein the first filter gap is provided in the magnetic flux path between the filter core element and the first transformer core element.

[0039] However, features a), b), and c) above can be implemented independently of each other.

[0040] In a further advantageous embodiment of the invention, the integrated magnetic component includes a second filter inductor, which includes a second filter winding disposed on at least one leg of the magnetic core element.

[0041] By using a second filter inductor, the performance of the integrated magnetic components can be further increased, especially enabling a rectifier topology with better performance at the output.

[0042] In a further preferred embodiment of the integrated magnetic assembly, the second filter core element is stacked on top of the first filter core element, or on the side of the second transformer core element opposite to the first transformer core element. The second filter core element and the adjacent magnetic core element form at least one second filter winding window for receiving turns of the second transformer winding. Furthermore, a second filter gap is provided in the flux path between the filter core element and the adjacent core element.

[0043] By distributing the filter windings and gaps across two filter core elements, the field is dispersed, and thus losses are further reduced. A further advantage of this embodiment is that the integrated magnetic components will result in improved transient response.

[0044] In a further preferred embodiment, the integrated magnetic assembly includes exactly two filter core elements.

[0045] By stacking the second filter core element on top of the first filter core element, the electrical connection between the first and second filter windings becomes shorter. This arrangement simplifies the modular design and assembly of the circuit. It is particularly advantageous if two circuit boards are used to connect the windings: the first board connects to the higher current transformer winding, and the second board connects to the filter winding.

[0046] On the other hand, when the second filter core element is arranged on the side of the second transformer core element, a symmetrical arrangement can be achieved, allowing for a shorter connection between the higher current transformer winding and the filter winding. The symmetrical arrangement is also beneficial for the magnetic flux distribution in the magnetic circuit. Therefore, I²R (copper) losses and core (iron) losses can be reduced.

[0047] In another preferred embodiment, the transformer core element and the filter core element are legged core elements, wherein the transformer core elements are adjacent to each other with their legs. Here, the first filter core element preferably has its leg adjacent to the flange of the first transformer core element, while the second filter core element preferably has its leg adjacent to the flange of the second transformer core element or the flange of the second filter core element. This arrangement is preferred because it allows for the use of a minimal number of core elements and the clearance is easily achieved by grinding the legs of the core elements.

[0048] Alternatively, the single-core structure may include leg core elements and I-cores. However, by using only leg core elements, the gaps can be arranged more towards the inside of the core structure, representing lower electromagnetic interference. Therefore, transformer gaps can be arranged between the legs of opposing transformer core elements. Filter gaps can also be arranged towards the flanges of adjacent transformer core elements and / or adjacent filter core elements. Thus, the gaps are more oriented towards the center of the core structure.

[0049] In another preferred embodiment, the multi-legged core element is a U-shaped core.

[0050] A U-shaped core is a standardized magnetic core that is U-shaped or C-shaped. In the context of this application, the term U-shaped core also includes UR-shaped cores or similar cores. Using a U-shaped core allows for a very simple and compact core structure, where the amount of core material required is minimized. The use of standardized components reduces the cost of integrated magnetic assemblies. The two-legged core elements of a U-shaped core are particularly advantageous when a high total cross-sectional area of ​​the winding inductor and therefore a large winding window are required, since the ratio between the core material and the window winding size is optimal for a U-shaped core.

[0051] The legs of the linearly stacked U-shaped core form the first and second rows of legs. The windings are preferably arranged on either the first or second row of legs. By mounting the windings in the same row, including the portion of the winding wound along the edge, the installation of the windings becomes simple and a more compact, integrated magnetic assembly can be achieved. Preferably, the transformer windings are arranged in series on the same leg to improve coupling.

[0052] In another preferred embodiment, the core element is a three-legged core element comprising an inner leg and two outer legs. At least one three-legged core element, together with a second three-legged core element, forms a first transformer winding window and a second transformer winding window for receiving turns of the transformer winding. The winding with integrated magnetic components is preferably arranged on the inner leg.

[0053] Three-legged core elements can be standardized E-shaped core elements, including E-shaped, ER-shaped, EFD-shaped, ETD-shaped, PQ-shaped, PM-shaped, or RM-shaped cores or similar three-legged core elements. Using standardized elements reduces the cost of integrated magnetic components. Different E-shaped core elements differ in their geometry. The E-shaped core has the simplest geometry, with its flange and legs having rectangular cross-sections. The ER-shaped core is similar, but its legs include circular cross-sections. The ETD-shaped core also has circular inner legs, but its outer legs have concave surfaces oriented towards the inner legs. The EFD-shaped (Economic Flat Design) core has a flat design, with its legs having substantially rectangular cross-sections and its inner legs having a particularly flat shape. PQ-shaped, RM-shaped, and PM-shaped cores are so-called can-shaped cores. They include strongly optimized geometries with circular inner legs and flanges, which are formed to at least partially wrap around and shield the winding.

[0054] By arranging the windings on the inner legs, magnetic flux leakage is reduced, thus losses and electromagnetic interference are decreased. Assembly is also simplified if all windings are arranged in the inner legs, which are preferably arranged in a row along a common axis. It is also possible to arrange the windings on the two outer legs, or on both the outer and inner legs.

[0055] However, by arranging the windings in the same row, including the winding portion wound along the edge, the installation of the windings becomes simple and a more compact, integrated magnetic assembly can be achieved.

[0056] In another preferred embodiment, the first filter gap is divided into a first part and a second part, wherein the first part of the first filter gap is arranged between one of the outer legs of the first filter core element and the flange of the first transformer core element, and wherein the second part of the first filter gap is arranged between the flange of the first transformer core element and the other outer legs of the first filter core element.

[0057] More preferably, when a second filter element is present, the second filter gap is divided into a first portion and a second portion, wherein the first portion of the second filter gap is disposed between one of the outer legs of the second filter element and the flange of the first transformer core element or the first filter element. The second portion of the second filter gap is disposed between the other outer legs of the second filter element and the flange of the first filter element or the second transformer core element.

[0058] Distributing the first and / or second filter gaps across two air gap sections is particularly advantageous when a significant amount of energy must be stored in the filter gap and / or if a large amount of power must be transferred on an isolation transformer with integrated magnetic components. Distributing the stored magnetic energy across two gap sections reduces total air gap scattering compared to a single gap with twice the length. Furthermore, by arranging the gap sections between the outer leg and the corresponding flange, while the filter winding is arranged on the inner leg, the distance between the gap and the filter winding is increased, and gap losses are reduced.

[0059] However, arranging gaps on the inner legs reduces electromagnetic interference from the integrated magnetic components.

[0060] In a specific embodiment of the present invention, the first filter core element is a leg core element with a single inner leg, and the first filter winding is arranged on the single inner leg, which is adjacent to the flange of the first transformer core on the side opposite to the inner leg of the first transformer core element.

[0061] Furthermore, in a further preferred embodiment, a second filter core element is provided, which is a leg core element with a single inner leg, on which a second filter winding is arranged. The single inner leg is adjacent to the flange of the second transformer core on the side opposite to the inner leg of the second transformer core element or the flange of the first filter core element, and on the side opposite to the first filter core element.

[0062] The magnetic flux generated by the first filter winding causes its forward path to pass through the single inner leg of the first filter core element and the flanges of the first filter core element and the first transformer core element. First filter gaps are arranged between those flanges, where the gaps form the return path of the magnetic flux.

[0063] In a preferred embodiment, the single inner leg is arranged toward the center of the flange, and the first filter gap is divided into two gap portions arranged on both sides of the single leg.

[0064] The space between the flanges not only defines the first filter gap / second filter gap, but also forms a space for receiving the first filter winding turn / second filter winding turn, and is therefore considered a winding window in the context of this application, but with the side of the window open.

[0065] The filter gap from one flange to the adjacent flange can also be considered a special case where the leg is shortened to zero length. Although the opening defines the corresponding gap, the transformer winding window and / or filter winding window are also considered windows.

[0066] In a preferred embodiment, the space between the two flanges is at least partially filled with a low-permeability material, which mechanically closes the winding window but leaves space for the filtering winding window. This allows for increased mechanical stability of the integrated magnetic components.

[0067] With this arrangement, a large amount of energy can be stored in the magnetic circuit, and the switching mode power converter transmits power in each cycle, resulting in a high power transfer rate, especially when combined with the use of the edge winding section.

[0068] In a particularly advantageous embodiment, the higher current transformer winding and / or filter winding is adapted to an operating current greater than 10 A, preferably greater than 20 A or greater than 30 A (RMS).

[0069] Edge-wound sections are particularly suitable for those operating currents because a high fill factor of the winding window can be achieved. It is also possible to use edge-wound portions for smaller currents; however, edge-wound portions are especially advantageous for preferred operating currents. As the conductor cross-section decreases, the improved fill factor is reduced by using edge-wound sections because the fraction of the conductor's insulating material relative to the conductor area increases.

[0070] Particularly preferred is that if the higher current transformer winding of the isolation transformer includes at least a second edge-wound portion, the edge-wound portion of the higher current transformer winding, the lower current transformer winding, and / or an additional portion of the lower current transformer winding are arranged in an alternating manner along the legs of the two transformer core elements.

[0071] With this preferred arrangement, the coupling between the lower current transformer winding and the higher current transformer winding can be increased, and the leakage flux can be reduced.

[0072] Alternatively, the edge windings can be arranged concentrically by alternating the edge-wound portions of the higher-current transformer windings with the edge-wound portions of the lower-current transformer windings.

[0073] In a further preferred embodiment, the integrated magnetic component includes at least a second edge-wound winding portion connected in parallel with an edge-wound winding portion of a higher current transformer winding or a filter winding, so that the integrated magnetic component can scale according to the required operating current.

[0074] This allows the transformer windings and / or filter windings to be scaled to specific operating currents, such as 10A, 20A, or 30A (RMS), by increasing the number of winding portions wound along the edges of the parallel-connected higher current transformer windings.

[0075] In other cases, it may be advantageous to connect the winding portions of the higher current transformer winding in series, for example if the voltage ratio must be adapted.

[0076] A further preferred option is that the lower current transformer winding is integrated into the printed circuit board.

[0077] By integrating the lower current transformer winding into a printed circuit board, the assembly of the integrated core components is simplified and better suited for automated assembly processes. The winding length of the isolation transformer can be kept very short by combining the printed circuit board integrating the lower current transformer winding with the edge-wound portion of the higher current transformer winding. As both, the edge-wound portion of the higher current transformer winding and the printed circuit board with the lower current transformer winding are adjacent to each other on flat surfaces, enabling increased coupling between the higher current transformer winding and / or the winding (partially) and the lower current transformer winding. Therefore, stray losses can be reduced. If the lower current transformer winding comprises more than one winding portion, the winding portions may be integrated into more than one printed circuit board, where the printed circuit board and the higher current transformer winding portion can be arranged in an interleaved manner.

[0078] In a further preferred embodiment, at least one of the filter gaps has a length that is at least 10%, more preferably at least 30%, 50%, 75%, or 100% of the length of the distance between the flange of the filter core element and the flange of the magnetic core element, which are magnetically interconnected by the magnetic flux path formed by the filter gap.

[0079] By increasing the length of the filter gap, the transmission power of the integrated magnetic component can be increased without further increasing the operating current of the magnetic component. Since a larger gap can store more energy than a smaller gap, more energy can be transmitted per operating cycle.

[0080] A further preferred embodiment of the integrated magnetic components is particularly suitable for use with a current multiplier rectifier. This embodiment includes two magnetic core elements, wherein the legs of the two core elements form at least three adjacent winding windows, wherein turns of the higher current transformer winding are arranged on at least one of the legs, turns of the lower current transformer winding are arranged on at least one of the legs, and turns of the filter winding are arranged on at least one other leg.

[0081] Because it requires only two magnetic core elements, this embodiment is particularly simple to assemble. Even automated assembly is possible using winding portions wound along the edges. Furthermore, this integrated magnetic assembly achieves three independent flux loops within a single integrated magnetic assembly.

[0082] Preferably, each of the windings may be arranged on more than one leg. The winding may, for example, be arranged on two adjacent legs, defining a magnetic flux path between the two core elements. It is also preferred that the winding portion, for example, the edge-wound portion of a higher current transformer winding, is arranged on two adjacent legs, thereby defining a magnetic flux path between the two core elements. More preferably, the higher current transformer winding includes a second edge-wound portion, wherein the first edge-wound portion is arranged on at least one leg (arranged in a first magnetic flux path between the first and second core elements), and the second edge-wound portion is arranged on at least one leg (in a second magnetic flux path between the first and second core elements). The lower current transformer winding also preferably includes a first winding portion and a second winding portion. Preferably, the first winding portion is arranged on at least one leg (in a first flux path between the first and second magnetic core elements), and the second winding portion is arranged on at least one leg (in a second flux path between the first and second magnetic core elements). The first filter winding is preferably arranged on at least one leg in a third flux path between the first and second magnetic core elements. The integrated magnetic assembly also includes a second filter inductor having a second filter winding, which is preferably arranged on at least one leg in a fourth flux path between the first and second magnetic core elements.

[0083] In a preferred embodiment, at least one of the two integrated magnetic components includes a first inner leg and a second inner leg, as well as a first outer leg and a second outer leg.

[0084] Preferably, the legs are arranged in parallel on one side of the flange, the inner leg and the flange form a transformer winding window, the first outer leg, its adjacent first inner leg and the flange form a first filter winding window, and the second outer leg, its adjacent second inner leg and the flange form a second filter winding window.

[0085] Advantageously, the isolation transformer includes a second lower current transformer winding and a second higher current transformer winding, and the integrated magnetic assembly also includes a second filter inductor with a second filter winding. Preferably, the lower current transformer winding and the higher current transformer winding are arranged on the inner legs, and the filter winding is on the outer legs of the magnetic core structure.

[0086] Therefore, the transformer winding window receives turns of the lower current transformer winding and the higher current transformer winding, the first filter winding window receives turns of the first filter winding, as well as turns of the lower current transformer winding and the higher current transformer winding, and the second filter winding window receives turns of the second filter winding, as well as turns of the lower current transformer winding and the higher current transformer winding. This means that the lower current transformer winding and the higher current transformer winding are arranged such that their turns pass through the transformer winding window, while the first filter winding is arranged such that its turns pass through the first filter winding window, and the second filter winding is arranged such that its turns pass through the second filter winding window.

[0087] In a further preferred embodiment of the invention, the integrated magnetic component includes a circuit board, wherein at least one of the winding portions wound along the edge has a first end and a second end of the circuit board oriented in the same direction.

[0088] By aligning the first and second ends in the same direction, the circuit and the winding portion wound along the edge can be efficiently connected to the circuit board.

[0089] Alternatively, the ends of the winding portion wound along the edge may be arranged in different, non-parallel directions, such as in opposing directions. This arrangement may be advantageous in certain applications, such as if the two ends of the winding portion are to be connected to different circuit boards.

[0090] Advantageously, the circuit board electrically connects the higher current transformer winding to the filter winding.

[0091] By using a circuit board, such as a printed circuit board, to connect the transformer windings to the filter windings and / or multiple windings, no additional lead conductors are required, but the winding portions wound along the edges can be directly connected to the circuit board. Therefore, no additional solder joints are required, leading to a reduction in conduction losses. Consequently, heat generation is also reduced. This allows for a more compact design of the component.

[0092] Furthermore, assembly is simplified because the corresponding edge-wound winding portions and circuit boards can be pre-assembled to one or more edge-wound winding modules, thus simplifying production and logistics. Moreover, the production of such edge-wound winding modules (including edge-wound winding portions and circuitry) is particularly suitable for automated production. These edge-wound winding modules can be assembled integrally with the core structure.

[0093] In another preferred embodiment of the invention, the integrated magnetic component includes a rectifier circuit comprising at least two rectifier elements, particularly synchronous rectifiers, wherein the rectifier elements are mounted on a circuit board that connects the rectifier elements to a higher current transformer winding of a transformer and to a first filter winding.

[0094] By integrating the rectifier components onto the circuit board, the number of connection points and copper losses can be further reduced. This simplifies the assembly process. For higher current requirements, multiple rectifiers can be connected in parallel on the integrated circuit board to increase the circuit's maximum current.

[0095] Alternatively, at least one of the rectifier components can be integrated into an additional circuit board. This can be advantageous if a large number of rectifier components are required.

[0096] Particularly preferred is that the rectifier element is surface-mounted. The rectifier element is preferably a synchronous rectifier.

[0097] By using surface-mount rectifiers, less space is required and higher power density can be achieved. Production costs are also reduced because a high degree of automation can be enabled.

[0098] Synchronous rectifiers are actively controlled switches. These switches include, for example, metal-oxide-semiconductor field-effect transistors (MOSFETs) and bipolar junction transistors (BJTs). Synchronous rectifiers allow for improved rectification efficiency. Due to their low turn-on impedance, they significantly reduce ohmic resistance compared to ordinary semiconductor diodes, especially in the presence of high currents. Furthermore, they avoid the voltage drop exhibited by semiconductor diodes in the conduction state, which is typically 0.7 V for silicon diodes and / or 0.3 V for germanium diodes.

[0099] For very high currents, the voltage drop of a synchronous rectifier may exceed that of a passive rectifier. In this case, it may be preferable to use a rectifier, such as a diode. In particular, Schottky diodes may be used instead of standard diodes because they exhibit a voltage drop of even less than 0.2 V.

[0100] Alternatively, through-hole mounting of the rectifier element can be used. This is advantageous if, for example, a heat sink rectifier element is required.

[0101] In a further preferred embodiment, the circuit board is provided with rectangular through holes for mounting an edge-wound portion of the winding, which is adapted to mechanically support the single-core structure.

[0102] This embodiment allows for the utilization of the mechanical stability of the edge winding. Since the integrated magnetic assembly is supported by at least one circuit board, additional mechanical support is negligible and assembly can be greatly simplified. This also implies that the size and / or weight of the integrated magnetic assembly can be further reduced.

[0103] In some cases, however, additional mechanical support may be preferred, for example, to further increase mechanical stability, or if a body shell is already present or anticipated. In some cases, it may be advantageous to avoid through-holes in the circuit board, for example, to further reduce costs or to make integrated magnetic components suitable for certain assembly techniques.

[0104] Preferably, the rectifier circuit is a current multiplier.

[0105] A current doubler rectifier is a full-wave rectifier current doubler, which is particularly advantageous when high output current is required. Higher current transformer windings are used, in this case the transformer's secondary winding must only carry about half of the output current. This allows for reduced copper losses. Additionally, only two rectifier elements are required, and a center tap on the secondary side is unnecessary. Heat is also distributed across the first and second filter windings. Furthermore, higher resolution is possible in the transformer turns compared to a full-wave center-tapped rectifier because the two secondary windings of a center-tapped rectifier are replaced by a single secondary winding in current doubler applications. Typically, a lower smoothing capacitor is also required at the output, as an inductor is needed for the filter rectifier.

[0106] Alternatively, the rectifier circuit can be a center-tapped rectifier. Center-tapped rectifiers also use two rectifier elements, only one of which causes a voltage drop in the current path, and are therefore suitable for high-current applications. Typically, they require a higher output inductance than current-multiplying rectifiers and only a single filter winding, but are preferably divided into two parts.

[0107] In some applications, particularly where the output voltage has certain voltage levels and power losses, appropriate voltage reduction of the rectifier elements is not critical, and full-wave bridge rectifier circuits may also be advantageously used.

[0108] In a further preferred embodiment, the integrated magnetic assembly is adapted for use with a voltage multiplier rectifier circuit. Here, the higher current transformer winding is on the primary side of the isolation transformer, while the lower current transformer winding is on the secondary side of the isolation transformer. The integrated magnetic assembly may also include rectifier elements and / or capacitor elements of the voltage multiplier rectifier circuit. Those rectifier elements are connected to the secondary side of the isolation transformer, while the filter winding is adapted to be connected to the primary side of the isolation transformer, correspondingly to the side of the transformer including the higher current transformer winding. The integrated magnetic assembly may also include a circuit board that connects the higher current transformer winding to at least the first filter winding.

[0109] The integrated magnetic assembly according to any one of the preceding claims, wherein the winding portion wound along the edge is wound from an overglazed flat wire, and / or wherein the lower current transformer winding comprises triple-insulated wire.

[0110] By using triple-insulated wire and glazed flat wire, no further isolation layers are required between the primary and secondary transformer windings and / or between the higher-current and lower-current transformer windings. Assemblies can therefore be arranged in direct contact with each other, which reduces flux leakage and results in a more compact and efficient design.

[0111] Alternatively, an additional isolation layer may be disposed between the winding portions of the higher current transformer winding and the lower current transformer winding. The isolation layer typically comprises insulating material, or may include mechanical spacers. In this case, a simple double-layer isolation can be used for the lower current transformer winding.

[0112] The present invention also relates to a switching mode power converter, particularly a switching mode DC-DC power converter, which includes any integrated magnetic component according to the embodiments mentioned in the description.

[0113] Switching-mode power converters inherit all the advantages of integrated magnetic components mentioned above. Integrated magnetic components are particularly advantageous for switching-mode DC-DC converters, or corresponding AC-DC converters that include a switching DC-DC mode power converter stage.

[0114] Other advantageous embodiments and combinations of features are derived from the following detailed description and the claims as a whole. Attached Figure Description

[0115] The accompanying drawings used to explain the embodiments show:

[0116] Figure 1 The circuit configuration of a DC-DC switching mode power converter with a current multiplier rectifier according to the present invention is shown.

[0117] Figure 2 It shows that according to Figure 1 A DC-DC switching mode power converter with a current multiplier rectifier, the current waveforms of the higher current winding section of the isolation transformer, the current in the filter winding, and the output current.

[0118] Figure 3 A first embodiment of the integrated magnetic component according to the present invention is shown, which is implemented in a DC-DC switching mode power converter with a current multiplier rectifier, the integrated magnetic component comprising a U-shaped core element;

[0119] Figure 4 Showing according to Figure 3 A magnetoresistive model of the core structure of an integrated magnetic component;

[0120] Figure 5 Showing according to Figure 3 The waveforms of different magnetic flux densities in the magnetic core structure, the waveforms of the magnetic flux densities corresponding to Figure 2 The current waveform shown;

[0121] Figure 6a -d means... Figure 3 A simplified geometric diagram of a first embodiment of an integrated magnetic component, schematically illustrated here. Figure 6a It is an exploded view of the integrated magnetic components, without showing the edge-wound portion of the winding connected to the printed circuit board; Figure 6b Is it like this? Figure 6a The same component is shown in the same view axis diagram, but the integrated magnetic component is shown in an assembled form; Figure 6c This is another isometric view of the integrated magnetic components, now featuring a printed circuit board 202 and rectifier elements D1 and D2 in assembly form; and Figure 6d yes Figure 6c Another representation of an integrated magnetic component, but in which the winding portion is not assembled to a printed circuit board;

[0122] Figure 7a schematically shown Figure 3 The first variation of the magnetic core structure depicted in the figure;

[0123] Figure 7b schematically shown Figure 3 The second variation of the magnetic core structure depicted in the figure;

[0124] Figure 8 Another embodiment of the integrated magnetic assembly according to the present invention is shown; the integrated magnetic assembly includes a U-shaped core element, wherein filter core elements are stacked together;

[0125] Figure 9a , 9b yes Figure 8 A geometric view of an embodiment schematically depicted in the figure, wherein Figure 9a 9b is an exploded view of the integrated magnetic components, and 9b is the same but in assembled form of the components; the printed circuit board is not shown.

[0126] Figure 10a and Figure 10b This is a geometric view of another embodiment of the present invention. This embodiment is similar to... Figure 9a and 9b The embodiment shown is illustrated, but the lower current winding is implemented using a printed circuit board;

[0127] Figure 11Another embodiment of the integrated magnetic component according to the invention is shown, which is implemented in a DC-DC switching mode power converter with a current multiplier rectifier, the integrated magnetic component comprising a U-shaped transformer core element and an L-shaped filter core element;

[0128] Figure 12 Another embodiment of the integrated magnetic component according to the present invention is shown, which is similar to Figure 11 The embodiment shown in the figure, but in which the filter core elements are stacked together;

[0129] Figure 13 Another embodiment of the integrated magnetic assembly according to the invention is shown, implemented in a DC-DC switching mode power converter with a current multiplier rectifier, the integrated magnetic assembly comprising a three-legged core element;

[0130] Figure 14a b is Figure 13 The geometric view of the schematically drawn embodiment shows that the integrated magnetic component includes a three-legged core element; Figure 14a This is an exploded view of the integrated magnetic components, and 14b is the same, however, view of the components in assembled form; the printed circuit board is not shown.

[0131] Figure 15a , 15b This is a geometric view of another embodiment of the present invention. This embodiment is similar to... Figure 14a and 14b The embodiment shown is illustrated, but the lower current winding is implemented using a printed circuit board;

[0132] Figure 16a Showing according to Figure 13 The combination (building-up) of the core structure of the integrated magnetic components; by using four three-legged core elements;

[0133] Figure 16b schematically shown Figure 16a The first variation of the magnetic core structure depicted in the figure;

[0134] Figure 16c schematically shown Figure 16a The second variation of the magnetic core structure depicted in the figure;

[0135] Figure 17 Another embodiment of the integrated magnetic assembly according to the present invention is shown; the integrated magnetic assembly includes a three-legged core element, wherein filter elements are stacked together;

[0136] Figure 18a , 18b yes Figure 17 The geometric view of the embodiment is schematically drawn in the figure, wherein Figure 18aThis is an exploded view of the integrated magnetic components, and 18b is the same, however, view of the components in assembled form; the printed circuit board is not shown.

[0137] Figure 19a and Figure 19b This is a geometric view of another embodiment of the present invention. This embodiment is similar to... Figure 18a and 18b The embodiment shown is illustrated, but the lower current winding is implemented using a printed circuit board;

[0138] Figure 20 Another embodiment of the integrated magnetic assembly according to the invention is shown, implemented in a DC-DC switching mode power converter with a current multiplier rectifier, the integrated magnetic assembly comprising a three-legged transformer core element and a T-shaped filter core element;

[0139] Figure 21 Another embodiment of the integrated magnetic assembly according to the present invention is shown, the integrated magnetic assembly comprising a three-legged transformer core element and a T-shaped filter core element, wherein the filter core elements are stacked together;

[0140] Figure 22 Another embodiment of the integrated magnetic assembly according to the invention is shown, wherein the magnetic core structure includes two four-legged core elements and is integrated in a switching mode DC-DC power converter with a full-wave center-tapped output rectifier;

[0141] Figure 23 It shows according to Figure 21 A variation of the embodiment of the integrated magnetic component, wherein the magnetic core structure also includes two four-legged core elements, but which are integrated into a switching mode DC-DC power converter with a current multiplier rectifier.

[0142] In the figures, identical components are given the same reference numerals. Similar elements in different embodiments are indicated by similar reference numerals that differ by several hundred digits, if they are depicted in different figures. Detailed Implementation

[0143] The integrated magnetic component 101 according to the present invention is integrated in Figure 1The circuit configuration shown is a switching-mode DC-DC power converter 100, which converts power from a higher DC input voltage Uin to a lower DC output voltage Uout. The switching-mode DC-DC power converter 100 includes a converter stage 102, an isolation transformer 103, and a current multiplier rectifier stage 104. The converter stage 102 is a full-bridge converter comprising four switches Q11, Q12, Q21, and Q22. However, it can be replaced by other converter types with different dual-terminal topologies, such as forward, two-transistor-forward, push-pull, and half-bridge converter topologies. The converter stage 102 is connected across the first input terminal e1 and the second input terminal e2 to the primary side of the isolation transformer 103, which includes a lower current transformer winding divided into a first lower current transformer winding portion 106.1 and a second lower current transformer winding portion 106.2 (both connected in series). The isolation transformer 103 also includes a higher current transformer winding on its secondary side, which is divided into a first higher current transformer winding portion 107.1 and a second higher current transformer winding portion 107.2 (which are also connected in series). The higher current transformer winding portions 107.1 and 107.2 are implemented as winding portions wound along the edges.

[0144] The current multiplier rectifier stage 104 at the output of the switching mode DC-DC power converter 100 includes a first diode D1 and a second diode D2 as rectifier elements, and two identical but separate filter inductors, namely a first filter inductor Ls1 and a second filter inductor Ls2. The filter inductors Ls1 and Ls2 are implemented by means of a first filter winding and a second filter winding, wherein both windings include winding portions wound at least along the edges. Diodes D1 and D2 have been chosen as rectifier elements in the circuit diagram for better understanding. Other rectifier elements may be used instead of diodes D1 and D2, such as Schottky diodes or bipolar junction diodes. Particularly useful are active switching and / or synchronous rectifiers, such as transistors, typically power MOSFETs or power BJTs.

[0145] Two filter inductors, Ls1 and Ls2, are connected in series with respect to each other at a common filter connection point a3. They are further associated with higher current transformer windings, including a first higher current transformer winding portion 107.1 and a second higher current transformer winding portion 107.2. At the first filter connection point a1, the first filter inductor Ls1 is connected to the free end of the first higher current transformer winding portion 107.1 and also to the anode of the first diode D1. Similarly, the second filter inductor Ls2 is connected to the free end of the second higher current transformer winding portion 107.2 at the second filter connection point a2 and is connected to the anode of the second diode D2. Diodes D1 and D2 are connected at the output connection point a4, where their cathodes are connected to the terminals of the output capacitor Cout. The output capacitor Cout is connected at the other terminal to the filter connection point a3, which is shared by both filter inductors Ls1 and Ls2.

[0146] The inductor components of the isolation transformer 103 (i.e., the lower current transformer winding portions 106.1 and 106.2, the higher current transformer winding portions 107.1 and 107.2, and the filter inductors Ls1 and Ls2) are all integrated by a single integrated magnetic component 101. In this specific embodiment, diodes are also part of the integrated magnetic component 101. However, they may also be arranged outside the integrated magnetic component. It should be noted that the output capacitor Cout may also be part of the integrated magnetic component 101.

[0147] Figure 2 The simplified diagram in the figure shows the switching mode DC-DC power converter 100 ( Figure 1 The waveform of the secondary voltage Us across filter connection points a1 and a2, and the secondary transformer current Is (see also...) Figure 1 The currents iL1 and iL2 are the currents flowing through the higher current transformer windings 107.1 and 107.2, the filter currents iL1 and iL2 flowing through the filter inductors Ls1 and Ls2, and the output current iout (which is the sum of the filter currents Ls1 and Ls2). The waveforms are shown over a period slightly longer than the operating cycle period Ts, typically in the range of µs (e.g., 10 µs), with a switching frequency of approximately and above 100 kHz.

[0148] Throughout the entire operating cycle Ts, the filter currents iL1 and iL2, and therefore the output current Iout (i.e., their sum), always have the same direction, but after half of the operating cycle Ts, the transformer current changes its sign. During the first time interval 10 until Ts / 4, the secondary voltage Us is positive. During this cycle, the first diode D1 is forward biased, while the second diode D2 is blocked by the secondary voltage Us. Therefore, the current path of the first filter current iL1 passes through Ls1, the first diode D1, and the output capacitor Uout. Because the first filter voltage UL1 applied to the first filter inductor Ls1 is negative, the first filter current iL1 passing through the first filter inductor Ls1 decreases. On the other hand, the second diode D2 is blocked, so the current flows through the second filter inductor Ls2, the higher current transformer winding sections 107.1 and 107.2, the first diode D1, and the output capacitor Uout. Since the second filter voltage UL2 across the second filter inductor Ls2 is positive, the current through the second filter inductor Ls2 increases. Therefore, in this cycle, only the second filter current iL2 across the second filter inductor Ls2 flows through the transformer. In the second time interval 11, until Ts / 2, the secondary voltage Us is 0V. This will result in not only the second filter current iLs2 across the first filter inductor Ls1 decreasing further, but also the first filter current iLs1 across the second filter inductor Ls2 decreasing, because the second filter voltage UL2 across the second filter inductor Ls2 will now become negative, equal to the output voltage Uout. In the same time interval, only the second filter current iLs2 will flow through the higher current transformer winding portions 107.1 and 107.2. In the third time interval 12, until 3 / 4 Ts, the secondary voltage Us becomes negative, producing a situation similar to the first interval of the cycle, but with the sign reversed. Now, the first diode D1 will be off and the second diode D2 will be on. The current Is flowing through the higher current winding of the transformer now rapidly changes direction and becomes equal to the first filter current iLs1, while the second filter current iLs2 flows through the second diode D2 and remains decreasing. At the fourth time interval 13, until Ts, the secondary voltage Us turns off again, resulting in both filter currents decreasing (before the next cycle begins with a positive secondary voltage Us).

[0149] Therefore, the transformer carries only one of the filter currents iL1 and iL2, and thus only approximately half of the output current iout, which is the sum of the two currents. The filter currents iL1 and iL2 have a 180° phase shift.

[0150] Figure 3 A first embodiment of the integrated magnetic component 201 according to the present invention is illustrated, which is integrated into a switching mode DC-DC power converter 200 and implements... Figure 1 The circuit shown in the figure.

[0151] The integrated magnetic assembly 201 includes a single magnetic core structure 205 having four linearly stacked U-shaped core elements: a first transformer core element 212, a second transformer core element 213, a first filter core element 211, and a second filter core element 214.

[0152] Each of the core elements 211, 212, 213, and 214 includes a first outer leg 220a, a second outer leg 220b, and a flange 222. Two transformer core elements 212 and 213 face each other with their first outer legs 220a.2, 220a.3 and their second outer legs 220b.2, 220b.3, forming an O-shaped transformer core section having an opening-like window that provides a transformer winding window for receiving turns of the first lower current transformer winding portion 106.1 and the second lower current transformer winding portion 106.2, as well as the first higher current transformer winding portion 107.1 and the second higher current transformer winding portion 107.2. The higher current transformer winding portions 207.1, 207.2 and the lower current transformer winding portions 206.1, 206.2 form the isolation transformer of the switching mode DC-DC power converter 200, corresponding to... Figure 1 The schematic circuit diagram shows an isolation transformer 103. Higher current transformer winding portions 207.1, 207.2 and lower current transformer winding portions 206.1, 206.2 are arranged in a sandwich-like manner on the first outer legs 220a.2 and 220a.3 of transformer core elements 212, 213, with the lower current transformer winding portions 206.1, 206.2 positioned between the higher current transformer winding portions 207.1, 207.2. The higher current transformer winding portions 207.1, 207.2 are implemented as edge-wound winding portions to allow them to support high currents.

[0153] Figure 3 The two-dimensional representation of the magnetic circuit of the core structure 205 must be understood symbolically. The width of the corresponding core segment along the magnetic flux path (depicted by dashed lines) represents the cross-section of the corresponding core segment. For example, in Figure 3 In the middle, the first outer leg 220a.1-220a.4 has a larger cross section than the second outer leg 220b.1-220b.4.

[0154] In its simplest form, Figure 3 The U-shaped core elements 211-214 depicted in the figure can be standardized U-shaped cores, which have the form of upright prisms, wherein the basic shape has the form of U as depicted, and wherein the legs of the U-shaped core have a basic rectangular cross section.

[0155] A relatively short transformer gap 240.23 is arranged between the two first outer legs 220a.2 and 220a.3 of the first filter core element 212 and the second transformer core element 213. The transformer gap 240.23 reduces the negative impact of variations in the permeability of the core material (which is typically ferrite). The permeability of ferrite can vary by up to 30% from one batch to another. The relatively short transformer gap 240.23 also allows for limiting the magnetizing current. It also allows for avoiding saturation of the core material so that the integrated magnetic components can operate within the linear range of the core magnetization characteristics of the core material.

[0156] The first filter core element 211 is stacked on the flange 222.2 of the first transformer core element 212, such that its first outer leg 220a.1 and its second outer leg 220b.1 are adjacent to the flange 222.2 of the first transformer core element 212 on the side opposite to the outer legs 220a.2, 220b.2 of the first transformer core element 212. Adjacent core elements 211 and 212 define an opening-like window for receiving the winding turns of the first filter winding 208.1, which is arranged on the first outer leg 220a.1 of the first filter core element 211 and, together with the core structure 205, defines the first filter inductor Ls1. Figure 1 The inductance of the first filter gap 240.1 is placed between the flange 222.2 of the first transformer core element 212 and the first outer leg 220a.1 of the first filter core element 211.

[0157] The second filter core element 214 is stacked on the flange 222.3 of the second transformer core element 213, such that its first outer leg 220a.4 and its second outer leg 220b.4 are adjacent to the flange 222.3 of the second transformer core element 213 on the side opposite to the outer legs 220a.3, 220b.3 of the second transformer core element 213. A second filter gap 240.4 is placed between the flange 222.3 of the second transformer core element 213 and the first outer leg 220a.4 of the second filter core element 214. Adjacent core elements 213 and 214 define an opening-like window that provides a second filter winding window for receiving the winding turns of the second filter winding 208.2, which is arranged on the first leg 220a.4 of the second filter core element 214. The second filter winding 208.2 and the core structure 205 define a second filter inductor Ls2. Figure 1 ) inductance.

[0158] The gaps 240a.1, 240a.4, and 240a.23 can be achieved by grinding the corresponding first outer legs 220a.1, 220a.2, 220a.3, or 220a.4. They can be filled with air or any other material with low magnetic permeability.

[0159] exist Figure 3In the diagram, the three independent magnetic paths of the integrated magnetic component 201 are also depicted as dashed lines, each traveling around one of the three winding windows:

[0160] a) Transformer flux path 230.23, which passes around the transformer winding window and through transformer core elements 212 and 213.

[0161] b) A first filter flux path 230.12, which passes around the first filter winding window and through the flange 222.2 of the first filter core element 211 and the first transformer core element 212.

[0162] c) The second filter flux path 230.34 passes around the second filter winding window and through the flange 220.3 of the second filter core element 214 and the second transformer core element 213.

[0163] Here, the first filter flux path 230.12 and the transformer flux path 230.23 share the flange 222.2 of the first transformer core element 212, while the second filter flux path 230.34 and the transformer flux path 230.23 share the flange 222.3 of the second transformer core element 213. This reduces the core material required for the integrated magnetic components.

[0164] The first lower current transformer winding portion 206.1, the second lower current transformer winding portion 206.2, the first higher current transformer winding portion 207.1, and the second higher current transformer winding portion 207.2 are all arranged on one of the outer legs of the transformer core elements 212 and 213, that is, around the first outer leg 220a.2 of the first transformer core element 212 and / or the first outer leg portion 220a.3 of the second transformer core element 213.

[0165] The lower current transformer winding portions 206.1 and 206.2 are connected in series. The free end of the first lower current transformer winding portion 206.1 represents the first input terminal e1 of the integrated magnetic component 201, and the free end of the second lower current transformer winding portion 206.2 represents the second input terminal e2 of the integrated magnetic component 201.

[0166] Upstream of the integrated magnetic component 201, the switching-mode DC-DC power converter comprises a full-bridge converter with a switching network of four switches Q11, Q12, Q21, and Q22. The switching network provides a square voltage output from the DC input voltage Uin between the first input connection point e1 and the second input connection point e2 of the integrated magnetic component. The DC input voltage Uin can be provided by a rectifier circuit, such as an AC / DC power factor correction (PFC) converter. Alternatively, a half-bridge rectifier with two switches can be used instead of the full-bridge converter with the four-switch switching network.

[0167] The higher current transformer windings 207.1 and 207.2 are also connected in series, and the first higher current winding 207.1 and the second higher current winding 207.2 of the transformer have the same winding direction.

[0168] The switching mode DC-DC power converter 200 has features such as Figure 1 A similar current multiplier rectifier stage is depicted in the circuit diagram. It includes a first diode D1 and a second diode D2 as rectifier elements, as well as a first filter winding 208.1 and a second filter winding 208.2.

[0169] The first filter winding 208.1 and the second filter winding 208.2 are connected in series, thus sharing a common connection point a3 with the input capacitor Cout. At the first filter connection point a1, the first filter winding 208.1 is connected to the free end of the first higher current transformer winding portion 207.1 and also to the anode of the first diode D1. At the second filter connection point a2, the second filter winding 208.2 is connected to the free end of the second higher current transformer winding portion 207.2 and also to the anode of the second diode D2. The two diodes are connected at their cathodes to the free terminals of the output capacitor Cout at the output connection point a4. The output connection point a4 and the common connection point a3 form the output of the integrated magnetic assembly 205.

[0170] The first filter inductor Ls1 of the circuit is defined by a first filter winding 208.1, which is wound around the first outer leg 220a.1 of the first filter core element 211 and the first filter gap 240.1 between the flange 222.2 of the first transformer core element 212 and the first outer leg 220a.1.

[0171] Similarly, the second filter inductor Ls2 of the circuit is defined by a second filter winding 208.2, which is wound around the first outer leg 220a.4 of the second filter core element 214 and the second filter gap 240.4 between the first outer leg 220a.4 of the second filter core element 214 and the flange 222.3 of the second transformer core element 213.

[0172] Figure 4 Showing according to Figure 3 The magnetic core structure 205 of the embodiment shown is a magnetoresistive model 250. The flanges 222.1, 222.2, 222.3, and 222.4 of all four core elements 211, 212, 213, and 214 are considered equivalent and are determined by the flange magnetoresistive R. B The filter core elements 211 and 214 are considered equivalent, and therefore their first outer legs 220a.1, 220a.4 and their second outer legs 220b.1, 220b.4 are also considered equivalent. LF1The magnetic reluctance of the first outer legs 220a.1 and 220a.4 of the filter core elements 211 and 214 is indicated, and R LF2 The magnetic reluctance of the second outer legs 220b.1 and 220b.4 of the filter core elements 211 and 214 is indicated. IL1 indicates the first filter current passing through the first filter winding, and IL2 indicates the second filter current passing through the second filter winding.

[0173] Transformer core elements 212 and 213 are also considered equivalent. Therefore, their first outer legs 220a.2 and 220a.3, and second outer legs 220b.2 and 220b.3, are considered equivalent. LT1 Indicates the magnetic reluctance of the first outer legs 220a.2 and 220a.3, and R LT2 The magnetic reluctance of each of its second outer legs 220b.2 and 220b.3 includes a portion of the gap 240.23 in the magnetic flux path between the first transformer core element U2 and the second transformer core element U3. The current passing through the first lower current transformer winding portion 206.1 and the second lower current transformer winding portion 206.2 is considered to be the same and is indicated as current i. P Similarly, the current passing through the first higher current transformer winding section 207.1 and the second higher current transformer winding section 207.2 is considered to be the same and is indicated as current i. s .

[0174] The number of turns in the winding is: for the first filter winding N L1 For the second filter winding N L2 N P It is the sum of the number of turns in the two lower current transformer winding sections 206.1 and 206.2, and N S It is the sum of the number of turns in the higher current transformer winding sections 207.1 and 207.2. N L1 and N L2 Those considered equal: N L1 =N L2 =N L .

[0175] exist Figure 5 In the diagram, waveforms of different magnetic flux densities in the core structure 205 are depicted: those magnetic flux density waveforms correspond to... Figure 2 The current waveform shown is obtained by applying... Figure 4 The magnetoresistive model 250 of the current multiplier converter is used to determine the magnetic flux. The magnetic flux density BL1 is the flux density through R. LT1 ( Figure 4 The magnetic flux of R, and the magnetic flux density BL2 is through R LF2 ( Figure 4The magnetic flux density BL1 and BL2 do not change sign during the operating cycle and are substantially proportional to the first filter current iL1 and the second filter current iL2, respectively. Compared to those filter magnetic flux densities BL1 and BL2, R passing through the outer legs 220a.2 and 220a.3 of the first transformer... LT1 ( Figure 4 The sign of the magnetic flux density Bt changes because it depends primarily on the voltage present at the transformer terminals. The magnetic flux densities Bc1 and Bc2 in flanges 222.2 and 222.3 are generated from the sum of the first filter flux 230.12 and the transformer flux 230.23 and / or (respectively) the second filter flux 230.34 and the common transformer flanges 222.2 and 222.3. Figure 3 The sum of the transformer flux 230.23 in the common transformer flanges 222.2 and 222.3 is shown. As can be seen, the corresponding filter flux and transformer flux partially compensate each other in the common transformer flanges 222.2 and 222.3, thus reducing the losses in those flanges.

[0176] exist Figures 6a-6d The image shows a simplified geometric view of a first embodiment of the integrated magnetic component 201. Figure 6a This is an exploded view of the integrated magnetic component 201, without a printed circuit board and without diodes. Figure 6b These are isometric views of the same components, but in an assembled form. Figure 6c yes Figure 6c An isometric view of the integrated magnetic component 205 is shown, but the printed circuit board 206 is also shown. Figure 6d Another isometric view of the integrated magnetic components also has a printed circuit board 206; however, the winding portion wound along the edge is not mounted on the printed circuit board 206.

[0177] The integrated magnetic assembly includes four stacked U-shaped core elements 211-214, such as Figure 2As already depicted. The U-shaped core element in this embodiment is an optimized U-shaped core for use with a winding portion wound along its edge. The flanges 222.1-222.4 of the U-shaped core have the form of an upright prism, having a base region 260 composed of a rectangular segment 261, an isosceles trapezoidal segment 262, and a semicircular segment 263 arranged side by side. Here, the longer baseline of the isosceles trapezoid 262 is one of the longitudinal sides of the rectangular segment 261, and the shorter baseline of the isosceles trapezoid is the straight side of the semicircular segment 263. The first outer legs 220a.1-220a.4 of the four U-shaped core elements 211-214 have a cylindrical shape and are adapted to receive windings and / or winding portions with a circular inner diameter. Those first outer legs 220a.1-220a.4 are arranged on the corresponding semicircular portions of the base region of the respective flanges 222.1-222.4. Parallel to the first outer leg, the second outer legs 220a.1-220a.4 are arranged on the corresponding rectangular segments 261 of the base region 260 of the corresponding flange, and the second outer legs 220b.1-220b.4 have a rectangular cross-section. The first outer legs 220a.1-220a.4 and / or the columnar outer legs are slightly shorter than the second outer legs 220b.1-220b.4. This difference defines the first filter gap 240.1 and the second filter gap 240.4, as well as the transformer gap 240.23 (see...). Figure 2 The length of the void. To increase stability, the void can be filled with non- and / or low-permeability materials.

[0178] The U-shaped core elements 211-214 are preferably made of a single piece of ferrite material. However, they may also be assembled from different parts of ferrite and from different materials with different permeabilities.

[0179] The first filter winding 208.1 and the second filter winding 208.2, as well as the first higher current transformer winding portion 207.1 and the second higher current transformer winding portion 207.2, are winding portions wound along their edges. In this embodiment, the lower current transformer winding portions 206.1 and 206.2 include conventional windings with bobbins and are arranged adjacent to each other on the first outer legs 220a.2 and 220a.3 of transformer core elements 212 and 213. The first higher current transformer winding portion 207.1 is arranged on the first outer leg 220a.2 of the first transformer core element 212 between the flange 222.2 of the first transformer core element 212 and the first lower current transformer winding portion 206.1. The second higher current transformer winding portion 207.2 is arranged on the first outer leg 220a.3 of the second transformer core element 213 between the flange 222.3 of the second transformer core element and the second lower current transformer winding portion 206.2.

[0180] Each of those winding portions includes a flat coil wound in a circular helix around its shorter edge, the inner smaller edge of the flat coil defining a circular aperture, and the outer smaller edge defining a circular outer shape. Each of the edge-wound winding portions 207.1, 207.2, 208.1, and 208.2 also includes two straight free ends 243a and 243b, arranged parallel to each other. The flat coil is preferably glazed to electrically isolate two adjacent turns of the same winding portion (which have a relatively low voltage difference). The glazed insulation serves as an isolation layer relative to the lower current transformer winding portions 206.1 and 206.2, and is preferably triple-insulated, such that a total of four isolation layers separate the lower current transformer winding portions 206.1 and 206.2 from the adjacent higher current transformer winding portions 207.1 and 207.2.

[0181] Higher current transformer winding portions 207.1 and 207.2, and filter windings 208.1 and 208.2, are mounted on a printed circuit board 206. For this purpose, the printed circuit board 206 includes rectangular through-holes 245 that receive the free ends of the respective windings (which are used for soldering to the printed circuit board 206). Due to the mechanical stability of the winding portions wound along the edges, the entire core structure, including the windings, is supported by the printed circuit board, thus eliminating the need for specific mechanical support. The integrated magnetic components also function as a current multiplier stage (104, Figure 1 The rectifier elements are diodes D1 and D2. To increase the current capacity of the diodes, the first diode D1 is implemented as a group of four single diodes D1', and correspondingly, the second diode D2 is implemented as another group of four other single diodes D2', wherein the diodes in each group of four are arranged in parallel and surface-mounted on printed circuit board 206. Other rectifier elements, as mentioned above, can be used instead of diodes.

[0182] The surface-mount arrangement of the electrical components (here, diodes D1 and D2) on the printed circuit board 206 allows for even more compact designs that integrate the magnetic components 201.

[0183] Printed circuit board 206 also provides electrical connections between higher current transformer winding sections 207.1, 207.2 and transformer winding sections 208.1, 208.2. With the above arrangement, a high DC output current of 30A-200A at 12V DC can be achieved at a switching frequency of approximately 100kHz for a switching mode DC-DC power converter.

[0184] Figure 7a The magnetic core structure 305 shown is based on an integrated magnetic assembly ( Figure 3-6) is a variation of the core structure 205 of the first embodiment. However, in the core structure 305, the transformer winding window defining the transformer flux path 330.23 is formed by a first U-shaped transformer core element 312 and a second transformer core element 313 (which is an I-core). The filter core elements 311 and 314 are similar to those of the first embodiment ( Figure 3 -6) magnetic core structure 205 filter core element.

[0185] The first transformer core element 312 includes a first outer leg 320a.2, a second outer leg 320b.2, and a flange 322.2, while the second transformer core element 313 is an I-core with a flange 322.3 but no legs. The first transformer core element 312 abuts the flange 322.3 of the second transformer core element with its outer legs 320a.2 and 320b.2 to form an O-shaped transformer core region. The second filter core element 314 abuts the flange 322.3 of the second transformer core element 313 on the side opposite to the outer legs 320a.2 and 320b.2 of the first transformer core element. Similarly, the first filter core element 311 abuts the flange 322.2 of the first transformer core element 312 on the side opposite to the outer legs 320a.2 and 320b.2 of the first transformer core element 312. As in the first embodiment, the first filter gap 340.1 is positioned between the flange 322.2 of the first transformer core element 312 and the first outer leg 320a.1 of the first filter core element 311. The second filter gap 340.4 is positioned between the flange 322.3 of the second transformer core element 313 and the first outer leg 320a.4 of the second filter core element 314. However, the transformer gap 340.23 is positioned between the first outer leg 320a.2 of the first transformer core element 312 and the flange 322.3 of the second transformer core element 313.

[0186] Figure 7b The magnetic core structure 405 shown is also similar Figure 3 The first embodiment of the magnetic core structure 205 is shown. However, the O-shaped transformer core section (defining the transformer flux path 430.23 and / or the transformer winding window 465.23 for receiving transformer winding turns) is formed by the flanges 422.3 of the first transformer core element 412 (which is a U-shaped core element) and the second transformer core element 413 (which is also a U-shaped core element). The transformer gap 440.23 is arranged between the first outer leg 420a.2 of the first transformer core element 412 and the flange 422.3 of the second transformer core element 413.

[0187] The second filter flux path is defined by the flange 422.3 of the second transformer core element, the outer legs 420a.3 and 420b.3 of the second transformer core element 413, and the flange 422.4 of the second filter core element 414 (which is an I-core). The second transformer gap 440.3 is arranged between the first outer leg 420a.3 of the second transformer core element 413 and the flange 422.4 of the second filter core element 414.

[0188] Figure 8 The embodiment of the integrated magnetic component 501 shown is similar to Figure 3 The integrated magnetic assembly 201 is depicted in the figure. The core structure 505 of this embodiment also includes two U-shaped transformer core elements 512 and 513 and two U-shaped filter core elements 511 and 514. However, in this embodiment, the first filter core element 511 is stacked on the flange 522.4 of the second filter core element 514, wherein the outer legs 520a.1 and 520b.1 of the first filter core element 511 are adjacent to the flange 522.4 of the second filter core element 514 in the following manner: the flange 522.4 of the second filter core element 514 and the first filter core element 511 define a first filter flux path 530.34 and form a first filter winding window 565.1 for receiving turns of the first filter winding 508.1. A first filter gap 540.1 is disposed between the first outer leg 520a.1 of the first filter core element 511 and the flange 522.4 of the second filter core element 514.

[0189] Figure 9a , 9b yes Figure 8 A geometric view of an embodiment schematically depicted in the figure, wherein Figure 9a This is an exploded view of the integrated magnetic component 501, and 9b is a view of the same component but in assembled form. The printed circuit board is not shown. The core elements of the magnetic core structure (i.e., the first transformer core element 512 and the second transformer core element 513, and the first filter core element 511 and the second filter core element 514) are similar to... Figures 6a-6d The core elements 211, 212, 214, and 214 are shown. The winding portion is also similar. Figures 6a-6d The winding portion shown.

[0190] In the core structure 505 of the integrated magnetic component 501, the first filter core element 511 is stacked on the flange 522.4 of the second filter core element 514 with its first outer leg 520a.1 and second outer leg 520b.1. The second filter core element 514 itself is stacked on the flange 522.3 of the second transformer core element 513 with its legs. The first transformer core element 512 and the second transformer core element 513 are adjacent to each other with their outer legs 520a.2, 520a.3, 520b.2 and 520b.3 to form a transformer winding window for receiving transformer winding turns.

[0191] In this embodiment, the lower current transformer windings 506.1 and 506.2 are conventional windings with bobbins, and are arranged adjacent to each other on the first outer legs 520a.2 and 520a.3 of transformer core elements 512 and 513. A first higher current transformer winding portion 507.1 is arranged on the first outer leg 520a.2 of the first transformer core element 512 between the flange 522.2 and the first lower current transformer winding portion 506.1. A second higher current transformer winding portion 507.2 is arranged on the first outer leg 520a.3 of the second transformer core element 513 between the flange 522.3 and the second lower current transformer winding portion 506.2.

[0192] Figure 10a and 10b This is a geometric view of another embodiment of the present invention. This embodiment is similar to... Figure 9a and 9b The embodiment shown also has the same core structure, including a first transformer core element 612 and a second transformer core element 613, as well as a first filter core element 611 and a second filter core element 614. However, in this embodiment, two lower current transformer winding portions are arranged on a printed circuit board 670, which itself is arranged between the first higher current transformer winding portion 607.1 and the second higher current transformer winding portion 607.2. The printed circuit board includes a circular aperture 671 for receiving the first outer legs 620a.2 and 620a.3 of the first transformer core element 612 and the second transformer core element 613, and / or the transformer gap between the first outer legs 620a.2 and 620a.3 of the first transformer core element 612 and the second transformer core element 613. The printed circuit board 670 also includes a rectangular aperture 672 for receiving the second outer legs 620a.2 and 620a.3 of the first transformer core element 612 and the second transformer core element 613. By comparison Figure 9a , 9b and Figure 10a , 10b It can be seen that the outer legs 620 of transformer core elements 612 and 613 are in accordance with... Figure 9a , 9b The transformer core elements 512 and 513 can be designed to be shorter because the printed circuit board allows for a flat design of the lower current transformer windings 606.1 and 606.2.

[0193] Figure 11 The embodiment of the integrated magnetic component 701 shown is similar to Figure 3 The integrated magnetic component 201 is depicted in the image. Figure 11 The magnetic core structure 705 of the illustrated embodiment further includes two U-shaped transformer core elements 712 and 713, which are abutted against each other with their outer legs to form an O-shaped transformer core segment. The magnetic core structure 705 also includes a first filter core element 711 and a second filter core element 714. The two filter core elements 711 and 714 include flanges 722.1 and 722.4 and first outer legs 720a.1 and 720a.4 disposed on the respective flanges 722.1 and 722.4. Figure 3 Compared to the U-shaped core filter elements 211 and 214, the second outer leg of the filter elements 711 and 714 is omitted and / or shortened to a length of zero or near zero, making the filter element L-shaped, and representing a special case of the U-shaped core element in which one of the outer legs has a length of zero and / or near zero.

[0194] The first filter core element 711 is stacked on the flange 722.2 of the first transformer core element 712 with its first outer leg 720a.1 in the following manner: the first filter core element 711 and the flange 722.2 of the first transformer core element 712 define a first filter flux path 730.12, which is closed by a larger first filter gap 740b.1 between the flange 722.1 of the first filter core element 711 and the flange 722.2 of the first transformer core element 712.

[0195] The second filter core element 714 is stacked on the flange 722.3 of the second transformer core element 713 with its first outer leg 720a.4 in the following manner: the second filter core element 714 and the flange 722.3 of the second transformer core element 713 define a second filter flux path 730.34, which is closed by a larger second filter gap 740b.4 between the flange 722.3 of the second transformer core element 713 and the flange 722.4 of the second filter core element 714.

[0196] Figure 11 The embodiment of the integrated magnetic component 1701 shown is similar to Figure 8 The integrated magnetic component 501 is depicted in the figure. Figure 12The magnetic core structure 1705 of the illustrated embodiment further includes two U-shaped transformer core elements 1712 and 1713, which are abutted against each other with their outer legs to form an O-shaped transformer core segment. The magnetic core structure 1705 also includes a first filter core element 1711 and a second filter core element 1714. The two filter core elements 1711 and 1714 include flanges 1722.1 and 1722.4 and first outer legs 720a.1 and 1720a.4 disposed on the respective flanges 1722.1 and 1722.4. Figure 8 Compared to the U-shaped core filter elements 511 and 514, the second outer leg of filter elements 1711 and 1714 is omitted and / or shortened to a length of zero or near zero, making the filter element L-shaped, and representing a special case of the U-shaped core element in which one of the outer legs has a length of zero and / or near zero.

[0197] The second filter core element 1714 is stacked on the flange 1722.3 of the second transformer core element 1713 with its first outer leg 1720a.4 in the following manner: the flange 1722.3 of the second transformer core element 1713 and the second filter core element 1714 define a second filter flux path 1730a.34, which is closed by a larger second filter gap 1740b.4 between the flange 1722.3 of the second transformer core element 1713 and the flange 1722.4 of the second filter core element 1714.

[0198] The first filter element 1711 is stacked on the flange 1722.4 of the second filter element 1714 with its first outer leg 1720a.1 in the following manner: the flange 1722.4 of the first filter element 1711 and the second filter element 1714 defines a first filter flux path 1730.14, which is closed by a larger first filter gap 1740b.1 between the flange 1722.4 of the second filter element 1714 and the flange 1722.1 of the first filter element 1711.

[0199] Figure 13 Another embodiment of the integrated magnetic component 801 is shown, which is implemented according to Figure 1 The integrated magnetic component 101 is depicted in the circuit diagram of the switching mode DC-DC power converter 100.

[0200] The integrated magnetic component 801 is similar in many ways to... Figure 3 The integrated magnetic component 201. However, its single core structure 805 includes four linearly stacked three-legged core elements, instead of U-shaped core elements and / or U-shaped cores, namely the first transformer core element 812, the second transformer core element 813, the first filter core element 811, and the second filter core element 814.

[0201] Each of the core elements 811, 812, 813, and 814 includes a first outer leg 820a, a second outer leg 820b, an inner leg 821, and a flange 822. Two transformer core elements 812 and 813 face each other with their first outer legs 820a.2, 820a.3, their second outer legs 820b.2, 820b.3, and their inner legs 821.2, 821.3, forming an 8-shaped transformer core section having two opening-like windows providing a first transformer winding window and a second transformer winding window for receiving turns of a first lower current transformer winding portion 806.1 and a second lower current transformer winding portion 806.2, as well as a first higher current transformer winding portion 807.1 and a second higher current transformer winding portion 807.2. The higher current transformer winding sections 807.1 and 807.2 and the lower current transformer winding sections 806.1 and 806.2 form the isolation transformer of the switching mode DC-DC power converter 800, which corresponds to Figure 1 The circuit diagram shows the isolation transformer 103. Higher current transformer winding portions 807.1 and 807.2, and lower current transformer winding portions 806.1 and 806.2 are arranged in a sandwich-like manner on the inner legs 821.2 and 821.3 of transformer core elements 812 and 813, such that the lower current transformer winding portions 806.1 and 806.2 are positioned between the higher current transformer winding portions 807.1 and 807.2. The higher current transformer winding portions 807.1 and 807.2 are implemented as edge-wound winding portions, thereby allowing them to support high currents.

[0202] Figure 13 The two-dimensional representation of the magnetic circuit of the core structure 805 must be understood symbolically. The width of the corresponding segment along the magnetic flux path 830 represents the cross-section of the corresponding core segment. For example, the inner leg 821.1-4 has a larger cross-section than the outer legs 820a.1-820a.4 or 820b.1-820b.4.

[0203] In its simplest form, Figure 13 The four three-legged core elements 811, 812, 813 and 814 depicted in the figure can be standardized E-shaped core elements, such as E-shaped cores in the form of upright prisms, wherein the basic shape has the form of E as depicted, and wherein the flange and legs of the E-shaped core have a basic rectangular cross section.

[0204] A relatively short transformer gap 841.23 is arranged between the inner legs 821.2 and 821.3 of the first transformer core element 812 and the second transformer core element 813. This transformer gap 841.23 reduces the negative impact of variations in the permeability of the core material (which is typically ferrite). The permeability of ferrite can vary by up to 30% from one batch to another. The relatively short transformer gap 841.23 also allows for the limitation of the magnetizing current. It also allows for significant avoidance of core material saturation, enabling the integrated magnetic components to operate within the linear range of the core material's magnetization characteristics.

[0205] The first filter core element 811 is stacked on the flange 822.2 of the first transformer core element 812, such that its first outer leg 820a.1, its second outer leg 820b.1, and its inner leg 821.1 are adjacent to the flange 822.2 of the first transformer core element 812 on the side opposite to the legs 820a.2, 820b.2, and 821.2. Adjacent core elements 811 and 812 define two opening-like windows for receiving the winding turns of the first filter winding 808.1, which is arranged on the inner leg 821.1 of the first filter core element 811 and, together with the core structure 805, defines the first filter inductor Ls1. Figure 1 The inductance of the first filter gap 841.1 is placed between the flange 822.2 of the first transformer core element 812 and the inner leg 821.1 of the first filter core element 811.

[0206] The second filter core element 814 is stacked on the flange 822.3 of the second transformer core element 813, such that its first outer leg 820a, its second outer leg 820b.4, and its inner leg 821.4 are adjacent to the flange 822.3 of the second transformer core element 813 on the side opposite to the legs 820a.3, 820b.3, and 821.3 of the second transformer core element 813. Adjacent core elements 813 and 814 define two opening-like windows for receiving the winding turns of the second filter winding 808.2, which is arranged on the center leg 821.4 of the second filter core element 814. The second filter winding 808.2 and the core structure define a second filter inductor Ls2. Figure 1 The inductance of the second filter gap 841.4 is placed between the flange 822.3 of the second transformer core element 813 and the inner leg 821.4 of the second filter core element 814.

[0207] The gaps 841.1, 841.4, and 841.23 can be achieved by grinding the corresponding inner legs 821.1, 821.2, 821.3, or 821.4. They can be filled with air or any other material with low magnetic permeability.

[0208] exist Figure 13The image also depicts three independent magnetic paths of the integrated magnetic component 801, each traveling around one of the three winding windows:

[0209] a) The transformer flux path 830.23 passes around the transformer winding window and through the transformer core elements 812 and 813, wherein the forward flux passes through the inner legs 821.2, 821.3 and the gap 841.23, and the return flux path passes through the outer legs 820a.2, 820a.3, 820b.2, 820b.3. The flux changes direction within the operating cycle Ts, indicated by arrows pointing in different directions.

[0210] b) The first filter flux path 830.12 surrounds the first filter winding window and passes through the flange 822.2 of the first filter core element 811 and the first transformer core element 812; wherein the forward flux passes through the inner leg 821.1 and the first filter gap 841.1, and the return flux path passes through the outer legs 820a.1 and 820b.1, and the flux does not change its direction within the operating cycle Ts;

[0211] c) The second filter flux path 830.34 passes around the second filter winding window and through the flange 820.3 of the second filter core element 814 and the second transformer core element 813; wherein the forward flux passes through the inner leg 821.4 and the second filter air gap 841.4, and the return flux path passes through the outer legs 820a.4 and 820b.4, and the flux does not change its direction within the operating cycle Ts.

[0212] Here, the first filter flux path 830.12 and the transformer flux path 830.23 share the flange 822.2 of the first transformer core element 812, while the second filter flux path 830.34 and the transformer flux path 830.23 share the flange 822.3 of the second transformer core element 813. This reduces the core material required for integrating the magnetic components.

[0213] The first lower current transformer winding portion 806.1, the second lower current transformer winding portion 806.2, the first higher current transformer winding portion 807.1, and the second higher current transformer winding portion 807.2 are all arranged on one of the inner legs of the transformer core elements 812 and 813, that is, on the first inner leg 821.2 of the first transformer core element 812 and / or the inner leg 821.3 of the second transformer core element 813.

[0214] The lower current transformer winding portions 806.1 and 806.2 are connected in series. The free end of the first lower current transformer winding portion 806.1 represents the first input terminal e1 of the integrated magnetic component 801, and the free end of the second lower current transformer winding portion 806.2 represents the second input terminal e2 of the integrated magnetic component 801.

[0215] Upstream of the integrated magnetic component 801, the switching-mode DC-DC power converter 800 includes a full-bridge converter with a switching network of four switches Q11, Q12, Q21, and Q22. The switching network provides a square voltage output from the DC input voltage Uin between the first input connection point e1 and the second input connection point e2 of the integrated magnetic component. The DC input voltage Uin can be provided by a rectifier circuit, such as an AC / DC power factor correction (PFC) converter. Alternatively, a half-bridge rectifier with two switches can be used instead of the full-bridge converter with the four-switch switching network.

[0216] The higher current transformer windings 807.1 and 807.2 are also connected in series, and the first higher current winding 807.1 and the second higher current winding 807.2 of the transformer have the same winding direction.

[0217] The switching mode DC-DC power converter 800 has features such as Figure 1 A similar current multiplier rectifier stage is depicted in the circuit diagram. It includes a first diode D1 and a second diode D2 as rectifier elements, as well as a first filter winding 808.1 and a second filter winding 808.2. The first filter winding portion 808.1 is wound around the inner leg 821.1 of the first filter core element 811, while the second filter winding 808.2 is wound around the inner leg 820a.4 of the second filter element 814.

[0218] The first filter winding 808.1 and the second filter winding 808.2 are connected in series, thus sharing a common connection point a3 with the input capacitor Cout. At the first filter connection point a1, the first filter winding 808.1 is connected to the free end of the first higher current transformer winding portion 807.1 and also to the anode of the first diode D1. At the second filter connection point a2, the second filter winding 808.2 is connected to the free end of the second higher current transformer winding portion 807.2 and also to the anode of the second diode D2. Both diodes are connected with their cathodes to the free terminals of the output capacitor Cout at the output connection point a4. The output connection point a4 and the common connection point a3 form the output of the integrated magnetic assembly.

[0219] The first filter inductor Ls1 of the circuit is defined by a first filter winding 808.1, which is wound around the inner leg 822.1 of the first filter core element 811 and the first filter gap 841.1 between the flange 822.2 of the first transformer core 812 and the first inner leg 822.1.

[0220] Similarly, the second filter inductor Ls1 of the circuit is defined by a second filter winding 808.2, which is wound around the inner leg 821.4 of the second filter core element 814 and the second filter gap 841.4 between the inner leg 821.4 of the second filter core element 814 and the flange 822.3 of the second transformer core element 813.

[0221] Figure 14a and 14b yes Figure 13 A simplified geometric view of the integrated magnetic component 801. Here Figure 14a 14b is an exploded view of the integrated magnetic component 801, and 14b is an isometric view of the same component in an assembled form. In both geometric views, the printed circuit board including the sections connecting the filter winding and the higher current winding, and including diodes D1 and D2, is omitted.

[0222] The integrated magnetic assembly 801 includes four stacked three-legged core elements 811-814, such as Figure 13 The diagram has already been schematically depicted. Those three-legged core elements are optimized for use with winding portions wound along the edges. The flanges 822.1-822.4 of the core element have the form of upright prisms, having a base region 860 composed of a first outer rectangular segment 861, a first isosceles trapezoidal segment 862, a central rectangular segment 863, a second isosceles trapezoidal segment 864, and a second outer rectangular segment 864 arranged side-by-side. The first isosceles trapezoidal segment 862 connects the first outer rectangular segment 861 and the central rectangular segment 863, and the second isosceles trapezoidal segment 864 connects the central rectangular segment 863 and the second outer rectangular segment 865.

[0223] The inner legs of the four three-legged core elements 811-814 (only the inner legs 821.1, 821.4 of the second transformer core element 813 and the second filter core element 814 are visible) have a columnar shape and are adapted to receive windings and / or winding portions having a circular inner diameter. Those inner legs are arranged on corresponding flanges 822.1-822.4 in the region of the central rectangular section (863, referring only to the first filter core element 811). Parallel to the inner legs, the first outer legs 820a.1-820a.4 and the second outer legs 820b.1-820b.4 are arranged on corresponding flanges 822.1-822.4 in the regions of the first and second outer rectangular sections (861 and 865, referring only to the first filter core element 811).

[0224] The difference in length between the shorter inner and outer legs 820b.1–820b.4 defines the filter gaps 841.1, 841.4 and the transformer gap 841.23 (see...). Figure 13 To increase mechanical stability, the voids can be filled with non-magnetic or low-magnetic-permeability materials.

[0225] Three-legged core element 811-814 is based on Figures 6a-6d The U-shaped core elements 211-214 are made of similar materials.

[0226] Similarly, the winding arrangement of the integrated magnetic component 810 is similar to that shown in 6a-6d. However, in this embodiment, the winding portion is arranged on the inner columnar leg rather than on the first outer leg.

[0227] The higher current transformer winding portions 807.1 and 807.2, as well as the filter windings 808.1 and 808.2, are preferably mounted on a printed circuit board (not shown), similar to that described in 6a-6d. Due to the mechanical stability of the winding portions wound along the edges, the entire core structure, including the windings, can be supported by the printed circuit board, thus eliminating the need for specific mechanical support. Also here, the circuit board may include a current multiplier stage (104, Figure 1 Other rectifier components or surface-mount diodes D1 and D2. The arrangement of the electrical components (here, diodes D1 and D2) on the printed circuit board allows for a compact design that integrates the magnetic components 801.

[0228] The printed circuit board also provides electrical connections between the higher current transformer winding sections 807.1, 807.2 and the transformer winding sections 808.1, 808.2. Using this arrangement, a high DC output current of 30A-200A at 12V DC can be achieved at a switching frequency of approximately 100kHz for the switching mode DC-DC power converter.

[0229] Figure 15a and 15b The integrated magnetic component 901 shown is based on Figure 13 , 14a Variations of the embodiments of 14b. Figure 15a Figure 14 is an exploded view of the integrated magnetic assembly 901, and Figure 15b is an isometric view of the same assembly in assembled form. The printed circuit board is not shown. The core elements of the magnetic core structure (i.e., the first transformer core element 912, the second transformer core element 913, the first filter core element 911, and the second filter core element 914) are similar to the core elements 811, 812, 813, and 814 shown in Figures 14, 14a, and 14b. The higher transformer winding portion and the filter winding are also similar. Figure 13 , 14a The higher transformer winding section and filter winding shown in 14b.

[0230] However, in the integrated magnetic assembly 901, two lower current transformer winding portions 906.1 and 906.2 are arranged on a printed circuit board 970, positioned between the first higher current transformer winding portion 907.1 and the second higher current transformer winding portion 907.2. The printed circuit board includes a circular aperture 971 for receiving the inner legs (only the inner leg of the second transformer core 921.3 is shown) and / or the transformer gaps between those inner legs of the first transformer core element 912 and the second transformer core element 913. The printed circuit board 970 also includes a first rectangular aperture 972a and a second rectangular aperture 972b for receiving the first outer legs 920a.2 and 920a.3 and the second outer legs 920b.2 and 920b.3 of the first transformer core element 912 and the second transformer core element 913. (Comparison) Figure 14a , 14b and Figure 15a , 15b It can be seen that this leg of transformer core elements 912 and 913 is related to... Figure 14a , 14b The transformer core element 912 and 913 can be designed to be shorter.

[0231] Figure 16a -c illustrates a variation of the core structure of the integrated magnetic component according to the present invention.

[0232] Figure 16a Depicting based on Figure 13 , 14a And the core structure 805 of the integrated magnetic component 801 of 14b. In Figure 16b A similar core structure 1005 is shown in the diagram. However, in this core structure 1005, the transformer flux path 1030.23 is formed by a first transformer core element 1012 (which is a three-legged core element, such as an E-shaped core) and a second transformer core element 1013 (which is an I-shaped core). The first filter core element 1011 and the second filter core element 1014 are the same as those in core structure 805. Figure 16a ) filter core components.

[0233] The first transformer core element 1012 includes a first outer leg 1020a.2, a second outer leg 1020b.2, an inner leg 1021.2, and a flange 1022.2, while the second transformer core element 1013 is an I-core with a flange 1022.3 but no legs. The first transformer core element 1012 is adjacent to the flange 1022.3 of the second transformer core element with its outer legs 1020a.2, 1020b.2 and its inner leg 1021.2 to form a figure-eight shaped transformer core segment. The first filter core element 1011 is adjacent to the flange 1022.2 of the first transformer core element 1012 on the side opposite to the outer legs 1020a.2, 1020b.2 and the inner leg 1021.2. Similarly, the second filter core element 1014 has its legs adjacent to the flange 1022.3 of the second transformer core element 1013 on the side opposite to the outer legs 1020a.2, 1020b.2 and the inner leg 1021.2 of the first transformer core element 1012. The transformer gap 1041.23 is arranged between the inner leg 1021.2 of the first transformer core element 1012 and the flange 1022.3 of the second transformer core element 1013 (which is the I core).

[0234] Figure 16c The magnetic core structure 1105 depicted in the image is Figure 16a Another variation of the magnetic core structure 805 shown. However, in this embodiment of the magnetic core structure 1105, the figure-eight transformer core section of the magnetic core structure 1105 (which defines the transformer flux path 1130.23 and / or the first transformer winding window 1165a.23 and the second transformer winding window 1165b.23 for receiving transformer winding turns) is formed by the flanges 1122.3 of the first transformer core element 1112 (which is a three-legged core element) and the second transformer core element 1113 (which is also a three-legged core element). The transformer gap 1141.23 is arranged between the inner leg 1121.2 of the first transformer core element 1112 and the flange 1122.3 of the second transformer core element 1113.

[0235] Figure 17 Another embodiment of the integrated magnetic component 1201 is shown. This embodiment is also similar to... Figure 13The embodiment shown is illustrated. The core structure 1205 of this embodiment also includes two three-legged transformer core elements 1212 and 1213, and two filter core elements 1211 and 1214. However, in this embodiment, the first filter core element 1211 is stacked on the flange 1222.4 of the second filter core element 1214, wherein the first outer leg 1220a.1, the second outer leg 1220b.1, and their inner leg 1221.1 are adjacent to the flange 1222.4 of the second filter core element 1214. A first filter gap 1241.4 is disposed between the inner leg 1221.1 of the first filter core element 1211 and the flange 1222.4 of the second filter core element 1214. A first filter winding portion 1208.1 is disposed on the center leg 1221.1 of the first filter core element 1211.

[0236] Figure 18a , 18b yes Figure 17 A geometric view of an embodiment schematically depicted in the figure, wherein Figure 18a This is an exploded view of the integrated magnetic components, and 18b is a view of the same components but in assembled form. The printed circuit board for connecting the winding portions wound along the edges is not shown. The core elements of the core structure 1205 (i.e., the first transformer core element 1212 and the second transformer core element 1213, and the first filter core element 1211 and the second filter core element 1214) are similar to... Figure 14a and 14b The core components 811, 1812, 813, and 814 are shown. The transformer winding section and filter winding are also similar. Figure 14a and 14b The transformer winding section and filter winding are shown in the diagram.

[0237] According to Figure 18a and 18b In the magnetic core structure 1205, the first filter core element 1211 is stacked on the flange 1222.4 of the second filter core element 1214 with its legs, and itself is stacked on the flange 1222.3 of the second transformer core element 1212 with its legs. The first transformer core element 1212 and the second transformer core element 1213 are adjacent to each other with their legs to form a transformer winding window for receiving transformer winding turns.

[0238] In this embodiment, the lower current transformer windings 1206.1 and 1206.2 are conventional windings with bobbins, and are arranged adjacent to each other on the inner legs of transformer core elements 1212 and 1213 between the first higher current transformer winding portion 1207.1 and the first higher current transformer winding portion 1207.2.

[0239] Figure 19a and 19bThis is a geometric view of another embodiment of the present invention. This embodiment of the integrated magnetic core structure 1305 is similar to... Figure 18a and 18b The embodiment shown also has the same magnetic core structure 1305, including a first transformer core element 1312 and a second transformer core element 1313, as well as a first filter core element 1311 and a second filter core element 1314.

[0240] However, in the integrated magnetic assembly 1301, two lower current transformer winding portions are arranged on the printed circuit board 1370, positioned between the first higher current transformer winding portion 1307.1 and the second higher current transformer winding portion 1307.2, and are identical to... Figure 15a and 15b The printed circuit board 970 is depicted in the image.

[0241] Figure 20 A second embodiment of the integrated magnetic component 1401 according to the present invention is depicted. This integrated magnetic component is also similar to that according to... Figure 13 The embodiment; however, the core structure 1405 of this embodiment has a large filtering gap. The figure-eight transformer core section formed by the first filter core element 1412 and the second filter core element 1413 is the same as that according to Figure 13 The corresponding section of the magnetic core structure 805 includes two three-legged and / or E-shaped transformer core elements 1412, 1413, whose legs are adjacent to each other to form a figure-eight transformer core section. The magnetic core structure 1405 also includes a first filter core element 1411 and a second filter core element 1414. The two filter core elements 1411, 1414 include flanges 1422.1, 1422.4 and inner legs 1421.1, 1421.4 arranged on the respective flanges 1422.1, 1422.4. Figure 13 Compared to the three-legged and / or E-shaped filter core elements 811, 814, the outer legs of the filter core elements 1411, 1414 of this embodiment of the integrated magnetic assembly 1401 are omitted and / or shortened to zero or near zero length, making the filter core element T-shaped, having a single inner leg 1421.1, 1421.2 and representing a special case of an E-shaped core element, wherein the outer leg has a length of zero and / or near zero.

[0242] The first filter core element 1411 is stacked on the flange 1422.2 of the first transformer core element 1412 with its inner leg 1421.1, such that the flange 1422.2 of the first filter core element 1411 and the second transformer core element 1412 defines a first filter flux path 1430.12, which is closed by a first filter gap between the flange 1422.1 of the first filter core element 1411 and the flange 1422.2 of the first transformer core element 1412. The gap is divided into a first gap portion 1440a.1 and a second gap portion 1440b.1, wherein the two portions are arranged outward relative to the inner leg 1421.1 of the filter core element 1411.

[0243] Similarly, the second filter core element 1414 is stacked on the flange 1422.3 of the second transformer core element 1413 with its inner leg 1421.4, such that the second filter core element 1414 and the flange 1422.3 of the second transformer core element 1413 define a second filter flux path 1430.34, which is closed by a second filter gap between the flange 1422.3 of the second transformer core element 1413 and the flange 1422.4 of the second filter core element 1414. The gap is divided into a first gap portion 1440a.4 and a second gap portion 1440b.4, wherein both portions are arranged outward relative to the inner leg 1421.4 of the second filter core element 1414.

[0244] The embodiment of the integrated magnetic component 1501 is very similar to that according to Figure 17 The integrated magnetic component, but its core structure 1505 includes large filter gaps on the outer legs, similar to that of... Figure 20 The filtering gap in the embodiment.

[0245] The figure-eight transformer core section of the magnetic core structure 1505 formed by the first transformer core element 1512 and the second transformer core element 1513 is equivalent to that according to Figure 17 The corresponding section of the magnetic core structure. Similarly, in the integrated magnetic assembly 1501, the first filter core element 1511 is stacked on the flange 1522.4 of the second filter core element 1514, and the second filter core element 1514 is stacked on the flange 1522.3 of the second transformer core element 1513. However, with Figure 17 Compared to the three-legged and / or E-shaped filter core elements 1211 and 1214, the outer legs of filter core elements 1511 and 1514 are omitted and / or shortened to zero or near-zero length, making the filter core element T-shaped, and representing a special case of the E-shaped core element, wherein the outer legs have zero and / or near-zero length.

[0246] The second filter core element 1514 is stacked on the flange 1522.3 of the second transformer core element 1513 with its inner leg 1521.4, such that the second filter core element 1514 and the flange 1522.3 of the second transformer core element 1513 define a second filter flux path 1530.34 between the flange 1522.3 of the second transformer core element 1513 and the flange 1522.4 of the second filter core element 1514. The path is closed by a second filter gap, which is divided into a first gap portion 1540a.4 and a second gap portion 1540b.4.

[0247] The first filter core element 1511 is stacked on the flange 1522.4 of the second filter core element 1514 with its inner leg 1521.1, such that the flange 1522.4 of the first filter core element 1511 and the second filter core element 1514 defines a first filter flux path 1530.14 between the flange 1522.4 of the second filter core element 1514 and the flange 1522.1 of the first filter core element 1511, which is closed by a first filter gap, which is divided into a first gap portion 1540a.1 and a second gap portion 1540b.1.

[0248] Figure 22 Another DC-DC switching mode power converter 1600 with an integrated magnetic component 1601 according to the present invention is shown. (Compared to...) Figure 1 Compared to the DC-DC switching mode power converter shown, this DC-DC switching mode power converter includes a full-wave center-tapped rectifier stage 1604 at the output, instead of... Figure 1 The current multiplier rectifier stage 104.

[0249] The single magnetic core structure 1605 of the integrated magnetic component 1601 includes a first four-legged core element 1615.1 and a second four-legged core element 1615.2, both preferably made of ferrite and having the same geometry. The two four-legged core elements 1615.1 and 1615.2 include first inner legs 1616a.1 and 1616a.2, second inner legs 1616b.1 and 1616b.2, first outer legs 1617a.1 and 1617a.2, and second outer legs 1617b.1 and 1617b.2. The two inner legs 1616a.1, 1616a.2, 1616b.1, 1616b.2 and the two outer legs 1617a.1, 1617a.2, 1617b.1, 1617b.2 of the four-legged core elements 1615.1 and 1615.2 are arranged in parallel on one side of the flanges 1618.1 and 1618.2 of the corresponding four-legged core elements 1615.a and 1615.b. The two four-legged core elements 1615.1 and 1615.2 are adjacent to each other with their inner legs 1616a.1, 1616a.2, 1616b.1, 1616b.2 and their outer legs 1617a.1, 1617a.2, 1617b.1, 1617b.2. Thus, the first inner legs 1616a.1, 1616a.2 and the second inner legs 1616b.1, 1616b.2 of the two four-legged core elements 1615.1 and 1615.2 form the inner winding window 1619. The first inner legs 1616a.1, 1616a.2, the first outer legs 1617a.1, 1617a.2 and the flanges 1618.1, 1618.2 of the two core elements 1615.1 and 1615.2 form the first outer winding window 1620a, while the second inner legs 1616b.1, 1616b.2, the second outer legs 1617b.1, 1617b.2 and the flanges 1618.1, 1618.2 of the two core elements 1615.1 and 1615.2 form the second outer winding window 1620b.

[0250] The first gap 1621a is arranged between the first outer legs 1617a.1 and 1617a.2, and the second gap 1621b is arranged between the second outer legs 1617b.1 and 1617b.2 of the first and second four-legged core elements 1615.1 and 1615.2.

[0251] The first lower current transformer winding portion 1606.1 is arranged on the first inner legs 1616a.1 and 1616a.2 of the first and / or second four-legged core elements 1615.1 and 1615.2. The second lower current transformer winding portion 1606.2, connected in series with the first lower current transformer winding portion 1606.1, is arranged on the second inner legs 1616b.1 and 1616b.2 of the first and / or second four-legged core elements 1615.1 and 1615.2. The free ends of the lower current transformer winding portions 1606.1 and 1606.2 are connected to the four-switch converter stage 1602 at the first input connection point e1 and the second input connection point e2.

[0252] The first higher current winding portion 1607.1 is also arranged on the first inner legs 1616a.1 and 1616a.2 of the first and / or four-legged core elements 1615.1 and 1615.2, and the second higher current winding portion 1607.2 is arranged on the second inner legs 1616b.1 and 1616b.2 of the first and / or second four-legged core elements 1615.1 and 1615.2. The first filter winding 1608.1 is arranged on the first outer legs 1617a.1 and 1617a.2 of the first and / or second four-legged core elements 1615.1 and 1615.2, and the second filter winding 1608.2 is arranged on the second outer legs 1617b.1 and 1617b.2 of the first and / or second four-legged core elements 1615.1 and 1615.2. The first filter winding 1608.1 is connected in series with the first higher current transformer winding portion 1607.1, and the second filter winding 1608.2 is connected in series with the second higher current transformer winding portion 1607.2. Furthermore, the two higher current transformer winding portions 1607.1 and 1607.2 are connected in series at output connection point a4. The free end of the first filter winding 1608.1 is connected to the positive terminal of the first diode D1, and the free end of the second filter winding 1608.2 is connected to the positive terminal of the second diode D2. The output capacitor Cout is connected between the first output connection point a4 and the negative terminals of diodes D1 and D2.

[0253] The filter winding and higher current transformer winding sections are winding sections wound along the edges. They may also be connected to a printed circuit board (not shown).

[0254] Figure 23 The integrated magnetic component 1801 shown is similar to that according to Figure 22 The embodiment includes a current multiplier rectifier stage 1804 at the output, and thus achieves... Figure 1 The circuit shown here. Here, the positive terminal of the first diode D1 of the center-tapered rectifier 1804 is connected to the first filter connection point a1, which is the connection point between the first higher current transformer winding portion 1807.1 and the first filter winding 1808.2.

[0255] The positive terminal of the second diode D2 of the current multiplier rectifier 1804 is connected to the second filter connection point a2, which is the connection point between the second higher current transformer winding section 1807.2 and the second filter winding 1808.2.

[0256] The free ends of the first filter winding 1808.1 and the second filter winding 1808.2 are connected to the input capacitor Cout at the common connection point a3, and the other end of the capacitor is connected to the negative terminals of the first diode D1 and the second diode D2.

[0257] In summary, it should be noted that the present invention creates an integrated magnetic component for a switching mode power converter that further reduces losses and produces higher power density, while simultaneously allowing for lower production costs.

[0258] The present invention further creates a DC-DC switching mode power converter including this magnetic component.

Claims

1. An integrated magnetic component for a switching mode power converter, the integrated magnetic component comprising: a. A single-core structure, wherein the single-core structure is formed by linearly stacked core elements. b. Among them, At least one of the core elements is a leg core element, the leg core element having a flange and one or more legs extending from the same side of the flange. c. An isolation transformer having a higher current transformer winding disposed on at least one leg of the magnetic core element and a lower current transformer winding disposed on at least one leg of the magnetic core element. d. and a first filter inductor, the first filter inductor including a first filter winding disposed on at least one leg of the magnetic core element, Its features are, e. The integrated magnetic assembly includes two magnetic core elements, wherein the legs and flanges of the two magnetic core elements form at least three adjacent winding windows, wherein turns of the higher current transformer winding are arranged on at least one of the legs, turns of the lower current transformer winding are arranged on at least one of the legs, and turns of the filter winding are arranged on at least one other leg. f. The higher current transformer winding and the first filter winding include at least an edge-wound winding portion, wherein the edge-wound winding portion includes at least one turn of wire having a substantially rectangular cross-section with a shorter edge and a longer edge, wherein the wire is wound around the shorter edge of the substantially rectangular cross-section.

2. The integrated magnetic assembly of claim 1, further comprising a second filter inductor, the second filter inductor including a second filter winding disposed on at least one leg of the magnetic core element.

3. The integrated magnetic assembly of claim 2, wherein, The higher current transformer winding and / or the first filter winding and the second filter winding are adapted to an operating current greater than 10 A (RMS).

4. The integrated magnetic component according to claim 2, wherein, The higher current transformer winding and / or the first filter winding and the second filter winding are adapted to an operating current greater than 20A (RMS).

5. The integrated magnetic component according to claim 2, wherein, The higher current transformer winding and / or the first filter winding and the second filter winding are adapted to an operating current greater than 30A (RMS).

6. The integrated magnetic component according to any one of claims 1-5, wherein, The lower current transformer winding is integrated into a printed circuit board.

7. The integrated magnetic assembly according to any one of claims 1-5, comprising a filter gap disposed between the legs of the two core elements, the legs and flanges of the two core elements forming the at least three adjacent winding windows.

8. The integrated magnetic assembly according to any one of claims 2-5, further comprising a circuit board, wherein at least one of the edge-wound winding portions has being oriented in the same direction and mounted to first and second ends of the circuit board.

9. The integrated magnetic assembly of claim 8, wherein the circuit board electrically connects the higher current transformer winding to the first filter winding and the second filter winding.

10. The integrated magnetic assembly of claim 9, further comprising a rectifier circuit, the rectifier circuit comprising at least two rectifier elements, wherein, The rectifier element is mounted on the circuit board, which connects the rectifier element to the higher current transformer winding of the isolation transformer and to the first filter winding.

11. The integrated magnetic component according to claim 10, wherein, The rectifier element is surface mounted.

12. The integrated magnetic component according to claim 11, wherein, The rectifier element is a synchronous rectifier.

13. The integrated magnetic component according to claim 8, wherein, The circuit board is provided with rectangular through holes for mounting the edge-wound winding portion, which is adapted to mechanically support the single-core structure.

14. The integrated magnetic component according to claim 10, wherein, The rectifier circuit is a voltage multiplier.

15. The integrated magnetic component according to any one of claims 1-5, wherein, The winding portion wound along the edge is wound from an enamel flat wire, and / or wherein the lower current transformer winding includes triple-insulated wire.

16. A switching mode power converter, comprising an integrated magnetic component according to any one of the preceding claims.

17. The switching mode power converter according to claim 16, wherein, The switching mode power converter is a switching mode DC-DC power converter.

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