Magnetic element and core structure thereof

Abstract

The application discloses a magnetic element, which comprises a primary coil set, a secondary coil set and a magnetic core structure. A first primary coil and a second primary coil of the primary coil set are wound around a first winding column and a second winding column of the magnetic core structure respectively, and the number of turns of the first primary coil is different from that of the second primary coil. A first secondary coil and a second secondary coil of the secondary coil set are wound around the first winding column and the second winding column respectively, and the number of turns of the first secondary coil is different from that of the second secondary coil.

Description

Technical Field

[0001] This application relates to a magnetic element and its core structure, and more particularly to a magnetic element and its core structure that can reduce the overall size while maintaining good energy conversion efficiency. Background Technology

[0002] Magnetic components are one of the important components widely used in various electronic products. In recent years, due to the rise of environmental awareness, many mobile vehicles such as buses and cars have switched to electric drive instead of fuel drive. Therefore, these mobile vehicles need to have built-in on-board battery chargers (OBC). The charger will dynamically adjust the current or voltage parameters of the mobile vehicle during charging based on the data provided by the battery management system and perform corresponding actions to complete the charging process.

[0003] Because the magnetic components used in vehicle battery chargers are quite large, they occupy too much space in the overall circuit design, thus affecting the installation of other electrical components. However, simply reducing the size of the magnetic components would limit the winding space of the coil, thereby affecting the switching efficiency.

[0004] Therefore, how to provide a magnetic component and its core structure that can reduce the overall size while maintaining good energy conversion efficiency is a problem that the industry urgently needs to solve. Summary of the Invention

[0005] This application provides a magnetic element and its core structure to solve the problem that the magnetic element installed in the vehicle battery charger has a large volume, which causes the overall circuit to occupy too much space during design, thus affecting the installation of other electrical components.

[0006] To solve the above-mentioned technical problems, this application is implemented as follows:

[0007] In a first aspect, a magnetic element is provided, comprising:

[0008] The primary coil assembly includes a first primary coil and a second primary coil;

[0009] The secondary coil assembly includes a primary coil and a secondary coil; and

[0010] The magnetic core structure includes:

[0011] First cover plate and second cover plate;

[0012] A central column connects the first cover plate and the second cover plate, and there is no air gap between the central column and the first and second cover plates; and

[0013] The first winding post and the second winding post are located on two opposite sides of the central post, respectively;

[0014] The first primary coil and the second primary coil are wound on the first winding post and the second winding post, respectively, and the number of turns of the first primary coil is different from the number of turns of the second primary coil. The first secondary coil and the second secondary coil are wound on the first winding post and the second winding post, respectively, and the number of turns of the first secondary coil is different from the number of turns of the second secondary coil.

[0015] In the magnetic element of this application, the first winding post and the second winding post are connected to the first cover plate, and there is an air gap between the first winding post and the second winding post and the second cover plate.

[0016] In the magnetic element of this application, the first winding post and the second winding post are respectively connected to the center post.

[0017] The magnetic element of this application further includes a first support post and a second support post, the first support post and the second support post being connected to the first cover plate and the second cover plate respectively, and the first winding post being disposed between the first support post and the center post, and the second winding post being disposed between the second support post and the center post.

[0018] In the magnetic element of this application, the first winding post or the second winding post has an air gap.

[0019] The magnetic element of this application further includes a third winding post and a fourth winding post, which are respectively disposed on the first support post and the second support post. A third primary coil and a fourth primary coil of the primary coil group are respectively wound on the third winding post and the fourth winding post, and a third secondary coil and a fourth secondary coil of the secondary coil group are respectively wound on the third winding post and the fourth winding post.

[0020] In the magnetic element of this application, one end of the first winding post is connected to the first support post, and the other end of the first winding post has an air gap with the center post; one end of the second winding post is connected to the second support post, and the other end of the second winding post has an air gap with the center post.

[0021] In the magnetic element of this application, the first winding post has a first cross-sectional area, and the second winding post has a second cross-sectional area, wherein the first cross-sectional area is not equal to the second cross-sectional area.

[0022] In the magnetic element of this application, the wire diameter of the first primary coil of the primary coil group is not equal to the wire diameter of the second primary coil.

[0023] In the magnetic element of this application, the wire diameter of the primary coil of the secondary coil group is not equal to the wire diameter of the secondary coil.

[0024] In the magnetic element of this application, the first primary coil is electrically connected to the second primary coil via a first external circuit, or the first primary coil is electrically connected to the second primary coil via a second external circuit.

[0025] Secondly, a magnetic core structure is provided, comprising:

[0026] First cover plate and second cover plate;

[0027] A central column connects the first cover plate and the second cover plate, and there is no air gap between the central column and the first and second cover plates; and

[0028] The first winding post and the second winding post are located on two opposite sides of the central post.

[0029] In the magnetic core structure of this application, the first winding post and the second winding post are connected to the first cover plate, and there is an air gap between the first winding post and the second winding post and the second cover plate.

[0030] In the magnetic core structure of this application, the first winding post and the second winding post are respectively connected to the center post.

[0031] The magnetic core structure of this application further includes a first support post and a second support post, the first support post and the second support post being connected to the first cover plate and the second cover plate respectively, and the first winding post being disposed between the first support post and the center post, and the second winding post being disposed between the second support post and the center post.

[0032] In the magnetic core structure of this application, the first winding post or the second winding post each has an air gap.

[0033] The magnetic core structure of this application further includes a third winding post and a fourth winding post, which are respectively disposed on the first support post and the second support post.

[0034] In the magnetic core structure of this application, one end of the first winding post is connected to the first support post, and the other end of the first winding post has an air gap with the center post; one end of the second winding post is connected to the second support post, and the other end of the second winding post has an air gap with the center post.

[0035] In the magnetic core structure of this application, the first winding post has a first cross-sectional area, and the second winding post has a second cross-sectional area, wherein the first cross-sectional area is not equal to the second cross-sectional area.

[0036] In this embodiment, the design eliminates air gaps between the central column and both the first and second cover plates, resulting in a simple structure for the magnetic element and its core. This allows the magnetic element and its core to maintain excellent energy conversion efficiency despite having a smaller overall size. Attached Figure Description

[0037] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings:

[0038] Figure 1A , 1B This is a schematic diagram of the first embodiment of the magnetic element of the present invention.

[0039] Figure 2 This is a schematic diagram of a second embodiment of the magnetic element of the present invention.

[0040] Figure 3A This is a schematic diagram of a third embodiment of the magnetic element of the present invention.

[0041] Figure 3B This is a schematic diagram of another aspect of the third embodiment of the magnetic element of the present invention.

[0042] Figure 4 This is a schematic diagram of the fourth embodiment of the magnetic element of the present invention.

[0043] Figure 5A This is a schematic diagram of the fifth embodiment of the magnetic element of the present invention.

[0044] Figure 5B This is a schematic diagram of another aspect of the fifth embodiment of the magnetic element of the present invention.

[0045] Figure 6A This is a schematic diagram of the sixth embodiment of the magnetic element of the present invention.

[0046] Figure 6B This is a schematic diagram of another aspect of the sixth embodiment of the magnetic element of the present invention.

[0047] Figure 7 This is a schematic diagram of the seventh embodiment of the magnetic element of the present invention.

[0048] Figure 8 This is a schematic diagram of the eighth embodiment of the magnetic element of the present invention.

[0049] Figure 9A This is a schematic diagram of the ninth embodiment of the magnetic element of the present invention.

[0050] Figure 9B This is a schematic diagram of another aspect of the ninth embodiment of the magnetic element of the present invention. Detailed Implementation

[0051] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0052] like Figure 1A As shown in the first embodiment, a magnetic element 100 of the present invention includes a primary coil group 200, a secondary coil group 300, and a magnetic core structure 400. The primary coil group 200 has a first primary coil 201 and a second primary coil 202. The secondary coil group 300 has a first primary coil 301 and a second secondary coil 302. The magnetic core structure 400 includes a first cover plate 420, a second cover plate 430, a center post 410, a first winding post 440, and a second winding post 450. The center post 410 connects the first cover plate 420 and the second cover plate 430, and there is no air gap between the center post 410 and the first cover plate 420 and the second cover plate 430. The first winding post 440 and the second winding post 450 are respectively located on two opposite sides of the center post 410.

[0053] The first primary coil 201 and the second primary coil 202 are wound on the first winding post 440 and the second winding post 450, respectively, and the number of turns of the first primary coil 201 is different from the number of turns of the second primary coil 202. The first primary coil 301 and the second primary coil 302 are wound on the first winding post 440 and the second winding post 450, respectively, and the number of turns of the first primary coil 301 is different from the number of turns of the second primary coil 302.

[0054] Please continue reading Figure 1BThe central post 410 has a first end 411, a second end 412, a first side 413, and a second side 414; the second end 412 is disposed opposite to the first end 411, and the first side 413 and the second side 414 are located between the first end 411 and the second end 412 and are disposed opposite to each other. A first cover plate 420 and a second cover plate 430 are respectively disposed on the first end 411 and the second end 412 of the central post 410. A first winding post 440 and a second winding post 450 are respectively located on two opposite sides of the central post 410; the first winding post 440 has a first winding portion 441 and a second winding portion 442, and the second winding post 450 has a third winding portion 451 and a fourth winding portion 452. The primary coil group 200 has a first primary coil 201 and a second primary coil 202 respectively wound on the first winding portion 441 of the first winding post 440 and the third winding portion 451 of the second winding post 450, and the secondary coil group 300 has a first primary coil 301 and a second secondary coil 302 respectively wound on the second winding portion 442 of the first winding post 440 and the fourth winding portion 452 of the second winding post 450.

[0055] In detail, such as Figure 1B As shown, in a first embodiment of the magnetic element 100 of the present invention, the first cover plate 420 has a first cover plate end 421 and a second cover plate end 422 opposite to each other, and the first winding post 440 and the second winding post 450 are respectively disposed at the first cover plate end 421 and the second cover plate end 422 of the first cover plate 420. In other words, the first winding post 440 and the second winding post 450 are respectively disposed at two opposite ends of the first cover plate 420.

[0056] Since there are no air gaps between the central post 410 and the first cover plate 420 and the second cover plate 430 of the magnetic element 100 of the present invention, when designing the magnetic element 100 based on a specific leakage inductance, it is only necessary to consider the ratio of the number of turns of the primary coil group 200 and the secondary coil group 300 wound on the core structure 400, and to ensure that the number of turns of the primary coil group 200 and the secondary coil group 300 wound on the first winding post 440 and the second winding post 450 are unequal. Therefore, the magnetic element 100 of the present invention can effectively reduce the overall volume and reduce the total loss obtained by adding up the iron loss and copper loss during AC charging simply by adjusting the ratio of the number of turns of the primary coil group 200 and the secondary coil group 300 wound on the core structure 400, thereby achieving excellent energy conversion efficiency.

[0057] In embodiments of the present invention, the primary coil group 200 and the secondary coil group 300 may be, for example, enameled wire windings, Litz wire windings, metal foil windings, printed circuit board windings, etc., and are not limited thereto.

[0058] like Figure 2 As shown, the magnetic element 100 of the second embodiment of the present invention has the same components as the first embodiment, and there are no air gaps between the central post 410 and the first cover plate 420 and the second cover plate 430. The difference between the second embodiment and the first embodiment is that in the second embodiment, the first winding post 440 and the second winding post 450 are respectively connected to the central post 410. That is, in the second embodiment, the first winding post 440 and the second winding post 450 are respectively disposed on the first side 413 and the second side 414 of the central post 410, so that the magnetic element 100 has a vertically symmetrical structure centered on the horizontal line.

[0059] Similar to the first embodiment, since there is no air gap between the center post 410 and the first cover plate 420 and the second cover plate 430 in the second embodiment, when controlling the leakage inductance, it is only necessary to consider the ratio of the number of turns of the primary coil group 200 and the secondary coil group 300 wound on the first winding post 440 and the second winding post 450 and make them unequal. Therefore, the structure of the second embodiment can also effectively reduce the overall volume and reduce the total loss obtained by adding iron loss and copper loss during AC charging by simply adjusting the ratio of the number of turns of the primary coil group 200 and the secondary coil group 300 wound on the first winding post 440 and the second winding post 450, thereby achieving excellent energy conversion efficiency.

[0060] In another embodiment of the present invention, the magnetic element 100, in addition to including the components of the first embodiment, further includes a first support post 460 and a second support post 470. The first support post 460 and the second support post 470 are respectively connected to the first cover plate 420 and the second cover plate 430, and a first winding post 440 is disposed between the first support post 460 and the center post 410, and a second winding post 450 is disposed between the second support post 470 and the center post 410.

[0061] The following will describe various embodiments of this state.

[0062] Figure 3AThis is a third embodiment of the magnetic element 100 of the present invention. In addition to having the same components as the first embodiment, the third embodiment of the magnetic element 100 further includes a first support post 460 and a second support post 470. The first support post 460 is disposed between the first cover plate 420 and the second cover plate 430 and on a first side 413 away from the central post 410. The second support post 470 is disposed between the first cover plate 420 and the second cover plate 430 and on a second side 414 away from the central post 410. A first winding post 440 and a second winding post 450 are respectively disposed on the first support post 460 and the second support post 470.

[0063] The arrangement of the first support column 460 and the second support column 470 strengthens the supporting relationship between the first cover plate 420 and the second cover plate 430, thus enabling the magnetic element 100 itself to have a more stable structure. Furthermore, in Figure 3A In this design, a plurality of air gaps (GAPs) exist between the first winding post 440 and the second winding post 450. The multiple air gaps are illustrated by an example where they are evenly distributed between the first winding post 440 and the second winding post 450. However, in actual application, the number and placement of the air gaps can be adjusted according to different needs. By placing the first winding post 440 on the first support post 460 and the second winding post 450 on the second support post 470, the sizes of the air gaps between the first winding post 440 and the second winding post 450 can be further stabilized.

[0064] On the other hand, in the third embodiment, since both the primary coil group 200 and the secondary coil group 300 are covered inside the magnetic core structure 400, the leakage flux generated by the primary coil group 200 and the secondary coil group 300 will not leak into the air. This not only reduces the electromagnetic interference generated by the magnetic element 100 to other surrounding devices, but also reduces the electromagnetic interference of other devices to the magnetic element 100. Therefore, the structure of the third embodiment of the magnetic element 100 can effectively reduce electromagnetic compatibility (EMC) problems.

[0065] It should be noted that the central column in the third embodiment can also be composed of two columns, such as... Figure 3B As shown, the central column is composed of a first central column 510 and a second central column 520. In other words, in this embodiment, the magnetic element 100 can be considered as being composed of two independent transformers connected to each other.

[0066] Figure 4This is a fourth embodiment of the magnetic element 100 of the present invention. In addition to having the same first support post 460 and second support post 470 as the third embodiment, the fourth embodiment of the magnetic element 100 further includes a third winding post 480 and a fourth winding post 490. The third winding post 480 and the fourth winding post 490 are respectively disposed on the first support post 460 and the second support post 470. A third primary coil 203 and a fourth primary coil 204 of the primary coil group 200 are respectively wound around the third winding post 480 and the fourth winding post 490. A third secondary coil 303 and a fourth secondary coil 304 of the secondary coil group 300 are respectively wound around the third winding post 480 and the fourth winding post 490.

[0067] In other words, the fourth embodiment modifies the structure so that the first winding post 440 and the third winding post 480 are disposed on the first support post 460, and the second winding post 450 and the fourth winding post 490 are disposed on the second support post 470.

[0068] As shown in the figure, the third winding post 480 has a fifth winding portion 481 and a sixth winding portion 482, and the fourth winding post 490 has a seventh winding portion 491 and an eighth winding portion 492. Thus, in addition to the first winding portion 441 of the first winding post 440 and the third winding portion 451 of the second winding post 450 respectively, the primary coil group 200 further includes a third primary coil 203 and a fourth primary coil 204, which are respectively wound around the fifth winding portion 481 of the third winding post 480 and the seventh winding portion 491 of the fourth winding post 490. Furthermore, the number of turns of the first primary coil 201, the second primary coil 202, the third primary coil 203, and the fourth primary coil 204 are all unequal.

[0069] Correspondingly, in addition to the first winding portion 442 of the first winding post 440 and the fourth winding portion 452 of the second winding post 450 respectively, the secondary coil group 300 further includes a third winding portion 303 and a fourth secondary coil 304 which are wound on the sixth winding portion 482 of the third winding post 480 and the eighth winding portion 492 of the fourth winding post 490 respectively. The number of turns of the first winding portion 301, the second winding portion 302, the third winding portion 303 and the fourth secondary coil 304 are also different from each other.

[0070] The arrangement of placing the first winding post 440 and the third winding post 480 on the first support post 460, and placing the second winding post 450 and the fourth winding post 490 on the second support post 470, not only stabilizes the air gap size of each winding post, but also allows the magnetic element 100 to have a thinner winding post height, thereby effectively reducing the overall volume of the magnetic element 100.

[0071] It should be noted that, in the fourth embodiment, because a third primary coil 203, a fourth primary coil 204, a third secondary coil 303, and a fourth secondary coil 304 are added, the ratio of the number of turns of the primary coil group 200 to the number of turns of the secondary coil group 300 on each winding post will also be adjusted accordingly to ensure that the number of turns of each coil is not equal.

[0072] Figure 5A This is the fifth embodiment of the magnetic element 100 of the present invention, which is Figure 3A The structure of the magnetic element 100 in the fifth embodiment has changed. Figure 3A The difference is that the fifth embodiment further includes a third winding post 480, and the first winding post 440 is disposed on the first support post 460, the second winding post 450 is disposed on the second support post 470, and the third winding post 480 is disposed on the second side 414 of the center post 410.

[0073] In this way, the first primary coil 201 and the second primary coil 202 of the primary coil group 200 will be wound on the first winding portion 441 and the third winding post 480 of the first winding post 440, respectively, while the first primary coil 301 and the second primary coil 302 of the secondary coil group 300 will be wound on the second winding portion 442 and the second winding post 450 of the first winding post 440, respectively.

[0074] Since both the primary coil group 200 and the secondary coil group 300 are encased inside the magnetic core structure 400, the leakage flux generated by the primary coil group 200 and the secondary coil group 300 in the fifth embodiment will not leak into the air, thus effectively reducing electromagnetic compatibility issues.

[0075] like Figure 5B As shown, the structure of the magnetic element 100 in the fifth embodiment can also be regarded as being composed of three E-type iron cores, and still has the aforementioned effect of effectively reducing electromagnetic compatibility.

[0076] Figure 6AThis is a sixth embodiment of the magnetic element 100 of the present invention. In addition to having the same components as in the fifth embodiment, the magnetic element 100 of the sixth embodiment further includes a fourth winding post 490, and the fourth winding post 490 is disposed on the first side 413 of the central post 410. In other words, in the sixth embodiment, the first winding post 440 is disposed on the first support post 460, the second winding post 450 is disposed on the second support post 470, the third winding post 480 is disposed on the second side 414 of the central post 410, and the fourth winding post 490 is disposed on the first side 413 of the central post 410.

[0077] Through the above arrangement, the first primary coil 201 and the second primary coil 202 of the primary coil group 200 will be wound on the fourth winding post 490 and the third winding post 480 respectively, and the first primary coil 301 and the second primary coil 302 of the secondary coil group 300 will be wound on the first winding post 440 and the second winding post 450 respectively.

[0078] Compared to other embodiments, the first winding post 440, the second winding post 450, the third winding post 480, and the fourth winding post 490 of the sixth embodiment will each have a shorter length, so that the first winding post 440, the second winding post 450, the third winding post 480, and the fourth winding post 490 can avoid bending and deforming along the direction of gravity due to gravity, thereby making the overall structure of the magnetic element 100 more stable.

[0079] like Figure 6B As shown, the structure of the magnetic element 100 in the sixth embodiment can also be regarded as being composed of four E-type iron cores, and still has the effect of the above-mentioned more stable overall structure of the magnetic element 100.

[0080] Figure 7 This is the seventh embodiment of the magnetic element 100 of the present invention, which is Figure 3B The structure of the magnetic element 100 in the seventh embodiment has changed. Figure 3B The difference lies in the fact that the left and right core structures in the seventh embodiment are not equal (i.e., the dimensions of the first winding post 440 and the second winding post 450 are not equal). In other words, during actual manufacturing, appropriate dimensions (such as cross-sectional area) of the first winding post 440 and the second winding post 450 can be selected according to the required magnetic flux to optimize core loss.

[0081] For example, in the seventh embodiment, the first winding post 440 can have a first cross-sectional area A1, and the second winding post 450 can have a second cross-sectional area A2, wherein the first cross-sectional area A1 is not equal to the second cross-sectional area A2. Furthermore, the ratio of the larger of the first cross-sectional area A1 to the smaller of the second cross-sectional area A2 can be ≤2:1 to optimize core wear. Figure 7In the first case, the second cross-sectional area A2 is greater than the first cross-sectional area A1, and the ratio between the two is no greater than 2:1.

[0082] Figure 8 This is the eighth embodiment of the magnetic element 100 of the present invention, which is Figure 3B Another change in the structure. The magnetic element 100 of the eighth embodiment and... Figure 3B The difference lies in that the wire diameter of the first primary coil 201 of the primary coil group 200 in the eighth embodiment is not equal to the wire diameter of the second primary coil 202, and the wire diameter of the first primary coil 301 of the secondary coil group 300 is not equal to the wire diameter of the second primary coil 302. Specifically, as... Figure 8 As shown, when the first primary coil 201 and the second primary coil 202 of the primary coil group 200 have a first wire diameter D1 and a second wire diameter D2 respectively, the first wire diameter D1 is not equal to the second wire diameter D2; when the first primary coil 301 and the second primary coil 302 of the secondary coil group 300 have a third wire diameter D3 and a fourth wire diameter D4 respectively, the third wire diameter D3 is not equal to the fourth wire diameter D4.

[0083] When the first wire diameter D1 is not equal to the second wire diameter D2, it means that one of the first wire diameter D1 and the second wire diameter D2 has a thicker wire diameter. When the third wire diameter D3 is not equal to the fourth wire diameter D4, it means that one of the third wire diameter D3 and the fourth wire diameter D4 has a thicker wire diameter.

[0084] In other words, because the total number of coils on the left and right sides of the magnetic element 100 of the present invention is different, in the eighth embodiment, the wire diameter of the thickened portion of the coil can be used, for example... Figure 8 As shown, the second wire diameter D2 of the second primary coil 202 and the third wire diameter D3 of the first primary coil 301 are thickened at the same time, so that the cross-sectional area of ​​the conductors of the second primary coil 202 and the first primary coil 301 is increased, thereby reducing the copper loss when current is passed through the second primary coil 202 and the first primary coil 301.

[0085] In this embodiment, the copper loss can also be reduced by increasing either the first wire diameter D1 of the first primary coil 201 or the fourth wire diameter D4 of the second primary coil 302, or by increasing both the first wire diameter D1 of the first primary coil 201 and the fourth wire diameter D4 of the second primary coil 302.

[0086] Figure 9A , 9B This is the ninth embodiment of the magnetic element 100 of the present invention, which is Figure 3B Another change in structure. The magnetic element 100 of the ninth embodiment and... Figure 3BThe difference lies in the ninth embodiment, where the first primary coil 201 is electrically connected to the second primary coil 202 via a first external circuit, or the first primary coil 301 is electrically connected to the second secondary coil 302 via a second external circuit. In other words, the first primary coil 201 and the second primary coil 202 of the primary coil group 200 can have a first electrical connection through the first external circuit, and the first primary coil 301 and the second secondary coil 302 of the secondary coil group 300 can have a second electrical connection through the second external circuit, and the first external circuit and the second external circuit can be a PCB trace 600.

[0087] In detail, when the magnetic element 100 of the ninth embodiment is composed of two independent transformers connected to each other from left to right, although the coil groups on the left and right sides can be directly electrically connected and connected under normal circumstances, in this invention, it can also be done as follows: Figure 9A As shown, the second electrical connection between the primary coil 301 and the secondary coil 302 is completed via a second external circuit (PCB trace 600), so that the primary coil 301 and the secondary coil 302 of the left and right transformers do not need to be connected in a single line. Alternatively, as... Figure 9B As shown, the first electrical connection between the first primary coil 201 and the second primary coil 202 is completed through the first external circuit (PCB trace 600), so that the first primary coil 201 and the second primary coil 202 of the left and right transformers do not need to be connected in a single line.

[0088] In addition, the cross-sectional area of ​​the PCB trace 600 may be the same as the cross-sectional area of ​​the winding of the primary coil group 200 or the secondary coil group 300, or the cross-sectional area of ​​the PCB trace 600 may be not less than half of the cross-sectional area of ​​the winding of the primary coil group 200 or the secondary coil group 300.

[0089] It should be noted that the aforementioned third embodiment ( Figure 3A ), fifth embodiment (Figure 5) and seventh embodiment ( Figure 7 The diagrams illustrate the states where, when one end of the first winding post 440 is connected to the first support post 460, there is an air gap (GAP) between the other end of the first winding post 440 and the center post 410, and when one end of the second winding post 450 is connected to the second support post 470, there is an air gap (GAP) between the other end of the second winding post 450 and the center post 410, thus facilitating the adjustment of the energy conversion efficiency between each winding post and the center post.

[0090] The present invention further provides a magnetic core structure 400, which has the following characteristics: Figure 1A , 1B The first state shown in the first embodiment and as follows Figure 2The second embodiment shows the second state. Both the first and second states of the magnetic core structure 400 are composed of components such as a center post 410, a first cover plate 420, a second cover plate 430, a first winding post 440, and a second winding post 450, and there are no air gaps between the center post 410 and the first and second cover plates 420 and 430. Therefore, the first and second states of the magnetic core structure 400 can be easily configured to ensure that the air gaps between the first winding post 440 and the second winding post 450 have consistent dimensions.

[0091] like Figure 3A , 3B As shown in the third embodiment, the third state of the magnetic core structure 400 of the present invention, compared with the first and second states, has an additional first support post 460 and a second support post 470. The provision of the first support post 460 and the second support post 470 strengthens the support relationship between the first cover plate 420 and the second cover plate 430, thus making the magnetic core structure 400 itself have a more stable structure, while further stabilizing the air gaps of the first winding post 440 and the second winding post 450 to ensure they have consistent dimensions. Furthermore, the leakage flux generated by the primary coil group 200 and the secondary coil group 300 will not leak into the air, thus effectively reducing electromagnetic compatibility issues. Also, because... Figure 7 The core structure is only Figure 3B The slight changes (i.e., the core structures on the left and right sides are not equal) therefore Figure 7 The magnetic core structure has the same features as the third embodiment. On the other hand, Figure 8 The embodiments in Figure 1 only change the wire diameter of the coil, while the embodiments in Figure 9 change the electrical connection of the coil group. Figure 8 The magnetic core structure in Figure 9 also has the same features as the third embodiment.

[0092] like Figure 4 As shown, the fourth state of the magnetic core structure 400 is an improvement upon the third state. In the fourth state, the magnetic core structure 400 may further include a third winding post 480 and a fourth winding post 490. Specifically, the first winding post 440 and the third winding post 480 are disposed on the first support post 460, and the second winding post 450 and the fourth winding post 490 are disposed on the second support post 470. In this way, the fourth state of the magnetic core structure 400, in addition to possessing the advantages of the third state, also allows the magnetic element 100 to have a thinner winding post height, thereby effectively reducing the overall volume of the magnetic element 100.

[0093] like Figure 5A , 5BAs shown, the fifth state of the magnetic core structure 400 is also an improvement based on the third state. In the fifth state, the magnetic core structure 400 further includes a third winding post 480, such that the first winding post 440 is disposed on the first support post 460, the second winding post 450 is disposed on the second support post 470, and the third winding post 480 is disposed on the second side 414 of the center post 410. Therefore, when the primary coil group 200 and the secondary coil group 300 are configured in the fifth state of the magnetic core structure 400, both the primary coil group 200 and the secondary coil group 300 are enclosed inside the magnetic core structure 400. Thus, the fifth state of the magnetic core structure 400 will not have any leakage flux leaking into the air, effectively reducing electromagnetic compatibility issues.

[0094] like Figure 6A , 6B As shown, the sixth state of the magnetic core structure 400 is an improvement based on the fifth state. In the sixth state, the magnetic core structure 400 may further include a fourth winding post 490, such that the first winding post 440 is disposed on the first support post 460, the second winding post 450 is disposed on the second support post 470, the third winding post 480 is disposed on the second side 414 of the central post 410, and the fourth winding post 490 is disposed on the first side 413 of the central post 410. Therefore, each winding post of the magnetic core structure 400 in the sixth state will have a shorter height, making it less likely for each winding post to deform downwards due to gravity, thereby making the overall structure of the magnetic element 100 more stable.

[0095] In summary, the magnetic element 100 and its core structure 400 of the present invention have a simple structure by employing a design in which there are no air gaps between the central post 410 and the first cover plate 420 and the second cover plate 430. Furthermore, the magnetic element 100 and its core structure 400, with a smaller overall size, reduce the total loss due to iron and copper losses during AC charging by adjusting the ratio of the number of turns of the primary coil group 200 and the secondary coil group 300 wound on the first winding post 440 and the second winding post 450, thereby achieving excellent energy conversion efficiency. Moreover, when multiple air gaps are provided between the first winding post 440 and the second winding post 450, the air gaps can be evenly distributed between the first winding post 440 and the second winding post 450 (e.g., ...). Figure 3A As shown), the air gap (GAP) can also be set on the winding post in an unevenly distributed manner (e.g., Figure 5A , Figure 6A (as shown), thereby adjusting the energy conversion efficiency between each winding post.

[0096] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0097] The embodiments of this application have been described above with reference to the accompanying drawings. However, this application is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of this application without departing from the spirit and scope of the claims, and all of these forms fall within the scope of protection of this application.

Claims

1. A magnetic element, characterized in that, Include: The primary coil assembly includes a first primary coil and a second primary coil; The secondary coil assembly includes a primary coil and a secondary coil; and The magnetic core structure includes: First cover plate and second cover plate; A central column connects the first cover plate and the second cover plate, and there is no air gap between the central column and the first cover plate and the second cover plate; The first winding post and the second winding post are located on two opposite sides of the central post, respectively; In this configuration, both the primary coil group and the secondary coil group are encased inside the magnetic core structure. The first primary coil and the second primary coil are wound around the first winding post and the second winding post, respectively, and the number of turns of the first primary coil is different from the number of turns of the second primary coil. The first secondary coil and the second secondary coil are wound around the first winding post and the second winding post, respectively, and the number of turns of the first secondary coil is different from the number of turns of the second secondary coil. A first support column and a second support column, the first support column and the second support column respectively connecting the first cover plate and the second cover plate, wherein the first winding column is disposed between the first support column and the central column, and the second winding column is disposed between the second support column and the central column; and The third and fourth winding posts are respectively disposed on the first support post and the second support post, and the third and fourth primary coils of the primary coil group are respectively wound on the third and fourth winding posts, and the third and fourth secondary coils of the secondary coil group are respectively wound on the third and fourth winding posts.

2. The magnetic element as described in claim 1, characterized in that, The first winding post and the second winding post are connected to the first cover plate, and there is an air gap between the first winding post and the second winding post and the second cover plate.

3. The magnetic element as described in claim 1, characterized in that, The first winding post and the second winding post are respectively connected to the central post.

4. The magnetic element as described in claim 1, characterized in that, The first winding post or the second winding post has an air gap.

5. The magnetic element as described in claim 1, characterized in that, One end of the first winding post is connected to the first support post, and the other end of the first winding post has an air gap with the central post. One end of the second winding post is connected to the second support post, and the other end of the second winding post has an air gap with the central post.

6. The magnetic element as claimed in claim 1, characterized in that, The first winding post has a first cross-sectional area, and the second winding post has a second cross-sectional area, wherein the first cross-sectional area is not equal to the second cross-sectional area.

7. The magnetic element as claimed in claim 1, characterized in that, The wire diameter of the first primary coil in the primary coil assembly is not equal to the wire diameter of the second primary coil.

8. The magnetic element as claimed in claim 1, characterized in that, The wire diameter of the primary coil in the secondary coil group is not equal to the wire diameter of the secondary coil.

9. The magnetic element as claimed in claim 1, characterized in that, The first primary coil is electrically connected to the second primary coil via a first external circuit, or the first primary coil is electrically connected to the second primary coil via a second external circuit.

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