Magnetic device and power supply module

Abstract

The embodiment of the invention provides a magnetic device and a power module. The magnetic device comprises a combined magnetic core and a plurality of windings, the combined magnetic core comprises a plurality of magnetic core units arranged in the length direction of the magnetic device, and each magnetic core unit comprises a bottom plate of an integrated structure and at least two columnar structures arranged in the length direction of the magnetic device at intervals. Each winding is used for surrounding one columnar structure or surrounding two adjacent columnar structures along the length direction of the magnetic device, and the two adjacent columnar structures respectively belong to two adjacent magnetic core units along the length direction of the magnetic device.

Description

Magnetic components and power modules Technical Field

[0001] The present application relates to the field of magnetic integration technology, and in particular to a magnetic device and a power supply module. Background Art

[0002] Power modules can utilize semiconductor plastic encapsulation, achieving an integrated molded package of magnetic components, circuit boards, and plastic encapsulation materials. Plastic encapsulation isolates the power module from external physical and chemical factors, ensuring safe and stable operation. However, during the plastic encapsulation process of existing power modules, the cores of the magnetic components can crack. Therefore, preventing this cracking during the plastic encapsulation process has become a pressing issue.

[0003] Summary of the Invention

[0004] An embodiment of the present application provides a magnetic device and a power module. During the process of plastic packaging the power module, since the combined magnetic core of the magnetic device is composed of multiple magnetic core units, the stress of the combined magnetic core is reduced, thereby preventing the combined magnetic core from cracking.

[0005] In a first aspect, the present application provides a magnetic device comprising a combined magnetic core and a plurality of windings. The combined magnetic core comprises a plurality of magnetic core units arranged along the length direction of the magnetic device, each magnetic core unit comprising a base plate of an integral structure and at least two columnar structures arranged at intervals along the length direction of the magnetic device, with the at least two columnar structures being located on the same side of the base plate. The plurality of windings are located between two columnar structures in the combined magnetic core and arranged at intervals along the length direction of the magnetic device. Each winding is configured to wrap around one columnar structure or around two adjacent columnar structures along the length direction of the magnetic device, the two adjacent columnar structures respectively belonging to two adjacent magnetic core units along the length direction of the magnetic device.

[0006] In the magnetic device provided in the embodiments of the present application, the composite magnetic core is composed of multiple magnetic core units, so that the length of the bottom plate of each magnetic core unit in the longitudinal direction of the magnetic device is relatively short, thereby reducing the stress of the magnetic core unit during the plastic packaging process, and further reducing the risk of cracking of the magnetic core unit. Therefore, the composite magnetic core composed of multiple magnetic core units experiences low stress during the plastic packaging process, and thus does not suffer from cracking.

[0007] In addition, in the magnetic device provided in the embodiment of the present application, each winding is wrapped around one or two adjacent columnar structures, so that multiple magnetic core units are integrated through magnetic integration, thereby reducing the volume of the combined magnetic core and reducing the loss of the magnetic device, thereby improving the power density of the power module.

[0008] In one embodiment, along the length direction of the magnetic device, two adjacent columnar structures are surrounded by the same winding.

[0009] In the magnetic device provided in the embodiment of the present application, two adjacent columnar structures are surrounded by the same winding, which not only increases the installation speed of the magnetic device by eliminating the need to consider the installation order when assembling multiple magnetic core units, but also reduces the length of the bottom plate in the magnetic core unit in the length direction of the magnetic device, thereby reducing the length of a single magnetic core unit, and further reducing the stress of the magnetic core unit during the plastic packaging process.

[0010] In one embodiment, along the length direction of the magnetic device, two adjacent columnar structures surrounded by the same winding are in contact.

[0011] In the magnetic device provided in the embodiment of the present application, two adjacent columnar structures surrounded by the same winding are in contact, which can not only reduce the length of the magnetic device and thus facilitate miniaturization of the magnetic device, but also ensure the magnetic flux distribution.

[0012] In one embodiment, along the length direction of the magnetic device, two adjacent columnar structures surrounded by the same winding have the same length.

[0013] In the magnetic device provided in the embodiment of the present application, the adjacent columnar structures surrounded by the same winding have the same length in the longitudinal direction of the magnetic device, which not only ensures the conduction of the magnetic circuit but also does not cause air gaps, thereby not affecting the magnetic flux distribution.

[0014] In one embodiment, at least two magnetic core units among the plurality of magnetic core units have different numbers of columnar structures.

[0015] The number of columnar structures of at least two of the multiple magnetic core units of the magnetic device provided in the embodiment of the present application is different, so that the combined magnetic core is composed of multiple magnetic core units, which not only reduces the number of types of magnetic core units and thus improves the manufacturing speed of the magnetic device, but also improves the assembly efficiency of the magnetic device.

[0016] In one embodiment, each winding of a portion of the plurality of windings is wound around one columnar structure, and each winding of another portion is wound around two adjacent columnar structures.

[0017] In the magnetic device provided by the embodiments of the present application, a portion of the windings are wrapped around a columnar structure, and another portion of the windings are wrapped around two adjacent columnar structures. This not only increases the number of windings in the magnetic device, but also reduces the volume of the magnetic device, thereby facilitating its miniaturization. Furthermore, this also prevents the formation of an air gap between the bottom plates of two adjacent magnetic core units, which could affect magnetic flux distribution.

[0018] In one embodiment, along the length direction of the magnetic device, projections of two adjacent columnar structures overlap.

[0019] In the magnetic device provided in the embodiment of the present application, the projections of two adjacent columnar structures along the length direction of the magnetic device overlap, which not only ensures the normal use of the windings surrounding the two adjacent columnar structures, but also reduces the thickness of the magnetic device, thereby facilitating the miniaturization of the magnetic device.

[0020] In one embodiment, each magnetic core unit includes an upper magnetic core and a lower magnetic core stacked along the thickness direction of the magnetic device, and the upper magnetic core is a plate-like structure extending along the length direction of the magnetic device. The lower magnetic core is an E-shaped magnetic core, which includes an integral bottom plate and at least two columnar structures. Along the thickness direction of the magnetic device, the columnar structure of each magnetic core unit is located between the bottom plate and the upper magnetic core of the magnetic core unit, and the end of the columnar structure of each magnetic core unit away from the bottom plate of the magnetic core unit is connected to the upper magnetic core of the magnetic core unit. The thickness direction of the magnetic device is perpendicular to the length direction of the magnetic device.

[0021] The magnetic core unit in the magnetic device provided in the embodiment of the present application is composed of an upper magnetic core of a plate-like structure and a lower magnetic core of an E-shaped magnetic core. It can not only form a complete magnetic circuit to ensure the normal use of the magnetic device, but also reduce the thickness of the magnetic core unit, which is conducive to the miniaturization of the magnetic device.

[0022] In one embodiment, the upper magnetic core is an I-type magnetic core.

[0023] The magnetic core unit in the magnetic device provided in the embodiment of the present application is an EI-type magnetic core, which can not only reduce the thickness of the magnetic core unit and thus facilitate miniaturization of the magnetic device, but also reduce the loss of the magnetic device.

[0024] In one embodiment, the composite magnetic core includes a mating magnetic core, which is a plate-like structure extending along the length of the magnetic device. Each core unit is an E-shaped core, which includes an integral bottom plate and at least two columnar structures. Along the thickness of the magnetic device, the multiple core units are located on the same side of the mating magnetic core, with the columnar structure of each core unit located between the bottom plate of the core unit and the mating magnetic core. The mating magnetic core is connected to one end of the columnar structure of each core unit that is away from the bottom plate of the core unit.

[0025] In the magnetic device provided in the embodiment of the present application, the matching magnetic core cooperates with multiple E-shaped magnetic cores, which can not only form a complete magnetic circuit to ensure the normal use of the magnetic device, but also improve the assembly efficiency of the magnetic device.

[0026] In one embodiment, the mating magnetic core is an I-type magnetic core.

[0027] The combined magnetic core of the magnetic device provided in the embodiment of the present application is composed of an I-type magnetic core and multiple E-type magnetic cores, which can not only reduce the loss of the magnetic device but also improve the assembly efficiency of the magnetic device.

[0028] In one embodiment, each magnetic core unit includes an upper magnetic core and a lower magnetic core, both of which are E-shaped magnetic cores, each of which includes an integral bottom plate and at least two sub-columnar structures. Along the thickness direction of the magnetic device, the bottom plates of the upper magnetic core and the lower magnetic core are parallel and spaced apart, and the sub-columnar structures of the upper magnetic core and the lower magnetic core are located between the bottom plates of the upper magnetic core and the lower magnetic core. The at least two sub-columnar structures of the upper magnetic core correspond one-to-one with the at least two sub-columnar structures of the lower magnetic core, and the axes of the corresponding two sub-columnar structures coincide and are connected, so that the corresponding two sub-columnar structures are used to form a columnar structure.

[0029] The magnetic core unit in the magnetic device provided in the embodiment of the present application is an EE-type magnetic core, which not only reduces the types of parts of the magnetic core unit and thus reduces the cost of the combined magnetic core, but also can form a complete magnetic circuit to ensure the normal use of the magnetic device.

[0030] In one embodiment, when the magnetic core unit includes two columnar structures, the lengths of the two columnar structures of the magnetic core unit along the length direction of the magnetic device are the same.

[0031] When the two columnar structures of the magnetic core unit in the magnetic device provided in the embodiment of the present application have the same length in the length direction of the magnetic device, there is no need to consider the placement order of the magnetic core units during the assembly process of the magnetic device, thereby improving the assembly efficiency of the magnetic device.

[0032] In one embodiment, when the magnetic core unit includes at least three columnar structures, the at least three columnar structures include two side column structures and at least one middle column structure, and at least one middle column structure is located between the two side column structures along the length direction of the magnetic device, and the length of the middle column structure is greater than the length of the side column structure.

[0033] In the magnetic device provided in the embodiment of the present application, the length of the center column structure along the length direction of the magnetic device is greater than the length of the side column structure. The length of the magnetic core unit along the length direction of the magnetic device can be reduced while ensuring the formation of a complete magnetic circuit, thereby reducing the length of the base plate and reducing the volume of the magnetic core unit.

[0034] In one embodiment, each columnar structure surrounded by a winding is provided with an air gap, and the columnar structures not surrounded by a winding are not provided with an air gap and are used to form a common magnetic circuit.

[0035] In the magnetic device provided by the embodiment of the present application, each columnar structure surrounded by the winding is provided with an air gap, and the columnar structure not surrounded by the winding is not provided with an air gap, which not only avoids magnetic saturation but also ensures the integrity of the magnetic circuit.

[0036] In one embodiment, each winding and the column-shaped structure surrounded by the winding are used to jointly form a transformer.

[0037] In the magnetic device provided in the embodiment of the present application, each winding and the columnar structure surrounded by the winding are used to form a transformer. Not only can multiple transformers be integrated together through magnetic integration to reduce the volume and loss of the magnetic device, but also the combined magnetic core can be prevented from cracking during the plastic packaging process.

[0038] A second aspect of the present application provides a power module comprising a circuit board, a plastic package, and a magnetic device according to any one of the first aspects. The circuit board and the magnetic device are disposed within the plastic package, and the magnetic device is disposed on the circuit board and, together with the electronic devices on the circuit board, forms a power conversion circuit. The composite magnetic core in the power module provided in an embodiment of the present application is formed by combining multiple magnetic core units, thereby preventing the composite magnetic core from cracking during the plastic packaging process. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] FIG1 is a cross-sectional view of a power module in the related art;

[0040] FIG2 is a cross-sectional view of a magnetic device in the related art;

[0041] FIG3 is a cross-sectional view of a power module provided in an embodiment of the present application;

[0042] FIG4 is a cross-sectional view of a first magnetic device provided in an embodiment of the present application;

[0043] FIG5 is a cross-sectional view of a second magnetic device provided in an embodiment of the present application;

[0044] FIG6 is a cross-sectional view of a third magnetic device provided in an embodiment of the present application;

[0045] FIG7 is a cross-sectional view of a fourth magnetic device provided in an embodiment of the present application;

[0046] FIG8 is a cross-sectional view of a fifth magnetic device provided in an embodiment of the present application;

[0047] FIG9 is a cross-sectional view of a sixth magnetic device provided in an embodiment of the present application.

[0048] Explanation of the accompanying drawings: 100, power module; 200, circuit board; 300, plastic package; 400, magnetic device; 10, winding; 20, combined magnetic core; 30, magnetic core unit; 31, first magnetic core unit; 32, second magnetic core unit; 33, upper magnetic core; 34, lower magnetic core; 40, columnar structure; 41, middle column structure; 42, side column structure; 43, sub-columnar structure; 50, bottom plate; 60, mating magnetic core; 70, air gap. DETAILED DESCRIPTION

[0049] Figure 1 is a cross-sectional view of a power module in the related art. To meet the requirements of high power, high density, and ultra-thin packaging, the power module 100 uses semiconductor plastic packaging to achieve an integrated molded package of a magnetic device 20, a circuit board 30, and a plastic packaging material. Currently, as shown in Figure 1, the existing power module 100 generally includes a plastic packaging body 10 formed of plastic packaging material, a circuit board 30 disposed within the plastic packaging body 10, and a magnetic device 20. The magnetic device 20 is disposed on the circuit board 30. To meet the requirements of high power and high density, multiple magnetic cores are integrated through magnetic integration to reduce the volume and loss of the magnetic device 20. In addition, the magnetic core of the magnetic device 20 includes two parts, one part is an I-type magnetic core 22, and the other part is an E-type magnetic core 21, thus the magnetic core is an EI-type magnetic core.

[0050] However, during the plastic-sealing process of the power module 100, temperature fluctuations cause different materials to deform differently, creating a significant risk of stress and deformation in the various components of the power module 100, resulting in varying degrees of deformation in each component. Furthermore, because the E-shaped core 21 of the magnetic device 20 is very brittle and its bottom plate 23 is very thin, the connection between the bottom plate 23 and the columnar portion 24 of the E-shaped core 21 is susceptible to cracking during the plastic-sealing process. Therefore, preventing cracking in the magnetic core of the magnetic device 20 during the plastic-sealing process has become a pressing issue.

[0051] FIG2 is a cross-sectional view of a magnetic device in the related art. In order to solve the problem of cracking of the magnetic core under the plastic sealing condition, in the related art, as shown in FIG2 , an elastic insulating layer 25 located on the surface of the bottom plate portion 23 is provided between two adjacent columnar portions 24. The stress generated by the thermal expansion of the plastic sealing material is released by the deformation of the elastic insulating layer 25, thereby avoiding cracking of the magnetic core. However, although this method can prevent the cracking of the magnetic core, there are also some problems. For example, during the plastic sealing, it is necessary to introduce additional elastic insulating filler to coat the magnetic core to form the elastic insulating layer 25, which will increase the cost and production process. In addition, the performance of the elastic insulating layer 25 will degrade over time, and the power module 100 will still face the risk of core cracking in the later stages of its life cycle.

[0052] In view of this, embodiments of the present application provide a magnetic device 400 and a power module 100 that reduce the risk of cracking in the composite magnetic core 20 of the magnetic device 400. Thus, during the plastic packaging process of the power module 100, the composite magnetic core 20 is subjected to minimal stress and does not crack. Furthermore, the elastic insulating layer 25 is not required, which reduces the cost of the magnetic device 400 and improves its production efficiency.

[0053] Figure 3 is a cross-sectional view of a power module provided in an embodiment of the present application. As shown in Figure 3, the power module 100 provided in an embodiment of the present application includes a circuit board 200, a plastic package 300, and a magnetic device 400. The circuit board 200 and the magnetic device 400 are disposed within the plastic package 300. The magnetic device 400 is disposed on the circuit board 200 and, together with the electronic components of the circuit board 200, forms a power conversion circuit.

[0054] In the embodiment of the present application, the power conversion circuit may include but is not limited to an input series output parallel (ISOP) circuit, a power factor correction (PFC) circuit, an LLC circuit, etc.

[0055] In the embodiment of the present application, there is no limitation on the shape and structure of the plastic encapsulation body 300. For example, the plastic encapsulation body 300 may be in the form of a rectangular parallelepiped. In addition, the material of the plastic encapsulation body 300 is a plastic encapsulation compound, and the specific type of the plastic encapsulation compound is not limited here.

[0056] In the embodiment of the present application, the magnetic device 400 may include but is not limited to realizing a transformer, an inductor, etc. In the embodiment of the present application, the magnetic device 400 is described as a transformer as an example.

[0057] The composite magnetic core 20 of the magnetic device 400 provided in the embodiment of the present application is composed of multiple magnetic core units 30, which reduces the length of the magnetic core units 30. This reduces the stress on the magnetic core units 30 during plastic packaging, thereby reducing the risk of cracking of the magnetic core units 30. Therefore, the risk of stress deformation of the composite magnetic core 20 during plastic packaging is reduced, reducing the risk of cracking of the composite magnetic core 20.

[0058] The magnetic device 400 provided in the embodiment of the present application is described in detail below with reference to the accompanying drawings.

[0059] FIG4 is a cross-sectional view of the first magnetic device provided in an embodiment of the present application. As shown in FIG4 , the magnetic device 400 provided in an embodiment of the present application includes a combined magnetic core 20 and a plurality of windings 10. The combined magnetic core 20 includes a plurality of magnetic core units 30 arranged along the length direction of the magnetic device 400. Each magnetic core unit 30 includes a bottom plate 50 of an integral structure and at least two columnar structures 40 arranged at intervals along the length direction of the magnetic device 400 (such as the X direction in FIG4 ), and at least two columnar structures 40 are located on the same side of the bottom plate 50. Along the length direction of the magnetic device 400, a plurality of windings 10 are located between two columnar structures 40 in the combined magnetic core 20 and arranged at intervals. Each winding 10 is used to surround one columnar structure 40 or surround two columnar structures 40 adjacent to each other along the length direction of the magnetic device 400. The two adjacent columnar structures 40 respectively belong to two magnetic core units 30 adjacent to each other along the length direction of the magnetic device 400.

[0060] In an embodiment of the present application, each winding 10 in the magnetic device 400 and the columnar structure 40 surrounded by the winding 10 are used to form a transformer. Not only can multiple transformers be integrated together through magnetic integration to reduce the volume and loss of the magnetic device 400, but the combined magnetic core 20 can also be prevented from cracking during the plastic packaging process.

[0061] Each winding 10 provided in an embodiment of the present application includes a primary winding and a secondary winding, and the primary winding and the secondary winding are surrounded by the same columnar structure 40 or two adjacent columnar structures 40. The primary winding and the secondary winding and the columnar structure 40 surrounded by the primary winding and the secondary winding are used to form a transformer.

[0062] In the embodiments of the present application, the relative positional relationship between the primary winding and the secondary winding is not limited. In one embodiment, the primary winding and the secondary winding are arranged in parallel along the length of the columnar structure 40, where the length of the columnar structure 40 is perpendicular to the length of the magnetic device 400. In one embodiment, the primary winding and the secondary winding are sequentially arranged around the columnar structure 40. In other words, the primary winding and the secondary winding are equivalent to two concentric rings.

[0063] In the embodiment of the present application, the magnetic device 400 is equivalent to integrating four transformers through magnetic integration, that is, one winding 10 corresponds to one transformer. Of course, the number of integrated transformers is not limited to four, and can also be two, three, five, etc.

[0064] The composite magnetic core 20 in the magnetic device 400 provided in the embodiment of the present application is composed of multiple magnetic core units 30, so that the length of the bottom plate 50 in the magnetic core unit 30 in the longitudinal direction of the magnetic device 400 is relatively short, thereby reducing the stress of the magnetic core unit 30 during the plastic packaging process, and further reducing the risk of cracking at the connection between the bottom plate 50 and the columnar structure 40 in the magnetic core unit 30. Therefore, the composite magnetic core 20 composed of multiple magnetic core units 30 will not crack during the plastic packaging process.

[0065] In addition, in the magnetic device 400 provided in the embodiment of the present application, each winding 10 is wrapped around one or two adjacent columnar structures 40, so that multiple magnetic core units 30 are integrated through magnetic integration, thereby reducing the volume of the combined magnetic core 20 and reducing the loss of the magnetic device 400, thereby improving the power density of the power module 100.

[0066] In the embodiment of the present application, referring to FIG4 , each magnetic core unit 30 includes an upper magnetic core 33 and a lower magnetic core 34 stacked along the thickness direction of the magnetic device 400. The upper magnetic core 33 is a plate-like structure extending along the length direction of the magnetic device 400. The lower magnetic core 34 is an E-type magnetic core, which includes an integral bottom plate 50 and at least two columnar structures 40. Along the thickness direction of the magnetic device 400 (such as the Y direction in FIG4 ), the columnar structure 40 of each magnetic core unit 30 is located between the bottom plate 50 and the upper magnetic core 33 of the magnetic core unit 30, and the end of the columnar structure 40 of each magnetic core unit 30 away from the bottom plate 50 of the magnetic core unit 30 is connected to the upper magnetic core 33 of the magnetic core unit 30. The thickness direction of the magnetic device 400 is perpendicular to the length direction of the magnetic device 400.

[0067] In the embodiment of the present application, the upper magnetic core 33 is an I-type magnetic core. Of course, the upper magnetic core 33 can also have other structures. Since the upper magnetic core 33 is an I-type magnetic core and the lower magnetic core 34 is an E-type magnetic core, the magnetic core unit 30 in the magnetic device 400 provided in the embodiment of the present application is an EI-type magnetic core. This not only reduces the thickness of the magnetic core unit 30, thereby facilitating the miniaturization of the magnetic device 400, but also reduces the loss of the magnetic device 400.

[0068] In the embodiment of the present application, the upper magnetic core 33 can be connected to the end of the columnar structure 40 of the lower magnetic core 34 away from the base plate 50 by bonding, which can improve the assembly efficiency of the upper magnetic core 33 and the lower magnetic core 34.

[0069] FIG5 is a cross-sectional view of the second magnetic device provided in an embodiment of the present application. In one embodiment, as shown in FIG5 , each magnetic core unit 30 includes an upper magnetic core 33 and a lower magnetic core 34, and both the upper magnetic core 33 and the lower magnetic core 34 are E-type magnetic cores. The E-type magnetic core includes a bottom plate 50 of an integral structure and at least two sub-columnar structures 43. In the thickness direction of the magnetic device 400, the bottom plate 50 of the upper magnetic core 33 and the bottom plate 50 of the lower magnetic core 34 are arranged in parallel and spaced apart, and the sub-columnar structures 43 of the upper magnetic core 33 and the lower magnetic core 34 are located between the bottom plate 50 of the upper magnetic core 33 and the bottom plate 50 of the lower magnetic core 34. The at least two sub-columnar structures 43 of the upper magnetic core 33 correspond to the at least two sub-columnar structures 43 of the lower magnetic core 34 one-to-one, and the axes of the corresponding two sub-columnar structures 43 coincide and are connected, and the corresponding two sub-columnar structures 43 are used to form a columnar structure 40.

[0070] The magnetic core unit 30 in the magnetic device 400 provided in the embodiment of the present application is an EE-type magnetic core, which not only reduces the types of parts of the magnetic core unit 30 and thus reduces the cost of the combined magnetic core 20 , but also forms a complete magnetic circuit to ensure the normal use of the magnetic device 400 .

[0071] 5 , since both the upper magnetic core 33 and the lower magnetic core 34 are E-shaped magnetic cores, each magnetic core unit 30 has two oppositely disposed bottom plates 50. Furthermore, for each bottom plate 50, all columnar structures 40 are located on the same side of the bottom plate 50.

[0072] The combined magnetic core 20 in the magnetic device 400 provided in the embodiment of the present application is composed of multiple magnetic core units 30, so that the bottom plate 50 of the E-shaped magnetic core in each magnetic core unit 30 is relatively short in the length direction of the magnetic device 400, thereby reducing the stress deformation risk of the magnetic core unit 30 during the plastic packaging process, and thus the connection between the bottom plate 50 and the columnar structure 40 in the magnetic core unit 30 will not crack.

[0073] Of course, each magnetic core unit 30 is composed of an upper magnetic core 33 and a lower magnetic core 34. Figure 6 is a cross-sectional view of the third magnetic device provided in an embodiment of the present application. In one embodiment, as shown in Figure 6, the magnetic device 400 includes a combined magnetic core 20 and a plurality of windings 10. Among them, the combined magnetic core 20 includes a matching magnetic core 60 and a plurality of magnetic core units 30. The matching magnetic core 60 is a plate-like structure extending along the length direction of the magnetic device 400. Each magnetic core unit 30 is an E-type magnetic core, and the E-type magnetic core includes a bottom plate 50 of an integral structure and at least two columnar structures 40 arranged at intervals along the length direction of the magnetic device 400, and at least two columnar structures 40 are located on the same side of the bottom plate 50. Along the thickness direction of the magnetic device 400, multiple magnetic core units 30 are located on the same side of the mating magnetic core 60, the columnar structure 40 of each magnetic core unit 30 is located between the bottom plate 50 of the magnetic core unit 30 and the mating magnetic core 60, and the mating magnetic core 60 is connected to one end of the columnar structure 40 of each magnetic core unit 30 away from the bottom plate 50 of the magnetic core unit 30.

[0074] In the magnetic device 400 provided in the embodiment of the present application, the cooperation of the magnetic core 60 and multiple E-type magnetic cores can not only form a complete magnetic circuit to ensure the normal use of the magnetic device 400, but also improve the assembly efficiency of the magnetic device 400.

[0075] In the embodiment of the present application, the mating magnetic core 60 is an I-shaped magnetic core. Of course, the mating magnetic core 60 may also be of other structures.

[0076] The combined magnetic core 20 of the magnetic device 400 provided in the embodiment of the present application is composed of an I-type magnetic core and multiple E-type magnetic cores, which can not only reduce the loss of the magnetic device 400 but also improve the assembly efficiency of the magnetic device 400.

[0077] In the embodiment of the present application, the mating magnetic core 60 can be connected to the columnar structure 40 by bonding, which not only allows the mating magnetic core 60 and the combination of multiple magnetic core units 30 to form a complete magnetic circuit, but also improves the assembly efficiency of the mating magnetic core 60 and multiple magnetic core units 30.

[0078] In summary, regardless of whether the composite magnetic core 20 is constructed from multiple magnetic core units 30 or from a mating magnetic core 60 and multiple magnetic core units 30, the magnetic core units 30 all have an integral bottom plate 50 and multiple columnar structures 40. Because the bottom plate 50 in each magnetic core unit 30 is relatively short, the stress on the magnetic core unit 30 during the molding process is minimal, and thus, the connection between the bottom plate 50 and the columnar structure 40 in the magnetic core unit 30 will not crack.

[0079] In the embodiment of the present application, referring to FIG. 4 , along the length direction of the magnetic device 400 , two adjacent columnar structures 40 are surrounded by the same winding 10 , and the two adjacent columnar structures 40 respectively belong to two adjacent magnetic core units 30 .

[0080] Accordingly, the two adjacent columnar structures 40 in the magnetic device 400 provided in the embodiment of the present application are surrounded by the same winding 10, which not only eliminates the need to consider the installation order when assembling multiple magnetic core units 30, thereby improving the installation speed of the magnetic device 400, but also reduces the length of the bottom plate 50 in the magnetic core unit 30 in the length direction of the magnetic device 400, thereby reducing the length of a single magnetic core unit 30, and further reducing the stress of the magnetic core unit 30 during the plastic packaging process.

[0081] In the magnetic device 400 provided in the embodiment of the present application, two adjacent columnar structures 40 are surrounded by the same winding 10. Therefore, it can be seen that the distance between the two adjacent columnar structures 40 in the length direction of the magnetic device 400 is small or even non-existent, so as to ensure that the winding 10 and the two columnar structures 40 surrounded by the winding 10 can form a transformer.

[0082] In an embodiment of the present application, as shown in Figure 4, in a part of the multiple windings 10 of the magnetic device 400, each winding 10 and a columnar structure 40 constitute a transformer, and in another part, each winding 10 and two columnar structures 40 constitute a transformer. Not only can multiple transformers be integrated by magnetic integration to reduce the volume and loss of the magnetic device 400, but also the combined magnetic core 20 can be prevented from cracking during the plastic packaging process.

[0083] FIG7 is a cross-sectional view of a fourth magnetic device provided in an embodiment of the present application. In one embodiment, as shown in FIG7 , each winding 10 is wrapped around a columnar structure 40 .

[0084] Accordingly, each winding 10 and a columnar structure 40 in the magnetic device 400 provided in the embodiment of the present application can constitute a transformer, which can not only integrate multiple transformers through magnetic integration to reduce the volume and loss of the magnetic device 400, but also avoid cracking of the combined magnetic core 20 during the plastic packaging process.

[0085] As shown in FIG7 , along the length of the magnetic device 400, two adjacent columnar structures 40 are respectively surrounded by two adjacent windings 10, and the two adjacent columnar structures 40 respectively belong to two adjacent magnetic core units 30. In other words, the distance between the two adjacent columnar structures 40 along the length of the magnetic device 400 is large, ensuring that the distance between the two adjacent columnar structures 40 is sufficient to accommodate the two adjacent windings 10.

[0086] FIG8 is a cross-sectional view of the fifth magnetic device provided in an embodiment of the present application. In one embodiment, as shown in FIG8 , along the length direction of the magnetic device 400, two adjacent columnar structures 40 in a portion of the columnar structures 40 of the composite magnetic core 20 are respectively surrounded by two adjacent windings 10, and two adjacent columnar structures 40 in another portion of the columnar structures 40 are surrounded by the same winding 10. In other words, the multiple windings 10 of the magnetic device 400 include at least two parts, wherein two adjacent windings 10 in a first portion of the at least two parts are respectively surrounded by two adjacent columnar structures 40, and each winding 10 in a second portion is surrounded by two adjacent columnar structures 40. The two adjacent columnar structures 40 belong to two adjacent magnetic core units 30.

[0087] Accordingly, in a part of the multiple windings 10 of the magnetic device 400 provided in the embodiment of the present application, each winding 10 and a columnar structure 40 form a transformer, and in another part, each winding 10 and two columnar structures 40 form a transformer. Not only can multiple transformers be integrated by magnetic integration to reduce the volume and loss of the magnetic device 400, but also the combined magnetic core 20 can be prevented from cracking during the plastic packaging process.

[0088] In the embodiment of the present application, along the length direction of the magnetic device 400 , two adjacent columnar structures 40 that are surrounded by the same winding 10 and are in contact (not shown in the figure) belong to two adjacent magnetic core units 30 respectively.

[0089] In one embodiment, along the length direction of the magnetic device 400 , there is a gap between two adjacent columnar structures 40 surrounded by the same winding 10 (as shown in FIG. 4 ), and the two adjacent columnar structures 40 belong to two adjacent magnetic core units 30 .

[0090] Accordingly, for the magnetic device 400 provided in the embodiment of the present application, whether two adjacent columnar structures 40 surrounded by the same winding 10 are in contact or spaced apart, magnetic flux distribution can be ensured, thereby allowing the two adjacent columnar structures 40 and the winding 10 surrounding the two adjacent columnar structures 40 to form a transformer. However, when two adjacent columnar structures 40 surrounded by the same winding 10 are in contact, not only can magnetic flux distribution be satisfied, but the length of the magnetic device 400 can also be reduced, thereby facilitating miniaturization of the magnetic device 400.

[0091] It can be understood that the contact between two adjacent columnar structures 40 surrounded by the same winding 10 can be understood as two opposite end faces of the two columnar structures 40 along the length direction of the magnetic device 400 being completely or partially in contact.

[0092] In the embodiment of the present application, referring to FIG. 4 , along the length direction of the magnetic device 400 , two adjacent columnar structures 40 surrounded by the same winding 10 have the same length, and the two adjacent columnar structures 40 belong to two adjacent magnetic core units 30 .

[0093] In some embodiments, along the length direction of the magnetic device 400 , two adjacent columnar structures 40 surrounded by the same winding 10 have different lengths (not shown in the figure), and the two adjacent columnar structures 40 belong to two adjacent magnetic core units 30 respectively.

[0094] For the magnetic device 400 provided in the embodiment of the present application, whether or not two adjacent columnar structures 40 surrounded by the same winding 10 have the same length can ensure magnetic circuit continuity, thereby allowing the two adjacent columnar structures 40 surrounded by the same winding 10 and the winding 10 to form a transformer. However, when the adjacent columnar structures 40 surrounded by the same winding 10 in the magnetic device 400 provided in the embodiment of the present application have the same length along the length of the magnetic device 400, not only can magnetic circuit continuity be ensured, but air gaps 70 can also be eliminated, thereby not affecting the magnetic flux distribution.

[0095] In the embodiment of the present application, at least two of the multiple magnetic core units 30 have different numbers of columnar structures 40. For example, referring to FIG4 , there are three magnetic core units 30 , one of which has a different number of columnar structures 40 than the other two.

[0096] In one embodiment, each of the plurality of magnetic core units 30 has the same number of columnar structures 40 (not shown in the figure).

[0097] In the magnetic device 400 provided in the embodiment of the present application, whether the number of columnar structures 40 of the multiple magnetic core units 30 is the same or different, it will not affect the stress risk of the magnetic core units 30 during plastic sealing. However, when the number of columnar structures 40 of the magnetic core units 30 is greater, the length of the bottom plate 50 of the magnetic core units 30 in the length direction of the magnetic device 400 is also longer. In order to reduce the stress deformation risk of the magnetic core units 30 during plastic sealing, the length of the bottom plate 50 of the magnetic core units 30 is as small as possible, but the smaller the length of the bottom plate 50, the smaller the number of columnar structures 40 in the magnetic core units 30, and thus the number of magnetic core units 30 is also increased, and the assembly efficiency of the magnetic device 400 is reduced.

[0098] Therefore, the number of columnar structures 40 of at least two of the multiple magnetic core units 30 of the magnetic device 400 provided in the embodiment of the present application is different, so that the combined magnetic core 20 is composed of multiple magnetic core units 30, which not only can reduce the length of the bottom plate 50 in the magnetic core unit 30 and thus reduce the risk of cracking of the magnetic core unit 30 during plastic sealing, but also can reduce the number of magnetic core units 30 and thus improve the assembly efficiency of the magnetic device 400.

[0099] In the embodiment of the present application, there is no limitation on the number and type of the magnetic core units 30 of the composite magnetic core 20. The number and type of the magnetic core units 30 refers to the number of columnar structures 40 in the magnetic core units 30.

[0100] 4 , the composite magnetic core 20 includes three magnetic core units 30, each of which includes a first magnetic core unit 31 and a second magnetic core unit 32. Along the length of the magnetic device 400, a second magnetic core unit 32 is disposed between two adjacent first magnetic core units 31. The first magnetic core units 31 and the second magnetic core units 32 have different numbers of columnar structures 40.

[0101] In one embodiment, the composite magnetic core 20 includes three magnetic core units 30, including a first magnetic core unit 31, a second magnetic core unit 32, and a third magnetic core unit arranged along the length of the magnetic device 400. Any two of the first magnetic core unit 31, the second magnetic core unit 32, and the third magnetic core unit have different numbers of columnar structures 40.

[0102] In summary, the number of types of magnetic core units 30 of the magnetic device 400 provided in the embodiment of the present application can be the same as or different from the number of magnetic core units 30. Of course, if the number of types of magnetic core units 30 is less than the number of magnetic core units 30, the production cost of the magnetic device 400 can be reduced and the assembly efficiency of the magnetic device 400 can be improved.

[0103] In the embodiment of the present application, referring again to FIG4 , the difference in the number of columnar structures 40 between the first magnetic core unit 31 and the second magnetic core unit 32 is equal to one. For example, if the number of columnar structures 40 in the first magnetic core unit 31 is two and the number of columnar structures 40 in the second magnetic core unit 32 is three, then the difference in the number of columnar structures 40 between the first magnetic core unit 31 and the second magnetic core unit 32 is one.

[0104] In one embodiment, the difference between the number of columnar structures 40 of the first magnetic core unit 31 and the number of columnar structures 40 of the second magnetic core unit 32 is equal to two (not shown in the figure). For example, the number of columnar structures 40 of the first magnetic core unit 31 is 2, and the number of columnar structures 40 of the second magnetic core unit 32 is 4. Then, the difference between the number of columnar structures 40 of the first magnetic core unit 31 and the second magnetic core unit 32 is 2.

[0105] In one embodiment, the difference between the number of columnar structures 40 of the first magnetic core unit 31 and the number of columnar structures 40 of the second magnetic core unit 32 is equal to three (not shown in the figure). For example, the number of columnar structures 40 of the first magnetic core unit 31 is 3, and the number of columnar structures 40 of the second magnetic core unit 32 is 6. Then, the difference in the number of columnar structures 40 of the first magnetic core unit 31 and the second magnetic core unit 32 is 3.

[0106] In summary, the difference in the number of columnar structures 40 between the first magnetic core unit 31 and the second magnetic core unit 32 in the magnetic device 400 provided in the embodiment of the present application may include but is not limited to one, two, three, four, etc.

[0107] In the embodiment of the present application, referring to FIG. 4 , along the length direction of the magnetic device 400 , the projections of two adjacent columnar structures 40 overlap.

[0108] Accordingly, in the magnetic device 400 provided in the embodiment of the present application, the overlapping projections of two adjacent columnar structures 40 along the length direction of the magnetic device 400 can not only ensure the normal use of the winding 10 surrounding the two adjacent columnar structures 40, but also reduce the thickness of the magnetic device 400, thereby facilitating the miniaturization of the magnetic device 400.

[0109] In the embodiment of the present application, referring again to FIG. 4 , the composite magnetic core 20 is formed by two types of magnetic core units 30, one type of magnetic core unit 30 including two columnar structures 40, and the other type of magnetic core unit 30 including at least three columnar structures 40. Along the length direction of the magnetic device 400, the two columnar structures 40 of one type of magnetic core unit 30 are of the same length. Along the length direction of the magnetic device 400, the at least three columnar structures 40 of the other type of magnetic core unit 30 include two side column structures 42 and at least one center column structure 41. Along the length direction of the magnetic device 400, the at least one center column structure 41 is located between the two side column structures 42, and the length of the center column structure 41 is greater than the length of the side column structures 42. Along the length direction of the magnetic device 400, the two side column structures 42 of the other type of magnetic core unit 30 are of the same length, and the length of the side column structures 42 of the other type of magnetic core unit 30 is the same as the length of the columnar structures 40 of the one type of magnetic core unit 30.

[0110] In one embodiment, the composite magnetic core 20 is formed by a magnetic core unit 30 (not shown in the figure), each magnetic core unit 30 includes two columnar structures 40, and the two columnar structures 40 have the same length in the longitudinal direction of the magnetic device 400.

[0111] In one embodiment, the composite magnetic core 20 is formed by a magnetic core unit 30 (not shown), each of which includes at least three columnar structures 40. The at least three columnar structures 40 include two side column structures 42 and at least one center column structure 41. Along the length of the magnetic device 400, the at least one center column structure 41 is located between the two side column structures 42, and the length of the center column structure 41 is greater than that of the side column structures 42. Along the length of the magnetic device 400, the two side column structures 42 of each magnetic core unit 30 are the same length.

[0112] The combined magnetic core 20 in the magnetic device 400 provided in the embodiment of the present application is composed of one magnetic core unit 30 or two magnetic core units 30, both of which can improve the assembly efficiency of the magnetic device 400. When the magnetic core unit 30 includes two columnar structures 40, since the two columnar structures 40 have the same length in the longitudinal direction of the magnetic device 400, there is no need to consider the placement order of the magnetic core units 30 during the assembly process of the magnetic device 400, thereby improving the assembly efficiency of the magnetic device 400. When the magnetic core unit 30 includes at least three columnar structures 40, since the two side column structures 42 of the magnetic core unit 30 have the same length in the longitudinal direction of the magnetic device 400, there is no need to consider the placement order of the magnetic core units 30 during the assembly process of the magnetic device 400, thereby improving the assembly efficiency of the magnetic device 400.

[0113] Continuing to refer to Figure 4, in the magnetic device 400 provided in the embodiment of the present application, the length of the center column structure 41 along the length direction of the magnetic device 400 is greater than the length of the side column structure 42. This can reduce the length of the magnetic core unit 30 along the length direction of the magnetic device 400 while ensuring the formation of a complete magnetic circuit, which is beneficial to reducing the length of the base plate 50 and reducing the volume of the magnetic core unit 30.

[0114] Continuing to refer to Figure 4, in the magnetic device 400 provided in the embodiment of the present application, the length of the columnar structure 40 of one magnetic core unit 30 along the length direction of the magnetic device 400 is equal to the length of the side column structure 42 of the other magnetic core unit 30. Therefore, during the assembly process of the magnetic device 400, there is no need to consider the placement order of the two magnetic core units 30, thereby improving the assembly efficiency of the magnetic device 400.

[0115] FIG9 is a cross-sectional view of a sixth magnetic device according to an embodiment of the present application. In this embodiment, as shown in FIG9 , each columnar structure 40 surrounded by a winding 10 is provided with an air gap 70 , while columnar structures 40 not surrounded by a winding 10 are not provided with an air gap 70 and are used to form a common magnetic circuit.

[0116] Accordingly, in the magnetic device 400 provided in the embodiment of the present application, each columnar structure 40 surrounded by the winding 10 is provided with an air gap 70, and the columnar structure 40 not surrounded by the winding 10 is not provided with an air gap 70, which not only avoids magnetic saturation but also ensures the integrity of the magnetic circuit.

[0117] In the embodiment of the present application, referring to FIG. 9 , an air gap 70 is provided at the end of each columnar structure 40 .

[0118] In one embodiment, the air gap 70 may also be provided in the middle of each columnar structure 40 (not shown in the figure).

[0119] In summary, magnetic saturation can be avoided regardless of whether the air gap 70 is disposed at the end or the middle of the columnar structure 40. However, disposing the air gap 70 at the end of the columnar structure 40 can reduce the difficulty of disposing the air gap 70 in the columnar structure 40.

[0120] The above are merely specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be based on the scope of protection of the claims.

Claims

1. A magnetic device, characterized in that: The invention comprises a combined magnetic core and a plurality of windings, wherein the combined magnetic core comprises a plurality of magnetic core units arranged along the length direction of the magnetic device, each of the magnetic core units comprises a bottom plate of an integral structure and at least two columnar structures arranged at intervals along the length direction of the magnetic device, wherein the at least two columnar structures are located on the same side of the bottom plate, wherein: Along the length direction of the magnetic device, the plurality of windings are located between the two columnar structures in the combined magnetic core and are arranged at intervals; Each of the windings is used to surround one of the columnar structures or two columnar structures adjacent to each other along the length direction of the magnetic device, and the two adjacent columnar structures respectively belong to two magnetic core units adjacent to each other along the length direction of the magnetic device.

2. The magnetic device according to claim 1, characterized in that: Along the length direction of the magnetic device, the two adjacent columnar structures are surrounded by the same winding.

3. The magnetic device according to claim 2, characterized in that: Along the length direction of the magnetic device, two adjacent columnar structures surrounded by the same winding are in contact.

4. The magnetic device according to claim 2, characterized in that: Along the length direction of the magnetic device, the lengths of two adjacent columnar structures surrounded by the same winding are the same.

5. The magnetic device according to claim 1, characterized in that: At least two of the plurality of magnetic core units have different numbers of the columnar structures.

6. The magnetic device according to claim 5, characterized in that: Each of the windings of a part of the plurality of windings is wound around one of the columnar structures, and each of the windings of another part is wound around the two adjacent columnar structures.

7. The magnetic device according to any one of claims 1 to 6, characterized in that: Along the length direction of the magnetic device, projections of the two adjacent columnar structures overlap.

8. The magnetic device according to any one of claims 1 to 7, characterized in that: Each of the magnetic core units comprises an upper magnetic core and a lower magnetic core stacked along the thickness direction of the magnetic device, wherein the upper magnetic core is a plate-like structure extending along the length direction of the magnetic device, wherein: The lower magnetic core is an E-shaped magnetic core, and the E-shaped magnetic core includes the bottom plate and the at least two columnar structures of an integrated structure; Along the thickness direction of the magnetic device, the columnar structure of each magnetic core unit is located between the bottom plate of the magnetic core unit and the upper magnetic core, and one end of the columnar structure of each magnetic core unit away from the bottom plate of the magnetic core unit is connected to the upper magnetic core of the magnetic core unit; The thickness direction of the magnetic device is perpendicular to the length direction of the magnetic device.

9. The magnetic device according to claim 8, characterized in that: The upper magnetic core is an I-type magnetic core.

10. The magnetic device according to any one of claims 1 to 7, characterized in that: The combined magnetic core comprises a matching magnetic core, and the matching magnetic core is a plate-like structure extending along the length direction of the magnetic device, wherein: Each of the magnetic core units is an E-shaped magnetic core, and the E-shaped magnetic core includes the bottom plate of an integral structure and the at least two columnar structures; Along the thickness direction of the magnetic device, the plurality of magnetic core units are located on the same side of the matching magnetic core, the columnar structure of each magnetic core unit is located between the bottom plate of the magnetic core unit and the matching magnetic core, The matching magnetic core is connected to an end of the columnar structure of each magnetic core unit away from the bottom plate of the magnetic core unit.

11. The magnetic device according to claim 10, characterized in that: The matching magnetic core is an I-type magnetic core.

12. The magnetic device according to any one of claims 1 to 11, characterized in that: When the magnetic core unit includes two columnar structures, the lengths of the two columnar structures of the magnetic core unit along the length direction of the magnetic device are the same; or, When the magnetic core unit includes at least three columnar structures, the at least three columnar structures include two side column structures and at least one middle column structure. Along the length direction of the magnetic device, the at least one middle column structure is located between the two side column structures, and the length of the middle column structure is greater than the length of the side column structure.

13. The magnetic device according to any one of claims 1 to 12, characterized in that: Each winding and the columnar structure surrounded by the winding are used to jointly form a transformer.

14. A power module, characterized in that: It comprises a circuit board, a plastic package and a magnetic device as claimed in any one of claims 1 to 13, wherein: The circuit board and the magnetic device are arranged inside the plastic package body, and the magnetic device is arranged on the surface of the circuit board and forms a power conversion circuit together with the electronic devices of the circuit board.

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