Magnetic integrated device and converter

Abstract

The invention relates to a magnetic integrated device and a converter. The magnetic integrated device comprises a first magnetic core, a second magnetic core, a first magnetic column, a second magnetic column, a third magnetic column, a fourth magnetic column, two first windings and two second windings, the first magnetic core and the second magnetic core are arranged at an interval; the first to fourth magnetic columns are fixedly connected between the first magnetic core and the second magnetic core; the area of the cross section of the first magnetic column is equal to that of the cross section of the second magnetic column, the area of the cross section of the third magnetic column is equal to that of the cross section of the fourth magnetic column, and the area of the cross section of the first magnetic column is different from that of the cross section of the third magnetic column; one first winding surrounds the first magnetic column and the third magnetic column, the other first winding surrounds the second magnetic column and the fourth magnetic column, one second winding surrounds the third magnetic column, and the other second winding surrounds the fourth magnetic column. The magnetic integrated device is high in integration level, and the size and the weight of the magnetic integrated device are reduced.

Description

Technical Field

[0001] The invention relates to the technical field of power electronic magnetic integration, and in particular to a magnetic integrated device and a converter. Background Art

[0002] The dual-active bridge converter can achieve electrical isolation of input and output, has bidirectional power processing capability, has the advantages of high power density, easy soft switching, high efficiency, etc. It can meet the needs of various application scenarios in DC power supply systems and has huge application potential and development prospects.

[0003] However, the dual-active bridge converter has many magnetic components and a large size. Currently, the magnetic components are magnetically integrated, but the integration level of the magnetic integrated device is low and the size is still large. Summary of the invention

[0004] The embodiment of the present application provides a magnetic integrated device and a converter. The magnetic integrated device of the present application has a high degree of integration, which is conducive to reducing the volume and weight of the magnetic integrated device, and realizing the miniaturization and lightness of the magnetic integrated device.

[0005] In the first aspect, the embodiment of the present application provides a magnetic integrated device. The magnetic integrated device includes a first magnetic core, a second magnetic core, a first magnetic column, a second magnetic column, a third magnetic column, a fourth magnetic column, two first windings and two second windings; the first magnetic core and the second magnetic core are arranged at intervals, the first magnetic column, the second magnetic column, the third magnetic column and the fourth magnetic column are all fixedly connected between the first magnetic core and the second magnetic core, and the first magnetic column to the fourth magnetic column are arranged at intervals; the area of ​​the cross section of the first magnetic column is equal to the area of ​​the cross section of the second magnetic column, the area of ​​the cross section of the third magnetic column is equal to the area of ​​the cross section of the fourth magnetic column, and the area of ​​the cross section of the first magnetic column is different from the area of ​​the cross section of the third magnetic column; one first winding surrounds the first magnetic column and the third magnetic column, another first winding surrounds the second magnetic column and the fourth magnetic column, one second winding surrounds the third magnetic column, and another second winding surrounds the fourth magnetic column.

[0006] The magnetic integrated device in the embodiment of the present application is an integration of an inductor and a transformer. It can be understood that the first magnetic column, the second magnetic column, the third magnetic column and the fourth magnetic column can be arranged in a matrix, which is conducive to reducing the number of layers and turns of the winding, and reducing the volume and weight of the magnetic integrated device. Exemplarily, the first magnetic column and the second magnetic column are arranged adjacent to each other, the third magnetic column and the fourth magnetic column are arranged adjacent to each other, the first magnetic column and the fourth magnetic column can be arranged diagonally, and the second magnetic column and the third magnetic column can be arranged diagonally. Any two magnetic columns of the first magnetic column, the second magnetic column, the third magnetic column and the fourth magnetic column are arranged at intervals from each other.

[0007] In the embodiment of the present application, the cross-sectional area of ​​the first magnetic column is reasonably configured to be different from the cross-sectional area of ​​the third magnetic column, so that the number of turns of the inductor winding is consistent with the number of turns of the primary winding of the transformer, so that the inductor winding and the primary winding of the transformer are shared, that is, the inductor and the primary winding of the transformer share the first winding. In other words, the first winding is both the inductor winding and the primary winding of the transformer, and the winding is shared, which is conducive to reducing the volume of the winding to reduce the volume and weight of the magnetic integrated device. The second winding is the secondary winding of the transformer. The magnetic integrated device in the embodiment of the present application has a high degree of integration, a small volume, and a light weight.

[0008] In a possible implementation manner, the magnetic integrated device satisfies the following relationship:

[0009] V=Lc×Wc×Hc,

[0010]

[0011] Wc=15β(Ap_T 0.50 / α) 0.50 +1+10.00Ap_L*α / [Ap_T 0.50 (α*Ap_T 0.50 ) 0.50 ]+10.00(α*Ap_T 0.50 ) 0.50 ,

[0012]

[0013] Ap_T=Pt×10 4 / (B ac f T J*K f K u ),

[0014] Ap_L=LI L 2 / (B m J*K u ),

[0015] α2=S3 M / (L3 M ×L4 M ),

[0016] β2=L3 M / L4 M ,

[0017] Ap_T+Ap_L=S3 M ×L3 M ×L4 M ,

[0018] S3=S3M ×(1±20%),

[0019] L3=L3 M ×(1±20%),

[0020] L4=L4 M ×(1±20%),

[0021] Wherein, V is the volume of the magnetic integrated device, Lc is the length of the magnetic integrated device, Wc is the width of the magnetic integrated device, Hc is the height of the magnetic integrated device, α is the first structure factor, β is the second structure factor, S3 M is the calculated area of ​​the cross section of the third magnetic column, L3 M is the calculated distance between the first magnetic column and the second magnetic column, L4 M is the calculated distance between the first magnetic core and the second magnetic core, S3 is the actual area of ​​the cross section of the third magnetic column, L3 is the actual distance between the first magnetic column and the second magnetic column, and L4 is the actual distance between the first magnetic core and the second magnetic core;

[0022] The magnetic integrated device is an integration of a transformer and an inductor, Ap_T is the product of the magnetic core area required by the transformer, Ap_L is the product of the magnetic core area required by the inductor, Pt is the apparent power of the transformer, B ac is the working magnetic flux density of the transformer, f T is the operating frequency of the transformer, J is the current density of the winding of the magnetic integrated device, K f is the operating waveform factor (4.44 for sine wave and 4.0 for square wave), K u is the winding window occupancy factor, L is the inductance of the inductor, I L is the working current of the inductor, B m is the working magnetic flux density of the inductor. The core area product Ap can be obtained by multiplying the core window area by the core cross-sectional area.

[0023] Design Pt, B according to the requirements of magnetic integrated devices ac 、f T , J, K f , K u , L, I L , B m The values ​​of Ap_T and Ap_L can be obtained.

[0024] In the embodiment of the present application, the minimum value of the volume V of the magnetic integrated device is obtained by calculating the preferred values ​​of α and β, and S3 is obtained according to the values ​​of α, β, Ap_T and Ap_L. M 、L3 M and L4 MThe value of S3 is in S3 M *(1±20%), L3 in L3 M *(1±20%), L4 in L4 M *(1±20%). The magnetic integrated components designed by S3, L3 and L4 calculated according to the above formula have high integration, small size and light weight.

[0025] It can be understood that the cross-sectional area of ​​the first magnetic column can be calculated according to AP_L and the obtained values ​​of S3, L3, and L4.

[0026] In a possible implementation, the cross-sectional area of ​​the first magnetic column is smaller than the cross-sectional area of ​​the third magnetic column. In other words, the cross-sectional area of ​​the third magnetic column is larger than the cross-sectional area of ​​the first magnetic column. It can be understood that the cross-sectional area of ​​the fourth magnetic column is larger than the cross-sectional area of ​​the second magnetic column. The second winding is the secondary winding of the transformer, and the second winding is wound around the third and fourth magnetic columns with larger cross-sectional areas, which is beneficial to reducing the excitation current of the transformer and improving the transmission efficiency of the transformer.

[0027] In one possible implementation, the first winding is a circuit board winding, and the second winding is a wire winding. The circuit board winding has high processing accuracy and good consistency of parasitic parameters. The first winding shared by the inductor and the primary side of the transformer in the embodiment of the present application uses a circuit board winding, which can fully reduce the volume and weight of the magnetic integrated device and realize the miniaturization and lightweight of the magnetic integrated device. The second winding can be a flat copper wire winding, which is conducive to increasing the current carrying capacity of the second winding. In other implementations, the first winding and the second winding can both be wire windings.

[0028] In a possible implementation manner, the shape of the cross section of the first magnetic column is the same as the shape of the cross section of the second magnetic column, and the shape of the cross section of the third magnetic column is the same as the shape of the cross section of the fourth magnetic column. In this implementation manner, by setting the shape of the first magnetic column to be the same as the shape of the second magnetic column, and the shape of the third magnetic column to be the same as the shape of the fourth magnetic column, the symmetrical arrangement of the first magnetic column and the second magnetic column and the symmetrical design of the third magnetic column and the fourth magnetic column are achieved, which is beneficial to the decoupling of the inductor and the transformer.

[0029] In a possible implementation manner, the first magnetic column and the second magnetic column are both square columns, and the third magnetic column and the fourth magnetic column are both runway-type columns. The first winding is a circuit board winding, and four through holes can be set on the first winding, and the first magnetic column to the fourth magnetic column pass through the four through holes respectively. The first winding is a circuit board winding, and the shape of the magnetic column will not affect the winding of the circuit board winding. The first magnetic column and the second magnetic column can be set to be square columnar structures to ensure the cross-sectional area of ​​the first magnetic column and the second magnetic column. The second winding is a winding winding, and the winding winding will be tightly arranged around the third magnetic column and the fourth magnetic column. The shape of the third magnetic column and the fourth magnetic column will affect the winding of the second winding. By setting the third magnetic column and the fourth magnetic column to be runway-type columns, the corners of the third magnetic column and the fourth magnetic column are smooth structures, which is conducive to the winding of the winding winding, avoiding the difficulty of winding the winding winding into a right-angle bend in the process, and reducing the difficulty of winding the second winding in the process. In other implementations, the first magnetic column and the second magnetic column may also be rectangular columns or cylindrical columns, and the third magnetic column and the fourth magnetic column may also be cylindrical columns, which is not limited in the present application.

[0030] In a possible implementation, the magnetic integrated device is provided with an air gap; the air gap is located on the first magnetic column; or, the air gap is located on the second magnetic column; or, the air gap is located between the first magnetic column and the first magnetic core, or, the air gap is located between the first magnetic column and the second magnetic core; or, the air gap is located between the second magnetic column and the first magnetic core, or, the air gap is located between the second magnetic column and the second magnetic core. The air gap is located in the first magnetic column; or, the air gap is located in the second magnetic column; or, the air gap is located between the first magnetic column and the first magnetic core or the second magnetic core; or, the air gap is located between the second magnetic column and the first magnetic core or the second magnetic core, that is, the air gap is located in the inductor magnetic circuit. The inductor needs to be designed with air gap energy storage and anti-saturation, and the transformer needs to be set with no air gap as much as possible. The air gap will cause the excitation inductance of the transformer to decrease and the transmission efficiency to be low. The first magnetic column and the second magnetic column are on the inductor magnetic circuit. The transformer magnetic circuit in the embodiment of the present application does not pass through the inductor winding, so an air gap can be set in the inductor magnetic circuit, and the air gap can be used for energy storage and anti-saturation in the inductor magnetic circuit. It can be understood that the inductor magnetic circuit does not pass through the transformer winding, and the transformer magnetic circuit does not need to have an air gap, which is beneficial to increasing the excitation inductance of the transformer and improving the transmission efficiency of the transformer.

[0031] It can be understood that the number of air gaps on the first magnetic column is the same as the number of air gaps on the second magnetic column, and the length of the air gap on the first magnetic column is the same as the length of the air gap on the second magnetic column. In other embodiments, the number of air gaps on the first magnetic column and the number of air gaps on the second magnetic column may be different, and the length of the air gap on the first magnetic column and the length of the air gap on the second magnetic column may be different.

[0032] In a possible implementation manner, a distance between the air gap and the first winding in a first direction is greater than a threshold value, and the first direction is an arrangement direction of the first magnetic core and the second magnetic core. In other words, the air gap is far away from the first winding. When the air gap is arranged close to the first winding, eddy current loss will be generated, affecting the performance of the inductor, so the eddy current loss is reduced by arranging the air gap away from the first winding.

[0033] In a possible implementation, the second winding includes a first sub-winding and a second sub-winding, the number of turns of the first sub-winding is the same as the number of turns of the second sub-winding, the first sub-winding and the second sub-winding are arranged in a first direction and connected in parallel, and the first direction is the arrangement direction of the first magnetic core and the second magnetic core. The number of turns of the first sub-winding is the same as the number of turns of the second sub-winding, and the first sub-winding and the second sub-winding can adopt the same design, which is convenient for processing the first sub-winding and the second sub-winding and reduces the difficulty of winding the first sub-winding and the second sub-winding. The first sub-winding and the second sub-winding are connected in parallel to increase the current capacity.

[0034] In a possible implementation, the two first windings are connected in series or in parallel. When the two first windings are connected in series, the number of turns of the primary side of the transformer can be doubled, and two first windings can be connected in series in high-voltage equipment. When the two first windings are connected in parallel, the current carrying capacity can be increased, and two first windings can be connected in parallel in high-current equipment.

[0035] In a possible implementation manner, the magnetic flux of the first magnetic column on the third magnetic column is equal in magnitude to the magnetic flux of the second magnetic column on the third magnetic column and is opposite in direction, and the magnetic flux of the first magnetic column on the fourth magnetic column is equal in magnitude to the magnetic flux of the second magnetic column on the fourth magnetic column and is opposite in direction. The first magnetic column, the first magnetic core, the second magnetic column and the second magnetic core form an inductor magnetic circuit, and the third magnetic column, the first magnetic core, the fourth magnetic column and the second magnetic core form a transformer magnetic circuit. The design in the implementation manner of the present application can realize the decoupling integration of the inductor and the transformer.

[0036] In a second aspect, the present application provides a converter, comprising a primary circuit, a secondary circuit, and a magnetic integrated device as described in any of the aforementioned embodiments, wherein the terminals of the primary circuit are connected to the terminals of the magnetic integrated device, and the terminals of the secondary circuit are connected to the terminals of the magnetic integrated device. It can be understood that the magnetic integrated device may include a plurality of terminals, the primary circuit is connected to some terminals of the magnetic integrated device, and the secondary circuit is connected to other terminals of the magnetic integrated device. The converter may be a dual active bridge converter, a resonant circuit converter, or a phase-shifted full-bridge converter, etc., and the present application does not limit the type of transformer. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the background technology, the drawings required for use in the embodiments of the present invention or the background technology will be described below.

[0038] Figure 1 is a schematic diagram of the structure of a converter provided in an embodiment of the present application;

[0039] Figure 2 yes Figure 1 A schematic diagram of the three-dimensional structure of the magnetic integrated device shown;

[0040] Figure 3 yes Figure 2 A schematic diagram of the exploded structure of the magnetic integrated device shown;

[0041] Figure 4 yes Figure 2 A partial structural schematic diagram of a magnetic integrated device shown;

[0042] Figure 5 yes Figure 2 A schematic diagram of the structure of the first winding shown;

[0043] Figure 6 yes Figure 2 A simplified schematic diagram of a partial structure of a magnetic integrated device is shown;

[0044] Figure 7 yes Figure 2 The driving circuit diagram of the magnetic integrated device shown;

[0045] Figure 8 yes Figure 2 The magnetic circuit diagram of the magnetic integrated device shown;

[0046] Fig. 9 yes Figure 2 A side view of the magnetic integrated component after removing the first winding and the second winding;

[0047] Fig.10 yes Figure 2 The magnetic integrated component is shown as a side view in another direction after the first winding and the second winding are removed. DETAILED DESCRIPTION

[0048] The following will be combined with the drawings in the embodiments of the present application to clearly and completely describe the technical solutions in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0049] All technical and scientific terms used herein have the same meanings as those commonly understood by those skilled in the art to which this application belongs. The term "and / or" as used herein includes any and all combinations of one or more of the related listed items. In this application, descriptions such as "first", "second", etc. are only used for descriptive purposes and are not to be understood as indicating or implying their relative importance or implicitly indicating the number of the indicated technical features.

[0050] like Figure 1 As shown, Figure 1 The figure is a schematic diagram of the structure of a converter 100. The converter 100 is a device that converts information sent by a source according to a certain purpose, and can be used for power conversion, isolation, and constant value adjustment, etc., and has a wide range of application prospects. The converter 100 can be a dual active bridge converter, a resonant circuit converter, or a phase-shifted full-bridge converter. The converter 100 can be used in electric vehicles and other equipment.

[0051] The converter 100 may include a primary circuit 10, a secondary circuit 20 and a magnetic integrated device 30. The magnetic integrated device 30 may include a plurality of terminals, the terminals of the primary circuit 10 may be connected to some terminals of the magnetic integrated device 30, and the terminals of the secondary circuit 20 may be connected to other terminals of the magnetic integrated device 30. The primary circuit 10 may include a plurality of switching devices, and the secondary circuit 20 may include a plurality of switching devices. The primary circuit 10 and the secondary circuit 20 may adopt pulse width modulation control, asymmetric pulse width control or phase shift frequency conversion control, etc. The magnetic integrated device 30 may integrate an inductor and a transformer into a magnetic structure to achieve the purpose of reducing the size of the magnetic device, reducing the loss of the magnetic device, reducing the number of magnetic devices, reducing the cost of the magnetic device, improving the efficiency of the switching power supply, and generating a new circuit topology.

[0052] Understandably, Figure 1 The converter 100 of the illustrated embodiment is merely illustrative, and the present application does not impose strict limitations on the specific structures and positions of the primary circuit 10 , the secondary circuit 20 , and the magnetic integrated device 30 , which may be arranged as required.

[0053] like Figure 2 and Figure 3 As shown, Figure 2 for Figure 1 The three-dimensional structure diagram of the magnetic integrated device 30 is shown in FIG. Figure 3 for Figure 2 The schematic diagram of the exploded structure of the magnetic integrated device 30 is shown. The magnetic integrated device 30 may include a first magnetic core 31 , a second magnetic core 32 , a first magnetic column 33 , a second magnetic column 34 , a third magnetic column 35 , a fourth magnetic column 36 , two first windings 37 and two second windings 38 .

[0054] The first magnetic core 31 and the second magnetic core 32 are arranged at intervals, the first magnetic core 31 and the second magnetic core 32 can be plate-shaped structures, the first magnetic core 31 and the second magnetic core 32 can be arranged in parallel, and the first magnetic core 31 and the second magnetic core 32 can be arranged along the first direction A1. The first magnetic column 33, the second magnetic column 34, the third magnetic column 35 and the fourth magnetic column 36 are all fixedly connected between the first magnetic core 31 and the second magnetic core 32, and any two magnetic columns among the first magnetic column 33, the second magnetic column 34, the third magnetic column 35 and the fourth magnetic column 36 are arranged at intervals. The first magnetic column 33, the second magnetic column 34, the third magnetic column 35 and the fourth magnetic column 36 can be arranged in a matrix, which is conducive to reducing the number of layers and turns of the winding of the magnetic integrated device 30, so as to reduce the volume and weight of the magnetic integrated device 30. Exemplarily, the first magnetic pillar 33 and the second magnetic pillar 34 can be arranged adjacent to each other and arranged along the second direction A2 (the second direction A2 can be perpendicular to the first direction A1), the third magnetic pillar 35 and the fourth magnetic pillar 36 can be arranged adjacent to each other and arranged along the second direction A2, the first magnetic pillar 33 and the fourth magnetic pillar 36 can be arranged diagonally, and the second magnetic pillar 34 and the third magnetic pillar 35 can be arranged diagonally.

[0055] The first magnetic column 33, the second magnetic column 34, the third magnetic column 35, and the fourth magnetic column 36 can be an integrated structure with the first magnetic core 31 and the second magnetic core 32, or the first magnetic column 33, the second magnetic column 34, the third magnetic column 35, and the fourth magnetic column 36 can be fixedly connected between the first magnetic core 31 and the second magnetic core 32 by assembly, such as gluing.

[0056] The first magnetic core 31, the second magnetic core 32, the first magnetic column 33, the second magnetic column 34, the third magnetic column 35 and the fourth magnetic column 36 can be made of alloy materials or ferrite materials. The materials of the first magnetic core 31, the second magnetic core 32, the first magnetic column 33, the second magnetic column 34, the third magnetic column 35 and the fourth magnetic column 36 can be the same or different, and this application does not limit this.

[0057] like Figure 2 and Figure 4 As shown, Figure 4 yes Figure 2 A partial structural diagram of the magnetic integrated device 30 is shown, Figure 4 The middle is the general Figure 2The top view after the first magnetic core 31, the first winding 37, and the second winding 38 are removed. The area S1 of the cross section 331 of the first magnetic column 33 is equal to the area S2 of the cross section 341 of the second magnetic column 34. The area S3 of the cross section 351 of the third magnetic column 35 is equal to the area S4 of the cross section 361 of the fourth magnetic column 36. The area S1 of the cross section 331 of the first magnetic column 33 is different from the area S3 of the cross section 351 of the third magnetic column 35. It can be understood that the area S1 of the cross section 331 of the first magnetic column 33 is different from the area S4 of the cross section 361 of the fourth magnetic column 36, the area S2 of the cross section 341 of the second magnetic column 34 is different from the area S3 of the cross section 351 of the third magnetic column 35, and the area S2 of the cross section 341 of the second magnetic column 34 is different from the area S4 of the cross section 361 of the fourth magnetic column 36. The magnetic column is usually a column with a uniform cross-section. The cross-section from the first magnetic column 33 to the fourth magnetic column 36 can be understood as the cross-section of the magnetic column in the direction perpendicular to the first direction A1. The contact surface between the magnetic column and the first magnetic core 31 or the contact surface between the magnetic column and the second magnetic core 32 can also be understood as the cross-section of the magnetic column.

[0058] See also Figure 2 , Figure 3 and Figure 5 , Figure 5 for Figure 2 A schematic diagram of the structure of the first winding 37 is shown. One first winding 37 is arranged around the first magnetic column 33 and the third magnetic column 35, and another first winding 37 is arranged around the second magnetic column 34 and the fourth magnetic column 36. One second winding 38 is arranged around the third magnetic column 35, and another second winding 38 is arranged around the fourth magnetic column 36. The first winding 37 is an inductor winding, and the first winding 37 is the primary winding of the transformer, and the second winding 38 is the secondary winding of the transformer.

[0059] The inductor and transformer of the magnetic integrated device 30 in the embodiment of the present application share the first magnetic core 31, the second magnetic core 32 and the first winding 37, so that the magnetic integrated device 30 has high integration, small volume and light weight. In the embodiment of the present application, by reasonably configuring the area S1 of the cross section 331 of the first magnetic column 33 to be different from the area S3 of the cross section 351 of the third magnetic column 35, the number of turns of the inductor winding is consistent with the number of turns of the primary winding of the transformer, and the winding and layer change of the inductor winding and the primary winding of the transformer are consistent, so that the inductor winding and the primary winding of the transformer are shared, that is, the inductor and the primary winding of the transformer share the first winding 37, and the difficulty of winding design can be reduced. In other words, the first winding 37 is both the inductor winding and the primary winding of the transformer, and the winding sharing is achieved, which is conducive to reducing the winding volume, so as to reduce the volume and weight of the magnetic integrated device 30. The inductor magnetic circuit and the transformer magnetic circuit of the present application both pass through the first magnetic core 31 and the second magnetic core 32 , thereby realizing the sharing of the first magnetic core 31 and the second magnetic core 32 , which is beneficial to the miniaturization and lightness of the magnetic integrated device 30 .

[0060] In some embodiments, the area S1 of the cross section 331 of the first magnetic column 33 is smaller than the area S3 of the cross section 351 of the third magnetic column 35, and the area S2 of the cross section 341 of the second magnetic column 34 is smaller than the area S4 of the cross section 361 of the fourth magnetic column 36. The second winding 38 is wound around the third magnetic column 35 and the fourth magnetic column 36 with larger cross-sectional areas, which is beneficial to reducing the excitation current of the transformer and improving the transmission efficiency of the transformer.

[0061] In other implementations, the area S1 of the cross section 331 of the first magnetic column 33 may be larger than the area S3 of the cross section 351 of the third magnetic column 35 , and the area S2 of the cross section 341 of the second magnetic column 34 may be larger than the area S4 of the cross section 361 of the fourth magnetic column 36 .

[0062] In some embodiments, the magnetic integrated device 30 satisfies the following relationship:

[0063] V=Lc×Wc×Hc,

[0064]

[0065] Wc=15β(Ap_T 0.50 / α) 0.50 +1+10.00Ap_L*α / [Ap_T 0.50 (α*Ap_T 0.50 ) 0.50 ]+10.00(α*Ap_T 0.50 ) 0.50 ,

[0066]

[0067] Ap_T=Pt×10 4 / (B ac f T JK f K u ),

[0068] Ap_L=LI L 2 / (B m JK u ),

[0069] α2=S3 M / (L3 M ×L4 M ),

[0070] β2=L3 M / L4 M ,

[0071] Ap_T+Ap_L=S3 M ×L3 M ×L4 M ,

[0072] S3=S3 M ×(1±20%),

[0073] L3=L3 M ×(1±20%),

[0074] L4=L4 M ×(1±20%),

[0075] Wherein, V is the volume of the magnetic integrated device 30, Lc is the length of the magnetic integrated device 30 (in mm), Wc is the width of the magnetic integrated device 30 (in mm), Hc is the height of the magnetic integrated device 30 (in mm), α is the first structure factor, β is the second structure factor, S3 M is the calculated area of ​​the cross section 351 of the third magnetic column 35, L3 M is the calculated distance between the first magnetic column 33 and the second magnetic column 34, L4 M is the calculated distance between the first magnetic core 31 and the second magnetic core 32, S3 (see Figure 4 ) is the actual area of ​​the cross section of the third magnetic column 35, L3 (see Figure 4 ) is the actual distance between the first magnetic column 33 and the second magnetic column 34, L4 (see Fig. 9 ) is the actual distance between the first magnetic core 31 and the second magnetic core 32;

[0076] The magnetic integrated device is the integration of transformer and inductor. Ap_T is the core area product Ap required by the transformer, Ap_L is the core area product Ap required by the inductor, Pt is the apparent power of the transformer, B ac is the working magnetic flux density of the transformer, f T is the operating frequency of the transformer, J is the current density of the winding of the magnetic integrated device. It can be understood that the winding here refers to the first winding or the second winding, and K f is the operating waveform factor (4.44 for sine wave and 4.0 for square wave), K u is the winding window occupancy factor. It can be understood that the winding here refers to the first winding or the second winding, L is the inductance of the inductor, and I L is the working current of the inductor, B m is the working magnetic flux density of the inductor.

[0077] Design Pt, B according to the requirements of magnetic integrated devices ac 、f T , J, K f , K u , L, IL , B m The values ​​of Ap_T and Ap_L can be obtained.

[0078] It can be understood that the calculated area and calculated spacing refer to the area and spacing calculated according to the minimum volume of the magnetic integrated device 30 , and the actual area and actual spacing refer to the actual size of the manufactured magnetic integrated device 30 .

[0079] In the embodiment of the present application, the minimum value of the volume V of the magnetic integrated device is obtained by calculating the preferred values ​​of α and β, and S3 is obtained according to the values ​​of α, β, Ap_T, and Ap_L. M 、L3 M and L4 M The value of S3 is in S3 M *(1±20%), L3 in L3 M *(1±20%), L4 in L4 M *(1±20%). The magnetic integrated components designed by S3, L3 and L4 calculated according to the above formula have high integration, small size and light weight.

[0080] It can be understood that the actual cross-sectional area S3 of the third magnetic column 35 is greater than or equal to 0.8S3 M And less than or equal to 1.2S3 M S3 within this range can meet the design requirements of miniaturization and lightness of the magnetic integrated device 30 and good performance. For example, S3 can be 0.85S3 M , 0.9S3 M , 0.95S3 M 、S3 M ,1.05S3 M ,1.1S3 M or 1.15S3 M wait.

[0081] It can be understood that the actual distance L3 between the first magnetic column 33 and the second magnetic column 34 is greater than or equal to 0.8L3 M And less than or equal to 1.2L3 M L3 within this range can meet the design requirements of miniaturization and lightness of the magnetic integrated device 30 and good performance. For example, L3 can be 0.85L3 M , 0.9L3 M , 0.95L3 M 、L3 M 、1.05L3 M ,1.1L3 M or 1.15L3 M wait.

[0082] It can be understood that the actual distance L4 between the first magnetic core 31 and the second magnetic core 32 is greater than or equal to 0.8L4 M And less than or equal to 1.2L4 M L4 within this range can meet the design requirements of miniaturization and lightness of the magnetic integrated device 30 and good performance. For example, L4 can be 0.85L4 M , 0.9L4 M , 0.95L4 M 、L4 M 、1.05L4 M ,1.1L4 M or 1.15L4 M wait.

[0083] The area S1 of the cross section 331 of the first magnetic column 33 can be calculated according to AP_L and the obtained values ​​of S3 , L3 , and L4 .

[0084] In some embodiments, the distance between the center of the first magnetic pillar 33 and the center of the second magnetic pillar 34 is L1, and L1 is related to the shape of the first magnetic pillar 33 and the second magnetic pillar 34. Taking the first magnetic pillar 33 and the second magnetic pillar 34 as squares as an example, after obtaining the value range of L3 according to the above formula, the area S1 of the cross section 331 of the first magnetic pillar 33 can be obtained according to AP_L and the obtained values ​​of S3, L3, and L4, that is, the side length of the cross section 331 can be obtained, and the value range of L1 can be obtained.

[0085] In some embodiments, the distance between the center of the first magnetic core 31 and the center of the second magnetic core 32 is L2 , and the value of L2 can be designed according to requirements to achieve miniaturization of the magnetic integrated device 30 .

[0086] See also Figure 2 , Figure 3 and Figure 5 The first winding 37 can be a circuit board winding. The circuit board winding can be formed by printing copper wire on a circuit board. The circuit board winding has high processing accuracy and good consistency of parasitic parameters. The first winding 37 shared by the inductor and the primary side of the transformer in the embodiment of the present application uses a circuit board winding, which can fully reduce the volume of the magnetic integrated device 30 and realize the miniaturization and lightweight of the magnetic integrated device 30.

[0087] The two first windings 37 may be connected in series or in parallel. Figure 5 Taking two first windings 37 connected in series as an example, when the two first windings 37 are connected in series, the number of turns of the primary side of the transformer can be doubled. In high-voltage equipment, two first windings 37 can be connected in series according to the design requirements of the high-voltage equipment.

[0088] In other implementations, when two first windings 37 are connected in parallel, the current carrying capacity can be increased. In a high-current device, two first windings 37 can be connected in parallel according to the design requirements of the high-current device.

[0089] The two first windings 37 can be provided with four through holes, which are respectively a first through hole 37-1, a second through hole 37-2, a third through hole 37-3 and a fourth through hole 37-4. The first magnetic column 33 passes through the first through hole 37-1, the second magnetic column 34 passes through the second through hole 37-2, the third magnetic column 35 passes through the third through hole 37-3, and the fourth magnetic column 36 passes through the fourth through hole 37-4.

[0090] The second winding 38 may be a wire winding, for example, a flat copper wire winding, which has a large cross-sectional area and is conducive to increasing the current carrying capacity of the second winding 38. In other embodiments, both the first winding 37 and the second winding 38 may be wire windings.

[0091] In some embodiments, the second winding 38 includes a first sub-winding 38-1 and a second sub-winding 38-2, the number of turns of the first sub-winding 38-1 is the same as the number of turns of the second sub-winding 38-2, and the first sub-winding 38-1 and the second sub-winding 38-2 are arranged along the first direction A1 and connected in parallel. The number of turns of the first sub-winding 38-1 is the same as the number of turns of the second sub-winding 38-2, and the first sub-winding 38-1 and the second sub-winding 38-2 can adopt the same design, which is convenient for the processing of the first sub-winding 38-1 and the second sub-winding 38-2, and reduces the difficulty of winding the first sub-winding 38-1 and the second sub-winding 38-2. The first sub-winding 38-1 and the second sub-winding 38-2 are connected in parallel to increase the current capacity.

[0092] In other implementations, the number of turns of the first sub-winding 38 - 1 and the number of turns of the second sub-winding 38 - 2 may also be different, and this application does not limit this.

[0093] See also Figure 4 In some embodiments, the shape of the cross section 331 of the first magnetic column 33 is the same as the shape of the cross section 341 of the second magnetic column 34, and the shape of the cross section 351 of the third magnetic column 35 is the same as the shape of the cross section 341 of the second magnetic column 34. In this embodiment, by setting the shape of the first magnetic column 33 to be the same as the shape of the second magnetic column 34, and the shape of the third magnetic column 35 to be the same as the shape of the fourth magnetic column 36, the symmetrical arrangement of the first magnetic column 33 and the second magnetic column 34 and the symmetrical design of the third magnetic column 35 and the fourth magnetic column 36 are achieved, which is beneficial to the decoupling of the inductor and the transformer, and avoids the mutual influence between the inductor and the transformer.

[0094] See also Figure 3 and Figure 4In some embodiments, the first magnetic column 33 and the second magnetic column 34 may both be square columns, and the third magnetic column 35 and the fourth magnetic column 36 may both be runway columns. The runway column refers to a column whose cross section is connected by two straight lines and two semicircular arcs. The first winding 37 is a circuit board winding. The shape of the magnetic column will not affect the winding of the circuit board winding. The first magnetic column 33 and the second magnetic column 34 can be set to be square column structures to ensure the cross-sectional area of ​​the first magnetic column 33 and the second magnetic column 34. The second winding 38 is a winding winding. The winding winding will be tightly arranged around the third magnetic column 35 and the fourth magnetic column 36. The shape of the third magnetic column 35 and the fourth magnetic column 36 will affect the winding of the second winding 38. By setting the third magnetic column 35 and the fourth magnetic column 36 to be runway columns, the corners of the third magnetic column 35 and the fourth magnetic column 36 are smooth structures, which is conducive to the winding of the winding winding, avoiding the difficulty of winding the winding winding into a right angle bend in the process, and reducing the difficulty of winding the second winding 38 in the process. In other implementations, the first magnetic column 33 and the second magnetic column 34 may also be rectangular columns or cylindrical columns, and the third magnetic column 35 and the fourth magnetic column 36 may also be cylindrical columns, which is not limited in the present application.

[0095] See also Figure 2 , Figure 6 and Figure 7 , Figure 6 yes Figure 2 A simplified schematic diagram of a partial structure of the magnetic integrated device 30 is shown, Figure 7 yes Figure 2 The driving circuit diagram of the magnetic integrated device 30 shown in the figure. The first winding 37 can form a first terminal 371, a second terminal 372 and a third terminal 373, and the second winding 38 can form a fourth terminal 381, a fifth terminal 382, ​​a sixth terminal 383 and a seventh terminal 384. The first terminal 371, the second terminal 372, the third terminal 373, the fourth terminal 381, the fifth terminal 382, ​​the sixth terminal 383 and the seventh terminal 384 are used to connect to the primary circuit or the secondary circuit. The embodiment of the present application does not limit the number and position of the terminals formed by the first winding 37 and the second winding 38, and can be set as needed.

[0096] like Figure 8 As shown, Figure 8 yes Figure 2The magnetic circuit diagram of the magnetic integrated device 30 shown. The first magnetic column 33, the first magnetic core 31, the second magnetic column 34 and the second magnetic core 32 form an inductor magnetic circuit. The inductor magnetic circuit does not pass through the second winding 38. The magnetic flux of the inductor is stored in the magnetic column and the air gap, which can form an inductor energy storage function. The third magnetic column 35, the first magnetic core 31, the fourth magnetic column 36 and the second magnetic core 32 form a transformer magnetic circuit. The transformer magnetic circuit passes through the second winding 38, and the magnetic flux is coupled to the second winding 38, which can form a transformer function. The integration method in which the inductor and transformer of the magnetic integrated device 30 in the embodiment of the present application share the first magnetic core 31 and the second magnetic core 32 has a high degree of integration.

[0097] In some embodiments, when current passes through the two first windings 37, the first magnetic column 33 generates a magnetic flux, the second magnetic column 34 generates a magnetic flux, the magnetic flux of the first magnetic column 33 on the third magnetic column 35 is equal in magnitude and opposite in direction to the magnetic flux of the second magnetic column 34 on the third magnetic column 35, and the magnetic flux of the first magnetic column 33 on the fourth magnetic column 36 is equal in magnitude and opposite in direction to the magnetic flux of the second magnetic column 34 on the fourth magnetic column 36, so as to realize the decoupling integration of the inductor and the transformer. The magnetic integrated device 30 in the embodiment of the present application realizes the decoupling integration of the inductor and the transformer, and the operation of the inductor and the operation of the transformer do not affect each other.

[0098] like Figure 2 , Fig. 9 and Fig.10 As shown, Fig. 9 for Figure 2 The side view of the magnetic integrated component 30 after removing the first winding 37 and the second winding 38 is shown. Fig.10 for Figure 2 The side view of the magnetic integrated component 30 in another direction after removing the first winding 37 and the second winding 38 is shown. It can be understood that Fig. 9 and Fig.10 The first winding 37 and the second winding 38 are removed in order to more clearly see the structure of the magnetic column.

[0099] The magnetic integrated device 30 may be provided with an air gap 39, and the air gap 39 may be located on the first magnetic column 33, or the air gap 39 may be located on the second magnetic column 34, or the air gap 39 may be located between the first magnetic column 33 and the first magnetic core 31, or the air gap 39 may be located between the first magnetic column 33 and the second magnetic core 32, or the air gap 39 may be located between the second magnetic column 34 and the first magnetic core 31, or the air gap 39 may be located between the second magnetic column 34 and the second magnetic core 32, that is, the air gap is located on the inductor magnetic path. It can be understood that the number of air gaps 39 may be one, two or three, etc., and the air gap 39 may be located at least one of the above positions. The inductor needs to be designed with air gap energy storage and anti-saturation, and the transformer needs to try not to set an air gap, as the air gap will cause the excitation inductance of the transformer to decrease and the transmission efficiency to be low. The first magnetic column 33 and the second magnetic column 34 are on the inductor magnetic path. The transformer magnetic circuit in the embodiment of the present application does not pass through the inductor winding, so the inductor magnetic circuit can be provided with an air gap 39, and the air gap 39 can be used for energy storage and anti-saturation in the inductor magnetic circuit. The air gap will cause the excitation inductance of the transformer to decrease and the transmission efficiency to be low. It can be understood that the inductor magnetic circuit in the embodiment of the present application does not pass through the transformer winding, and the transformer magnetic circuit can be provided with no air gap, which is conducive to increasing the excitation inductance of the transformer and improving the transmission efficiency of the transformer.

[0100] In some embodiments, the number of air gaps on the first magnetic column 33 is the same as the number of air gaps on the second magnetic column 34, and the length of the air gaps on the first magnetic column 33 is the same as the length of the air gaps on the second magnetic column 34. In other embodiments, the number of air gaps on the first magnetic column 33 and the number of air gaps on the second magnetic column 34 may be different, and the length of the air gaps on the first magnetic column 33 and the length of the air gaps on the second magnetic column 34 may be different.

[0101] In some embodiments, the distance between the air gap 39 and the first winding 37 in the first direction A1 is greater than a threshold value, that is, the air gap 39 is set away from the first winding 37. The specific value of the threshold value can be set as needed, and the present application does not limit this. When the air gap 39 is set close to the first winding 37, eddy current loss will be generated, affecting the performance of the inductor. Therefore, the air gap 39 is set away from the first winding 37 to reduce the eddy current loss. Exemplarily, the air gap 39 is not in the first through hole 37-1 and the second through hole 37-2 of the first winding 37, and is set away from the first through hole 37-1 and the second through hole 37-2.

[0102] In the embodiment of the present application, the primary turns of the inductor and the transformer are the same, the winding and layer changing are consistent, and the first winding 37 can be shared, which reduces the difficulty of winding design, improves the integration of the magnetic integrated device 30, and is conducive to reducing the volume and weight of the magnetic integrated device 30.

[0103] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art who is familiar with the present technical field can easily think of changes or substitutions within the technical scope disclosed in the present application, which should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be based on the protection scope of the claims.

Claims

1. A magnetic integrated device, characterized in that: It includes a first magnetic core, a second magnetic core, a first magnetic column, a second magnetic column, a third magnetic column, a fourth magnetic column, two first windings and two second windings; The first magnetic core and the second magnetic core are spaced apart, the first magnetic column, the second magnetic column, the third magnetic column and the fourth magnetic column are all fixedly connected between the first magnetic core and the second magnetic core, and the first magnetic column to the fourth magnetic column are spaced apart from each other; The cross-sectional area of ​​the first magnetic column is equal to the cross-sectional area of ​​the second magnetic column, the cross-sectional area of ​​the third magnetic column is equal to the cross-sectional area of ​​the fourth magnetic column, and the cross-sectional area of ​​the first magnetic column is different from the cross-sectional area of ​​the third magnetic column; One of the first windings surrounds the first magnetic column and the third magnetic column, another of the first windings surrounds the second magnetic column and the fourth magnetic column, one of the second windings surrounds the third magnetic column, and another of the second windings surrounds the fourth magnetic column.

2. The magnetic integrated device according to claim 1, characterized in that: The magnetic integrated device satisfies the following relationship: V=Lc×Wc×Hc, Wc=15β(Ap_T 0.50 / α) 0.50 +1+10.00Ap_L*α / [Ap_T 0.50 (α*Ap_T 0.50 ) 0.50 ]+10.00(α*Ap_T 0.50 ) 0.50 , Ap_T=Pt×10 4 / (B ac f T J*K f K u , Ap_L=L*I L 2 / (B m J*K u ), <h2 style=";text-align:left;direction:ltr">α2=S3<h2 style=";text-align:left;direction:ltr"> M <h2 style=";text-align:left;direction:ltr"> / (L3<h2 style=";text-align:left;direction:ltr"> M <h2 style=";text-align:left;direction:ltr"> ×L4<h2 style=";text-align:left;direction:ltr"> M <h2 style=";text-align:left;direction:ltr"> ), β2=L3 M / L4 M , Ap_T+Ap_L=S3 M ×L3 M ×L4 M , <h2 style=";text-align:left;direction:ltr">S3=S3<h2 style=";text-align:left;direction:ltr"> M <h2 style=";text-align:left;direction:ltr"> ×(1±20%), <h2 style=";text-align:left;direction:ltr">L3=L3<h2 style=";text-align:left;direction:ltr"> M <h2 style=";text-align:left;direction:ltr"> ×(1±20%), L4=L4 M ×(1±20%), Wherein, V is the volume of the magnetic integrated device, Lc is the length of the magnetic integrated device, Wc is the width of the magnetic integrated device, Hc is the height of the magnetic integrated device, α is the first structure factor, β is the second structure factor, S3 M is the calculated area of ​​the cross section of the third magnetic column, L3 M is the calculated distance between the first magnetic column and the second magnetic column, L4 M is the calculated distance between the first magnetic core and the second magnetic core, S3 is the actual area of ​​the cross section of the third magnetic column, L3 is the actual distance between the first magnetic column and the second magnetic column, and L4 is the actual distance between the first magnetic core and the second magnetic core; The magnetic integrated device is an integration of a transformer and an inductor, Ap_T is the product of the core area required by the transformer, Ap_L is the product of the core area required by the inductor, Pt is the apparent power of the transformer, B ac is the working magnetic flux density of the transformer, f T is the operating frequency of the transformer, J is the current density of the winding of the magnetic integrated device, K f is the operating waveform factor (4.44 for sine wave and 4.0 for square wave), K u is the winding window occupancy factor, L is the inductance of the inductor, I L is the working current of the inductor, B m is the working magnetic flux density of the inductor.

3. The magnetic integrated device according to claim 1 or 2, characterized in that: The cross-sectional area of ​​the first magnetic column is smaller than the cross-sectional area of ​​the third magnetic column.

4. The magnetic integrated device according to any one of claims 1 to 3, characterized in that: The first winding is a circuit board winding, and the second winding is a wire winding.

5. The magnetic integrated device according to claim 4, characterized in that: The shape of the cross section of the first magnetic column is the same as the shape of the cross section of the second magnetic column, and the shape of the cross section of the third magnetic column is the same as the shape of the cross section of the fourth magnetic column.

6. The magnetic integrated device according to claim 5, characterized in that: The first magnetic column and the second magnetic column are both in a square column shape, and the third magnetic column and the fourth magnetic column are both in a racetrack column shape.

7. The magnetic integrated device according to any one of claims 1 to 6, characterized in that: The magnetic integrated device is provided with an air gap; The air gap is located on the first magnetic column; Or, the air gap is located on the second magnetic column; Or, the air gap is located between the first magnetic column and the first magnetic core; Or, the air gap is located between the first magnetic column and the second magnetic core; Or, the air gap is located between the second magnetic column and the first magnetic core; Alternatively, the air gap is located between the second magnetic column and the second magnetic core.

8. The magnetic integrated device according to claim 7, characterized in that: A distance between the air gap and the first winding in a first direction is greater than a threshold, and the first direction is an arrangement direction of the first magnetic core and the second magnetic core.

9. The magnetic integrated device according to any one of claims 1 to 8, characterized in that: The second winding includes a first sub-winding and a second sub-winding, the number of turns of the first sub-winding is the same as the number of turns of the second sub-winding, the first sub-winding and the second sub-winding are arranged along a first direction and connected in parallel, and the first direction is the arrangement direction of the first magnetic core and the second magnetic core.

10. The magnetic integrated device according to any one of claims 1 to 9, characterized in that: The two first windings are connected in series or in parallel.

11. The magnetic integrated device according to any one of claims 1 to 10, characterized in that: The magnetic flux of the first magnetic column on the third magnetic column is equal to the magnetic flux of the second magnetic column on the third magnetic column and has an opposite direction, and the magnetic flux of the first magnetic column on the fourth magnetic column is equal to the magnetic flux of the second magnetic column on the fourth magnetic column and has an opposite direction.

12. A converter, characterized in that: It comprises a primary circuit, a secondary circuit and a magnetic integrated device as claimed in any one of claims 1 to 11, wherein the terminals of the primary circuit are connected to the terminals of the magnetic integrated device, and the terminals of the secondary circuit are connected to the terminals of the magnetic integrated device.

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