Magnetic integrated device and transformer

Abstract

The application relates to a magnetic integrated device and a transformer, the magnetic integrated device comprising a first magnetic core, a second magnetic core, a first magnetic column to a fourth magnetic column, two first windings and two second windings; the first magnetic core and the second magnetic core are arranged at intervals, and the first magnetic column to the fourth magnetic column are fixedly connected between the first magnetic core and the second magnetic core; 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 first winding is wound around the first magnetic column and the third magnetic column, the other first winding is wound around the second magnetic column and the fourth magnetic column, one second winding is wound around the third magnetic column, and the other second winding is wound around the fourth magnetic column. The magnetic integrated device has high integration, and the volume and weight of the magnetic integrated device are reduced.

Description

Technical Field

[0001] This invention relates to the field of power electronic magnetic integration technology, and in particular to a magnetic integrated device and converter. Background Technology

[0002] Dual active bridge converters can achieve electrical isolation between input and output, have bidirectional power processing capability, and have advantages such as high power density, easy soft switching, and high efficiency. They can meet the needs of various applications in DC power supply systems and have great application potential and development prospects.

[0003] However, dual active bridge converters have many magnetic components and are large in size. Currently, the magnetic components are magnetically integrated, but the integration degree of magnetically integrated devices is low and the size is still relatively large. Summary of the Invention

[0004] This application provides a magnetic integrated device and a converter. The magnetic integrated device of this application has a high degree of integration, which is beneficial for reducing the size and weight of the magnetic integrated device, and realizing the miniaturization and weight reduction of the magnetic integrated device.

[0005] In a first aspect, embodiments of this application provide a magnetic integrated device. The magnetic integrated device includes a first magnetic core, a second magnetic core, a first magnetic post, a second magnetic post, a third magnetic post, a fourth magnetic post, two first windings, and two second windings. The first magnetic core and the second magnetic core are spaced apart. The first magnetic post, the second magnetic post, the third magnetic post, and the fourth magnetic post are all fixedly connected between the first magnetic core and the second magnetic core, and the first magnetic post to the fourth magnetic post are spaced apart from each other. The cross-sectional area of ​​the first magnetic post is equal to the cross-sectional area of ​​the second magnetic post, the cross-sectional area of ​​the third magnetic post is equal to the cross-sectional area of ​​the fourth magnetic post, and the cross-sectional areas of the first magnetic post and the third magnetic post are different. One first winding surrounds the first magnetic post and the third magnetic post, another first winding surrounds the second magnetic post and the fourth magnetic post, one second winding surrounds the third magnetic post, and another second winding surrounds the fourth magnetic post.

[0006] The magnetic integrated device in this embodiment is an integration of an inductor and a transformer. Understandably, the first, second, third, and fourth magnetic pillars can be arranged in a matrix, which helps reduce the number of winding layers and turns, and thus the size and weight of the magnetic integrated device. Exemplarily, the first and second magnetic pillars are arranged adjacent to each other, the third and fourth magnetic pillars are arranged adjacent to each other, the first and fourth magnetic pillars can be arranged diagonally, and the second and third magnetic pillars can be arranged diagonally. Any two magnetic pillars among the first, second, third, and fourth magnetic pillars are spaced apart from each other.

[0007] In this embodiment, by reasonably configuring the cross-sectional areas of the first and third magnetic pillars to be different, the number of turns in the inductor winding is made consistent with the number of turns in the primary winding of the transformer. This allows the inductor winding and the primary winding of the transformer to share the same first winding. In other words, the first winding serves as both the inductor winding and the primary winding of the transformer, thus reducing the winding volume and consequently the size and weight of the magnetic integrated device. The second winding is the secondary winding of the transformer. The magnetic integrated device in this embodiment exhibits high integration, small size, and low weight.

[0008] In one possible implementation, 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] Where 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, and S3 M L3 is the calculated area of ​​the cross-section of the third magnetic column. M L4 is the calculated distance between the first magnetic pillar and the second magnetic pillar. M S3 is the calculated distance between the first magnetic core and the second magnetic core, S4 is the actual area of ​​the cross-section of the third magnetic post, L3 is the actual distance between the first magnetic post and the second magnetic post, 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 required core areas of the transformer, Ap_L is the product of the required core areas of the inductor, Pt is the apparent power of the transformer, and B... ac f is the operating magnetic flux density of the transformer. T Where J is the operating frequency of the transformer, J is the current density of the winding of the magnetic integrated device, and K is the operating frequency of the transformer. f K represents the working waveform coefficients (4.44 for sine wave and 4.0 for square wave). u Where L is the winding window occupancy factor, and I is the inductance of the inductor. L B is the operating current of the inductor. m Let be the operating 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 and B according to the requirements of magnetic integrated devices ac f T J, K f K u L, I L B m The values ​​can be used to obtain Ap_T and Ap_L.

[0024] In this embodiment, to find the minimum value of the volume V of the magnetic integrated device, the preferred values ​​of α and β can be calculated, and S3 can be obtained based on the values ​​of α, β, Ap_T, and Ap_L. M L3 M and L4 MThe value of S3 in S3 M *Within the range of (1±20%), L3 is in L3 M *Within the range of (1±20%), L4 is in L4 M Within the range of (1±20%), the magnetic integrated components designed using S3, L3, and L4, calculated according to the above formula, exhibit high integration, small size, and light weight.

[0025] Understandably, the cross-sectional area of ​​the first magnetic column can be calculated based on AP_L and the obtained values ​​of S3, L3, and L4.

[0026] In one possible implementation, the cross-sectional area of ​​the first magnetic post is smaller than that of the third magnetic post. In other words, the cross-sectional area of ​​the third magnetic post is larger than that of the first magnetic post. Understandably, the cross-sectional area of ​​the fourth magnetic post is larger than that of the second magnetic post. The second winding is the secondary winding of the transformer. The second winding is wound around the third and fourth magnetic posts, which have larger cross-sectional areas, which helps to reduce the excitation current of the transformer and improve its transmission efficiency.

[0027] In one possible implementation, the first winding is a circuit board winding, and the second winding is a wire winding. Circuit board windings have high processing precision and good consistency of parasitic parameters. In this embodiment, using a circuit board winding for the first winding shared by the inductor and transformer primary winding can significantly reduce the size and weight of the magnetic integrated device, achieving miniaturization and weight reduction. The second winding can be a flat copper wire winding, which helps increase its current-carrying capacity. In other implementations, both the first and second windings can be wire windings.

[0028] In one possible implementation, the cross-sectional shape of the first magnetic post is the same as that of the second magnetic post, and the cross-sectional shape of the third magnetic post is the same as that of the fourth magnetic post. In this embodiment, by setting the first magnetic post to have the same shape as the second magnetic post, and the third magnetic post to have the same shape as the fourth magnetic post, symmetrical arrangement of the first and second magnetic posts and symmetrical design of the third and fourth magnetic posts are achieved, which is beneficial for decoupling the inductor and the transformer.

[0029] In one possible implementation, the first and second magnetic pillars are both square pillars, while the third and fourth magnetic pillars are both racetrack-shaped pillars. The first winding is a circuit board winding, and four through holes can be provided on the first winding, through which the first to fourth magnetic pillars pass respectively. Since the first winding is a circuit board winding, the shape of the magnetic pillars will not affect the winding of the circuit board winding. The first and second magnetic pillars can be set to be square pillars to ensure their cross-sectional areas. The second winding is a wire winding, which is tightly wound around the third and fourth magnetic pillars. The shapes of the third and fourth magnetic pillars affect the winding of the second winding. By setting the third and fourth magnetic pillars to be racetrack-shaped pillars with smooth corners, it is beneficial for the winding of the wire winding, avoiding the difficulty of winding the wire winding into right-angle bends in the manufacturing process, and reducing the difficulty of winding the second winding in the manufacturing process. In other embodiments, the first and second magnetic pillars may also be rectangular or cylindrical, and the third and fourth magnetic pillars may also be cylindrical; this application does not limit this.

[0030] In one possible implementation, the magnetic integrated device has an air gap; the air gap is located on the first magnetic post; or, the air gap is located on the second magnetic post; or, the air gap is located between the first magnetic post and the first magnetic core; or, the air gap is located between the first magnetic post and the second magnetic core; or, the air gap is located between the second magnetic post and the first magnetic core; or, the air gap is located between the second magnetic post and the second magnetic core. The air gap is located on the first magnetic post; or, the air gap is located on the second magnetic post; or, the air gap is located between the first magnetic post and the first or second magnetic core; or, the air gap is located between the second magnetic post and the first or second magnetic core, i.e., the air gap is located on the inductor's magnetic circuit. Inductors need to be designed with air gaps for energy storage and saturation resistance, while transformers should ideally have no air gaps, as air gaps reduce the transformer's magnetizing inductance and reduce transmission efficiency. The first and second magnetic posts are on the inductor's magnetic circuit. In this embodiment, the transformer's magnetic circuit does not pass through the inductor winding; therefore, an air gap can be provided in the inductor's magnetic circuit, and the air gap can be used for energy storage and saturation resistance in the inductor's magnetic circuit. Understandably, since the inductor's magnetic circuit does not pass through the transformer windings, the transformer's magnetic circuit can be without an air gap, which helps to increase the transformer's magnetizing inductance and improve its transmission efficiency.

[0031] Understandably, the number of air gaps on the first magnetic pillar is the same as the number of air gaps on the second magnetic pillar, and the length of the air gaps on the first magnetic pillar is the same as the length of the air gaps on the second magnetic pillar. In other embodiments, the number of air gaps on the first magnetic pillar may be different from the number of air gaps on the second magnetic pillar, and the length of the air gaps on the first magnetic pillar may also be different from the length of the air gaps on the second magnetic pillar.

[0032] In one possible implementation, the distance between the air gap and the first winding in a first direction is greater than a threshold, where the first direction is the arrangement direction of the first magnetic core and the second magnetic core. In other words, the air gap is far from the first winding. When the air gap is located close to the first winding, eddy current losses will occur, affecting the performance of the inductor. Therefore, by setting the air gap far away from the first winding, eddy current losses can be reduced.

[0033] In one possible implementation, the second winding includes a first sub-winding and a second sub-winding. The first sub-winding has the same number of turns as the second sub-winding. The first and second sub-windings are arranged and connected in parallel along a first direction, which is the arrangement direction of the first and second magnetic cores. The first and second sub-windings have the same number of turns, and they can adopt the same design, which facilitates their processing and reduces their winding difficulty. The parallel connection of the first and second sub-windings increases the current carrying capacity.

[0034] In one 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 on the primary side of the transformer can be doubled; this can be used in high-voltage equipment. When the two first windings are connected in parallel, the current-carrying capacity can be increased; this can be used in high-current equipment.

[0035] In one possible implementation, the magnetic flux of the first magnetic post on the third magnetic post is equal in magnitude and opposite in direction to the magnetic flux of the second magnetic post on the third magnetic post, and the magnetic flux of the first magnetic post on the fourth magnetic post is equal in magnitude and opposite in direction to the magnetic flux of the second magnetic post on the fourth magnetic post. The first magnetic post, the first magnetic core, the second magnetic post, and the second magnetic core form an inductor magnetic circuit, and the third magnetic post, the first magnetic core, the fourth magnetic post, and the second magnetic core form a transformer magnetic circuit. The design in this embodiment allows for the decoupled integration of the inductor and the transformer.

[0036] Secondly, this application provides a converter, including a primary-side circuit, a secondary-side circuit, and a magnetic integrated device as described in any of the foregoing embodiments. Terminals of the primary-side circuit are connected to terminals of the magnetic integrated device, and terminals of the secondary-side circuit are also connected to terminals of the magnetic integrated device. Understandably, the magnetic integrated device may include multiple terminals; the primary-side circuit is connected to some terminals of the magnetic integrated device, and the secondary-side circuit is connected to other terminals of the magnetic integrated device. The converter can be a dual active bridge converter, a resonant circuit converter, or a phase-shifted full-bridge converter, etc. This application does not limit the type of transformer. Attached Figure Description

[0037] To more clearly illustrate the technical solutions in the embodiments of the present invention or the background art, the accompanying drawings used in the embodiments of the present invention or the background art will be described below.

[0038] Figure 1 This is a schematic diagram of the structure of a converter provided in an embodiment of this 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 The diagram shows an exploded view of the magnetic integrated device.

[0041] Figure 4 yes Figure 2 A partial structural schematic diagram of the magnetic integrated device is shown.

[0042] Figure 5 yes Figure 2 The diagram shows the structure of the first winding.

[0043] Figure 6 yes Figure 2 A simplified schematic diagram of part of the structure of the magnetic integrated device shown;

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

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

[0046] Figure 9 yes Figure 2 The side view of the magnetic integrated element shown is after the first and second windings have been removed.

[0047] Figure 10 yes Figure 2 The shown magnetic integrated element is viewed from another direction after the first and second windings have been removed. Detailed Implementation

[0048] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0049] All technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items. Uses of terms such as "first," "second," etc., in this application are for descriptive purposes only and should not be construed as indicating or implying relative importance or specifying the number of technical features indicated.

[0050] like Figure 1 As shown, Figure 1 This is a schematic diagram of a converter 100. The converter 100 is a device that transforms information emitted from a signal source according to a specific purpose. It can be used for electrical quantity conversion, isolation, and setting adjustment, and has broad application prospects. The converter 100 can be a dual active bridge converter, a resonant circuit converter, or a phase-shifted full-bridge converter, etc. The converter 100 can be used in equipment such as electric vehicles.

[0051] The converter 100 may include a primary-side circuit 10, a secondary-side circuit 20, and a magnetic integrated device 30. The magnetic integrated device 30 may include multiple terminals; terminals of the primary-side circuit 10 may be connected to some terminals of the magnetic integrated device 30, and terminals of the secondary-side circuit 20 may be connected to other terminals of the magnetic integrated device 30. The primary-side circuit 10 may include multiple switching devices, and the secondary-side circuit 20 may include multiple switching devices. The primary-side circuit 10 and the secondary-side circuit 20 may employ pulse width modulation control, asymmetrical pulse width control, or phase-shift frequency conversion control, etc. The magnetic integrated device 30 can integrate an inductor and a transformer onto a single magnetic structure to reduce the size of the magnetic components, lower their losses, reduce their number, lower their cost, improve the efficiency of the switching power supply, and create new circuit topologies.

[0052] Understandable, Figure 1 The converter 100 shown in the embodiment is merely illustrative. This application does not strictly limit the specific structure and position of the primary circuit 10, secondary circuit 20 and magnetic integrated device 30, which can be set as needed.

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

[0054] The first magnetic core 31 and the second magnetic core 32 are spaced apart. The first magnetic core 31 and the second magnetic core 32 can be plate-like structures, can be arranged in parallel, and can be arranged along a first direction A1. The first magnetic pillar 33, the second magnetic pillar 34, the third magnetic pillar 35, and the fourth magnetic pillar 36 are all fixedly connected between the first magnetic core 31 and the second magnetic core 32, and any two of the first magnetic pillars 33, the second magnetic pillar 34, the third magnetic pillar 35, and the fourth magnetic pillar 36 are spaced apart from each other. The first magnetic pillars 33, the second magnetic pillar 34, the third magnetic pillar 35, and the fourth magnetic pillar 36 can be arranged in a matrix, which helps to reduce the number of winding layers and turns of the magnetic integrated device 30, thereby reducing the size and weight of the magnetic integrated device 30. For example, the first magnetic post 33 and the second magnetic post 34 can be arranged adjacent to each other and along the second direction A2 (the second direction A2 can be perpendicular to the first direction A1), the third magnetic post 35 and the fourth magnetic post 36 can be arranged adjacent to each other and along the second direction A2, the first magnetic post 33 and the fourth magnetic post 36 can be arranged diagonally, and the second magnetic post 34 and the third magnetic post 35 can be arranged diagonally.

[0055] The first magnetic post 33, the second magnetic post 34, the third magnetic post 35, and the fourth magnetic post 36, together with the first magnetic core 31 and the second magnetic core 32, can be an integral structure, or they can be fixedly connected between the first magnetic core 31 and the second magnetic core 32 by assembly, such as by adhesive bonding.

[0056] The first magnetic core 31, the second magnetic core 32, the first magnetic pillar 33, the second magnetic pillar 34, the third magnetic pillar 35, and the fourth magnetic pillar 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 pillar 33, the second magnetic pillar 34, the third magnetic pillar 35, and the fourth magnetic pillar 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 schematic diagram of the magnetic integrated device 30 shown. Figure 4 The middle is the general Figure 2The image shows a top view after removing the first magnetic core 31, the first winding 37, and the second winding 38. The area S1 of the cross-section 331 of the first magnetic pillar 33 is equal to the area S2 of the cross-section 341 of the second magnetic pillar 34. The area S3 of the cross-section 351 of the third magnetic pillar 35 is equal to the area S4 of the cross-section 361 of the fourth magnetic pillar 36. The area S1 of the cross-section 331 of the first magnetic pillar 33 is different from the area S3 of the cross-section 351 of the third magnetic pillar 35. Understandably, the area S1 of the cross-section 331 of the first magnetic pillar 33 is different from the area S4 of the cross-section 361 of the fourth magnetic pillar 36, the area S2 of the cross-section 341 of the second magnetic pillar 34 is different from the area S3 of the cross-section 351 of the third magnetic pillar 35, and the area S2 of the cross-section 341 of the second magnetic pillar 34 is different from the area S4 of the cross-section 361 of the fourth magnetic pillar 36. The magnetic column is usually a column with a uniform cross-section. The cross-section of the first magnetic column 33 to the cross-section of 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 Figure 2 , Figure 3 and Figure 5 , Figure 5 for Figure 2 The diagram shows the structure of the first winding 37. One first winding 37 is arranged around the first magnetic post 33 and the third magnetic post 35, and another first winding 37 is arranged around the second magnetic post 34 and the fourth magnetic post 36. One second winding 38 is arranged around the third magnetic post 35, and another second winding 38 is arranged around the fourth magnetic post 36. The first winding 37 is an inductor winding and is the primary winding of the transformer, while the second winding 38 is the secondary winding of the transformer.

[0059] In this embodiment, the inductor and transformer of the magnetic integrated device 30 share the first magnetic core 31, the second magnetic core 32, and the first winding 37, resulting in high integration, small size, and light weight. In this embodiment, by reasonably configuring the cross-sectional area S1 of the first magnetic post 33 to be different from the cross-sectional area S3 of the third magnetic post 35, the number of turns in the inductor winding is consistent with the number of turns in the primary winding of the transformer. The winding and layer replacement of the inductor winding and the primary winding of the transformer are consistent, achieving the sharing of the inductor winding and the primary winding of the transformer. Specifically, the inductor and the primary winding of the transformer share the first winding 37, which reduces the difficulty of winding design. In other words, the first winding 37 is both the inductor winding and the primary winding of the transformer, achieving winding sharing, which helps to reduce the winding volume, thereby reducing the size and weight of the magnetic integrated device 30. In this application, both the inductor magnetic circuit and the transformer magnetic circuit pass through the first magnetic core 31 and the second magnetic core 32, realizing the sharing of the first magnetic core 31 and the second magnetic core 32, which is beneficial to the miniaturization and weight reduction of the magnetic integrated device 30.

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

[0061] In other embodiments, the area S1 of the cross-section 331 of the first magnetic post 33 may be greater than the area S3 of the cross-section 351 of the third magnetic post 35, and the area S2 of the cross-section 341 of the second magnetic post 34 may be greater than the area S4 of the cross-section 361 of the fourth magnetic post 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] Where 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, and S3 M L3 is the calculated area of ​​the cross-section 351 of the third magnetic column 35. M L4 is the calculated spacing between the first magnetic pillar 33 and the second magnetic pillar 34. M S3 is the calculated spacing between the first magnetic core 31 and the second magnetic core 32 (see [reference]). Figure 4 L3 is the actual area of ​​the cross-section of the third magnetic column 35. Figure 4 L4 represents the actual distance between the first magnetic post 33 and the second magnetic post 34. Figure 9 () represents the actual distance between the first magnetic core 31 and the second magnetic core 32;

[0076] Magnetic integrated devices are integrations of transformers and inductors. Ap_T is the product of the required core areas Ap for the transformer, Ap_L is the product of the required core areas Ap for the inductor, Pt is the apparent power of the transformer, and B... ac f is the operating magnetic flux density of the transformer. T Where J is the operating frequency of the transformer, and K is the current density of the winding of the magnetic integrated device. It can be understood that the winding here refers to either the first or second winding. f K represents the working waveform coefficients (4.44 for sine wave and 4.0 for square wave). u The winding window occupancy factor, where "winding" refers to either the first or second winding, L is the inductance, and I is the winding window occupancy factor. L B is the operating current of the inductor. m Let be the operating magnetic flux density of the inductor.

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

[0078] Understandably, the calculated area and calculated spacing refer to the area and spacing calculated based on the minimum volume of the magnetic integrated device 30, while the actual area and actual spacing refer to the actual dimensions of the manufactured magnetic integrated device 30.

[0079] In this embodiment of the application, to find the minimum value of the volume V of the magnetic integrated device, the preferred values ​​of α and β can be calculated, and S3 can be obtained based on the values ​​of α, β, Ap_T, and Ap_L. M L3 M and L4 M The value of S3 in S3 M *Within the range of (1±20%), L3 is in L3 M *(1±20%) range, L4 in L4 M Within the range of (1±20%), the magnetic integrated components designed using S3, L3, and L4, calculated according to the above formula, exhibit high integration, small size, and light weight.

[0080] Understandably, the actual cross-sectional area S3 of the third magnetic post 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, lightweighting, and good performance of magnetic integrated devices. 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] Understandably, the actual distance L3 between the first magnetic post 33 and the second magnetic post 34 is greater than or equal to 0.8L3. M And less than or equal to 1.2L3 M Within this range, L3 can meet the design requirements of miniaturization, weight reduction, and good performance of magnetic integrated devices. 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] Understandably, 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 Within this range, L4 can meet the design requirements of miniaturization, weight reduction, and good performance of magnetic integrated devices. 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] Based on AP_L and the obtained values ​​of S3, L3, and L4, the area S1 of the cross-section 331 of the first magnetic column 33 can be calculated.

[0084] In some embodiments, the distance between the center of the first magnetic post 33 and the center of the second magnetic post 34 is L1. L1 is related to the shape of the first magnetic post 33 and the second magnetic post 34. Taking the first magnetic post 33 and the second magnetic post 34 as squares as an example, after obtaining the range of L3 values ​​according to the above formula, the area S1 of the cross section 331 of the first magnetic post 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 thus the range of L1 values ​​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. The value of L2 can be designed according to requirements to achieve miniaturization of the magnetic integrated device 30.

[0086] See Figure 2 , Figure 3 and Figure 5 The first winding 37 can be a circuit board winding, which can be formed by printing copper wires on the circuit board. The circuit board winding has high processing precision and good consistency of parasitic parameters. In the embodiment of this application, the first winding 37, which is shared by the primary side of the inductor and the transformer, adopts a circuit board winding, which can significantly reduce the volume of the magnetic integrated device 30 and realize the miniaturization and weight reduction of the magnetic integrated device 30.

[0087] The two first windings 37 can be connected in series or in parallel. Figure 5 Taking two first windings 37 connected in series as an example, when two first windings 37 are connected in series, the number of turns on 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 embodiments, when the two first windings 37 are connected in parallel, the current carrying capacity can be increased. In high-current equipment, the two first windings 37 can be connected in parallel according to the design requirements of the high-current equipment.

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

[0090] The second winding 38 can be a wire winding. For example, the second winding 38 can be a flat copper wire winding. The large cross-sectional area of ​​the flat copper wire winding is beneficial to increasing the current carrying capacity of the second winding 38. In other embodiments, both the first winding 37 and the second winding 38 can 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 in the first sub-winding 38-1 is the same as the number of turns in the second sub-winding 38-2. The first sub-winding 38-1 and the second sub-winding 38-2 are arranged along a first direction A1 and connected in parallel. The first sub-winding 38-1 and the second sub-winding 38-2 can have the same design, which facilitates the processing of the first sub-winding 38-1 and the second sub-winding 38-2 and reduces the winding difficulty of the first sub-winding 38-1 and the second sub-winding 38-2. The parallel connection of the first sub-winding 38-1 and the second sub-winding 38-2 can increase the current carrying capacity.

[0092] In other embodiments, 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 Figure 4 In some embodiments, the shape of the cross-section 331 of the first magnetic pillar 33 is the same as the shape of the cross-section 341 of the second magnetic pillar 34, and the shape of the cross-section 351 of the third magnetic pillar 35 is the same as the shape of the cross-section 341 of the second magnetic pillar 34. In this embodiment, by setting the shape of the first magnetic pillar 33 to be the same as the shape of the second magnetic pillar 34, and the shape of the third magnetic pillar 35 to be the same as the shape of the fourth magnetic pillar 36, the symmetrical arrangement of the first magnetic pillar 33 and the second magnetic pillar 34, and the symmetrical design of the third magnetic pillar 35 and the fourth magnetic pillar 36 are achieved. This facilitates the decoupling of the inductor and the transformer, and avoids mutual interference between the inductor and the transformer.

[0094] See Figure 3 and Figure 4In some embodiments, the first magnetic post 33 and the second magnetic post 34 can both be square columns, and the third magnetic post 35 and the fourth magnetic post 36 can both be racetrack-shaped columns. A racetrack-shaped column is a column whose cross-section is formed by two straight lines and two semi-circular arcs. The first winding 37 is a circuit board winding. The shape of the magnetic posts will not affect the winding of the circuit board winding. The first magnetic post 33 and the second magnetic post 34 can be set to be square columns to ensure the cross-sectional area of ​​the first magnetic post 33 and the second magnetic post 34. The second winding 38 is a wire winding. The wire winding is tightly wound around the third magnetic post 35 and the fourth magnetic post 36. The shape of the third magnetic post 35 and the fourth magnetic post 36 will affect the winding of the second winding 38. By setting the third magnetic post 35 and the fourth magnetic post 36 to be racetrack-shaped columns, and the corners of the third magnetic post 35 and the fourth magnetic post 36 to have smooth structures, it is beneficial to the winding of the wire winding, avoiding the difficulty of winding the wire winding into right-angle bends in the process, and reducing the winding difficulty of the second winding 38 in the process. In other embodiments, the first magnetic post 33 and the second magnetic post 34 may also be rectangular or cylindrical, and the third magnetic post 35 and the fourth magnetic post 36 may also be cylindrical. This application does not limit the specific form of the magnetic post 33.

[0095] See Figure 2 , Figure 6 and Figure 7 , Figure 6 yes Figure 2 A simplified schematic diagram of part of the structure of the magnetic integrated device 30 shown. Figure 7 yes Figure 2 The diagram shows the driving circuit of the magnetic integrated device 30. 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 or secondary circuit. This application embodiment does not limit the number and position of the terminals formed by the first winding 37 and the second winding 38; they 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 is shown. The first magnetic pillar 33, the first magnetic core 31, the second magnetic pillar 34, and the second magnetic core 32 form an inductor magnetic circuit. This inductor magnetic circuit does not pass through the second winding 38. The magnetic flux of the inductor is stored in the magnetic pillars and the air gap, thus enabling inductor energy storage. The third magnetic pillar 35, the first magnetic core 31, the fourth magnetic pillar 36, and the second magnetic core 32 form a transformer magnetic circuit. This transformer magnetic circuit passes through the second winding 38, and the magnetic flux is coupled to the second winding 38, thus enabling transformer function. The magnetic integrated device 30 in this embodiment achieves high integration by sharing the first magnetic core 31 and the second magnetic core 32 for both the inductor and transformer.

[0097] In some embodiments, when current flows through the two first windings 37, the first magnetic post 33 generates magnetic flux, the second magnetic post 34 generates magnetic flux, the magnetic flux of the first magnetic post 33 on the third magnetic post 35 is equal in magnitude and opposite in direction to the magnetic flux of the second magnetic post 34 on the third magnetic post 35, and the magnetic flux of the first magnetic post 33 on the fourth magnetic post 36 is equal in magnitude and opposite in direction to the magnetic flux of the second magnetic post 34 on the fourth magnetic post 36, thereby achieving decoupled integration of the inductor and the transformer. The magnetic integrated device 30 in this embodiment achieves decoupled integration of the inductor and the transformer, and the operation of the inductor and the transformer do not affect each other.

[0098] like Figure 2 , Figure 9 and Figure 10 As shown, Figure 9 for Figure 2 The side view of the magnetic integrated element 30 shown is after removing the first winding 37 and the second winding 38. Figure 10 for Figure 2 The side view of the magnetic integrated element 30 shown, after removing the first winding 37 and the second winding 38, can be understood to be... Figure 9 and Figure 10 The first winding 37 and the second winding 38 are removed to make the structure of the magnetic column clearer.

[0099] The magnetic integrated device 30 may have an air gap 39. The air gap 39 may be located on the first magnetic post 33, or on the second magnetic post 34, or between the first magnetic post 33 and the first magnetic core 31, or between the first magnetic post 33 and the second magnetic core 32, or between the second magnetic post 34 and the first magnetic core 31, or between the second magnetic post 34 and the second magnetic core 32. In other words, the air gap is located on the inductor's magnetic circuit. Understandably, the number of air gaps 39 can be one, two, or three, and the air gap 39 can be located in at least one of the above positions. Inductors need to be designed with air gaps for energy storage and saturation resistance, while transformers should ideally have no air gaps, as air gaps reduce the transformer's magnetizing inductance and lower transmission efficiency. The first magnetic post 33 and the second magnetic post 34 are on the inductor's magnetic circuit. In this embodiment, the transformer magnetic circuit does not pass through the inductor winding. Therefore, an air gap 39 can be provided in the inductor magnetic circuit. The air gap 39 can be used for energy storage and anti-saturation in the inductor magnetic circuit. An air gap will reduce the excitation inductance of the transformer and reduce the transmission efficiency. Understandably, in this embodiment, since the inductor magnetic circuit does not pass through the transformer winding, an air gap can be omitted from the transformer magnetic circuit, which is beneficial to increase the excitation inductance of the transformer and improve the transmission efficiency of the transformer.

[0100] In some embodiments, the number of air gaps on the first magnetic post 33 is the same as the number of air gaps on the second magnetic post 34, and the length of the air gaps on the first magnetic post 33 is the same as the length of the air gaps on the second magnetic post 34. In other embodiments, the number of air gaps on the first magnetic post 33 and the number of air gaps on the second magnetic post 34 may be different, and the length of the air gaps on the first magnetic post 33 and the length of the air gaps on the second magnetic post 34 may also 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, that is, the air gap 39 is disposed away from the first winding 37. The specific value of the threshold can be set as needed, and this application does not limit it. When the air gap 39 is disposed close to the first winding 37, eddy current losses will be generated, affecting the performance of the inductor. Therefore, by displacing the air gap 39 away from the first winding 37, eddy current losses can be reduced. Exemplarily, the air gap 39 is not within the first through hole 37-1 and the second through hole 37-2 of the first winding 37, and is disposed away from the first through hole 37-1 and the second through hole 37-2.

[0102] In this embodiment, the inductor and transformer have the same number of primary turns, and the winding is consistent with the layer change. They can share the first winding 37, which reduces the design difficulty of the winding, improves the integration of the magnetic integrated device 30, and helps to reduce the size and weight of the magnetic integrated device 30.

[0103] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the 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, and the first magnetic post, the second magnetic post, the third magnetic post and the fourth magnetic post are all fixedly connected between the first magnetic core and the second magnetic core, and the first magnetic post to the fourth magnetic post 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 first winding surrounds the first magnetic post and the third magnetic post, another first winding surrounds the second magnetic post and the fourth magnetic post, one second winding surrounds the third magnetic post, and another second winding surrounds the fourth magnetic post; The actual cross-sectional area S3 of the third magnetic post of the magnetic integrated device, the actual distance L3 between the first and second magnetic posts, and the actual distance L4 between the first and second magnetic cores satisfy: S3 in S3 M Within the range of ×(1±20%), L3 is in L3 M Within the range of ×(1±20%), L4 is in L4 M Within the range of ×(1±20%); The S3 M L3 M and L4 M The value is calculated based on the minimum value of the volume V of the magnetic integrated device, where, V = Lc × Wc × Hc, Lc=20.00 +20β , 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 , Hc=10 / b+200a / (15b / 2+0.5+10.00 ), =S3 M / (L3 M × L4 M ), = L3 M / L4 M , Ap_T + Ap_L =S3 M × L3 M × L4 M , Where 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, and S3 M L3 is the calculated area of ​​the cross-section of the third magnetic column. M L4 is the calculated distance between the first magnetic pillar and the second magnetic pillar. M is the calculated distance between the first magnetic core and the second magnetic core; Ap_T is the product of the required magnetic core areas for the transformer, and Ap_L is the product of the required magnetic core areas for the inductor.

2. The magnetic integrated device as described in claim 1, characterized in that, 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 ), Where Pt is the apparent power of the transformer, and B ac f is the operating magnetic flux density of the transformer. T Where J is the operating frequency of the transformer, J is the current density of the winding of the magnetic integrated device, and K is the operating frequency of the transformer. f K represents the working waveform coefficient. u Where L is the winding window occupancy factor, and I is the inductance of the inductor. L B is the operating current of the inductor. m The operating magnetic flux density of the inductor is denoted as .

3. The magnetic integrated device as described in claim 1 or 2, characterized in that, The cross-sectional area of ​​the first magnetic post is smaller than the cross-sectional area of ​​the third magnetic post.

4. The magnetic integrated device as described in claim 1 or 2, characterized in that, The first winding is a circuit board winding, and the second winding is a wire winding.

5. The magnetic integrated device as described in claim 4, characterized in that, The cross-sectional shape of the first magnetic post is the same as that of the second magnetic post, and the cross-sectional shape of the third magnetic post is the same as that of the fourth magnetic post.

6. The magnetic integrated device as described in claim 5, characterized in that, The first and second magnetic pillars are both square pillars, while the third and fourth magnetic pillars are both racetrack-shaped pillars.

7. The magnetic integrated device as described in claim 1 or 2, characterized in that, The magnetic integrated device is provided with an air gap; The air gap is located on the first magnetic column; Alternatively, the air gap may be located on the second magnetic post; Alternatively, the air gap may be located between the first magnetic column and the first magnetic core; Alternatively, the air gap may be located between the first magnetic column and the second magnetic core; Alternatively, the air gap may be located between the second magnetic column and the first magnetic core; Alternatively, the air gap may be located between the second magnetic column and the second magnetic core.

8. The magnetic integrated device as described in claim 7, characterized in that, The distance between the air gap and the first winding in a first direction is greater than a threshold, where the first direction is the arrangement direction of the first magnetic core and the second magnetic core.

9. The magnetic integrated device as described in claim 1 or 2, characterized in that, The second winding includes a first sub-winding and a second sub-winding. The number of turns in the first sub-winding is the same as the number of turns in the second sub-winding. The first sub-winding and the second sub-winding are arranged in parallel along a first direction, which is the arrangement direction of the first magnetic core and the second magnetic core.

10. The magnetic integrated device as described in claim 1 or 2, characterized in that, The two first windings are connected in series or in parallel.

11. The magnetic integrated device as described in claim 1 or 2, characterized in that, The magnetic flux of the first magnetic post on the third magnetic post is equal in magnitude and opposite in direction to the magnetic flux of the second magnetic post on the third magnetic post, and the magnetic flux of the first magnetic post on the fourth magnetic post is equal in magnitude and opposite in direction to the magnetic flux of the second magnetic post on the fourth magnetic post.

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

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