Magnetic integrated structure, magnetic integrated device and power supply device

Abstract

The invention discloses a magnetic integrated structure, a magnetic integrated device and a power supply device. The magnetic integrated structure comprises a top magnetic column, a bottom magnetic column, a winding magnetic column group and an edge magnetic column. Each side magnetic column comprises an upper magnetic column arranged at the end part of the top magnetic column and a lower magnetic column arranged at the end part of the bottom magnetic column, and a first air gap is formed between the upper magnetic column and the lower magnetic column of the same side magnetic column; the top magnetic column and / or the bottom magnetic column are / is provided with a second air gap, and the second air gap is located in the area between the two winding magnetic column sets. The second air gap reduces the magnetic flux of the area between the two winding magnetic column groups on the top magnetic column and the bottom magnetic column, increases the magnetic flux of the side magnetic columns and the magnetic flux of other areas on the top magnetic column and the bottom magnetic column, and can reduce the magnetic flux difference of each part of the magnetic integrated structure. Besides, the magnetic flux in the area between the two winding magnetic column groups on the top magnetic column and the bottom magnetic column is reduced, the risk of magnetic flux saturation is reduced, the thickness of the top magnetic column and the bottom magnetic column can be reduced, and the size can be reduced.

Description

Technical Field

[0001] The present application relates to the technical field of power conversion, and in particular to a magnetic integrated structure, a magnetic integrated device and a power supply device. Background Art

[0002] Magnetic integrated devices are widely used in power supply devices such as charging piles, rectifiers, and vehicle power supplies. The related art proposes a magnetic integrated device composed of multiple magnetic columns. In the related art, the magnetic integrated device has the problems of large core loss and large volume. Summary of the invention

[0003] The present application provides a magnetic integrated structure, a magnetic integrated device and a power supply device, which can reduce the core loss of the magnetic integrated device and reduce the volume of the magnetic integrated device.

[0004] In order to solve the above technical problems, the first technical solution provided by the present application is to provide a magnetic integrated structure, which includes a top magnetic column, a bottom magnetic column, at least one group of winding magnetic column groups and two side magnetic columns. The group of winding magnetic column groups includes two winding magnetic column groups, the winding magnetic column group is arranged between the top magnetic column and the bottom magnetic column, and the two winding magnetic column groups are arranged at intervals along the second direction; each of the side magnetic columns includes an upper magnetic column arranged at the end of the top magnetic column and a lower magnetic column arranged at the end of the bottom magnetic column, and a first air gap is provided between the upper magnetic column and the lower magnetic column of the same side magnetic column; the top magnetic column and / or the bottom magnetic column are provided with a second air gap, and the second air gap is located in the area between the two winding magnetic column groups.

[0005] In a possible implementation manner, the top magnetic column and the bottom magnetic resistance respectively include a plurality of sub-magnetic columns, the plurality of sub-magnetic columns are arranged along the second direction, the plurality of sub-magnetic columns are spliced, and the second air gap is provided between two adjacent sub-magnetic columns.

[0006] In a possible implementation manner, each of the top magnetic column and the bottom magnetic column includes two sub-magnetic columns.

[0007] In a possible implementation manner, the top magnetic column and the bottom magnetic column include an integrally formed sub-magnetic column, and a notch groove is provided on the sub-magnetic column to form the second air gap.

[0008] In a possible implementation, the top magnetic column, the bottom magnetic column, and the edge magnetic column are all made of magnetic material; the first air gap on the edge magnetic column, the top magnetic column, and the second air gap on the bottom magnetic column are all filled with an adhesive, and the magnetic permeability of the adhesive is less than the magnetic permeability of the magnetic material.

[0009] In a possible implementation, the adhesive includes one or more of glass bead glue, magnetic powder glue, and resin glue.

[0010] In a possible embodiment, the magnetic integrated structure includes a first magnetic core and a second magnetic core; each of the winding magnetic column groups includes a first winding magnetic column and a second winding magnetic column; the first magnetic core includes: a top magnetic column; an upper magnetic column, two of the upper magnetic columns are arranged on both sides of the top magnetic column; a first winding magnetic column, two adjacent first winding magnetic columns are arranged on the top magnetic column at intervals along the second direction; the second magnetic core includes: a bottom magnetic column; a lower magnetic column, two of the lower magnetic columns are arranged on both sides of the bottom magnetic column; a second winding magnetic column, two adjacent second winding magnetic columns are arranged on the bottom magnetic column at intervals along the second direction; wherein a first winding magnetic column and a second winding magnetic column are arranged opposite to each other to form the winding magnetic column group, and a third air gap is provided between the first winding magnetic column and the second winding magnetic column, and the third air gap is filled with an adhesive.

[0011] In a possible implementation manner, the first magnetic core and the second magnetic core have the same shape and size.

[0012] In a possible implementation, the sum of the magnetic resistance of one edge magnetic column, the magnetic resistance of the region from the edge magnetic column to the winding magnetic column group on the top magnetic column on one side of the edge magnetic column, and the magnetic resistance of the region from the edge magnetic column to the winding magnetic column group on the bottom magnetic column on the other side of the edge magnetic column is the first magnetic resistance; the sum of the magnetic resistance of the region between the two winding magnetic column groups on the top magnetic column and the magnetic resistance of the region between the two winding magnetic column groups on the bottom magnetic column is the second magnetic resistance, and the second magnetic resistance is greater than the first magnetic resistance.

[0013] In a possible implementation manner, the second magnetic resistance is twice the first magnetic resistance.

[0014] To solve the above problems, the second technical solution provided in the present application is to provide a magnetic integrated device, which includes a magnetic integrated structure, a first excitation coil and a second excitation coil; wherein the magnetic integrated structure is the above-mentioned magnetic integrated structure; the first excitation coil and the second excitation coil are respectively wound on the two winding magnetic column groups of the group of winding magnetic column groups.

[0015] In a possible implementation, the magnetic integrated device includes a PCB, the PCB is disposed between the top magnetic column and the bottom magnetic column, the winding magnetic column group passes through the PCB, and the first excitation coil and the second excitation coil are integrated on the PCB.

[0016] In a possible implementation, the PCB includes a first PCB and a second PCB, wherein the first PCB and the second PCB are arranged opposite to each other, the first PCB is close to the top magnetic column, and the second PCB is close to the bottom magnetic column; the winding magnetic column group passes through the first PCB and the second PCB.

[0017] In a possible implementation manner, the first excitation coil and the second excitation coil are integrated on the first PCB and the second PCB.

[0018] In order to solve the above problems, the third technical solution provided in the present application is to provide a power supply device, which includes the above-mentioned magnetic integrated device.

[0019] The beneficial effect is as follows: the present application provides a magnetic integrated structure, a magnetic integrated device and a power supply device. The edge magnetic column on the top magnetic column of the magnetic integrated structure and the edge magnetic column on the bottom magnetic column have a first air gap; the top magnetic column and / or the bottom magnetic column have a second air gap. As mentioned above, the second air gap is introduced in the area between the two winding magnetic column groups on the top magnetic column and the bottom magnetic column. The second air gap reduces the magnetic flux in the area between the two winding magnetic column groups on the top magnetic column and the bottom magnetic column, increases the magnetic flux of the edge magnetic column and the magnetic flux of other areas on the top magnetic column and the bottom magnetic column, and can reduce the magnetic flux difference of the magnetic integrated structure. On the other hand, the magnetic flux in the area between the two winding magnetic column groups on the top magnetic column and the bottom magnetic column becomes smaller, reducing the risk of magnetic flux saturation, and can reduce the thickness of the top magnetic column and the bottom magnetic column, which can reduce the volume of the magnetic integrated device. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the description of the embodiments are briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For those skilled in the art, other drawings can be obtained based on these drawings without creative work, among which:

[0021] Figure 1 It is a structural schematic diagram of a magnetic integrated structure in the prior art;

[0022] Figure 2 for Figure 1 Schematic diagram of magnetic flux of magnetic integrated structure;

[0023] Figure 3 This is a schematic structural diagram of an embodiment of the magnetic integrated structure of the present application;

[0024] Figure 4 for Figure 3 Schematic diagram of the transmission path of magnetic flux in the magnetic integrated structure;

[0025] Figure 5 for Figure 3 Schematic diagram of magnetic flux of top magnetic column of magnetic integrated structure;

[0026] Figure 6 for Figure 3 Schematic diagram of magnetic resistance and magnetic flux distribution on the magnetic integrated structure;

[0027] Figure 7 This is a schematic structural diagram of an embodiment of a magnetic integrated device of the present application. Description of the drawings:

[0029] 10 / 20, magnetic integrated structure; 11, magnetic core; 113, air gap; 21, top magnetic column; 22, bottom magnetic column; 112 / 210, winding magnetic column group; 23, first magnetic core; 24, second magnetic core; 111 / 25, side magnetic column; 211, upper magnetic column; 212, lower magnetic column; 220, first air gap; 230, second air gap; 240, third air gap; 201, first winding magnetic column; 202, second winding magnetic column; 260, first excitation coil magnetic column group; 261, first coil winding magnetic column; 262, second coil winding magnetic column; 270, second excitation coil magnetic column group; 271, third coil winding magnetic column; 272, fourth coil winding magnetic column; 30, magnetic integrated device; 31, first PCB; 32, second PCB. DETAILED DESCRIPTION

[0030] 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.

[0031] It should be noted that the terms "first" and "second" in this application are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of indicated technical features. Thus, the features defined as "first" and "second" can explicitly or implicitly include at least one of the features. In the description of this application, the meaning of "multiple" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined. In addition, the terms "including" and "having" and any of their variations are intended to cover non-exclusive inclusions. For example, a process, method, system, product or device that includes a series of steps or units is not limited to the listed steps or units, but optionally also includes steps or units that are not listed, or optionally also includes other steps or units inherent to these processes, methods, products or devices.

[0032] The magnetic integrated structure composed of two magnetic cores has a too large magnetic density in the area between the two winding magnetic columns, which can easily cause large core losses. In order to prevent the magnetic integrated structure from being locally oversaturated, the thickness of the bottom of the magnetic core needs to be thickened, which can easily cause the volume of the magnetic integrated structure to become larger.

[0033] Based on the above problems, the present application proposes a magnetic integrated structure, a magnetic integrated device and a power supply device. By making the top magnetic column and / or the bottom magnetic column of the magnetic integrated structure have a second air gap, and the second air gap is located in the area between the two winding magnetic column groups, the above technical problems can be effectively solved.

[0034] Among them, in the exemplary embodiments of the present application, the magnetic integrated structure is a magnetic integrated structure in a magnetic integrated transformer. In some other embodiments, the magnetic integrated structure can also be a magnetic integrated structure in other devices such as a magnetic integrated inductor, a magnetic integrated mutual inductor, a magnetic integrated magnetic amplifier, and a magnetic integrated solenoid valve.

[0035] See also Figure 1 , Figure 1 The figure is a schematic diagram of a magnetic integration structure in the prior art. The related art proposes a magnetic integration structure 10. The magnetic integration structure 10 includes two magnetic cores 11.

[0036] There are edge magnetic columns 111 and winding magnetic column groups 112 between the two magnetic cores 11. There are two winding magnetic column groups 112. A first excitation coil (not shown) is arranged on one winding magnetic column group 112, and a second excitation coil (not shown) is arranged on the other winding magnetic column group 112. In the magnetic integrated structure 10, the edge magnetic columns 111 of the two magnetic cores 11 have air gaps 113. The magnetic permeability of the glue in the air gap 113 is smaller than the magnetic permeability of the magnetic core 11, so that a large magnetic resistance is generated between the edge magnetic columns 111 of the two magnetic cores 11. The existence of magnetic resistance makes the magnetic flux of the magnetic core 11 in the magnetic integrated structure 10 between the edge magnetic columns 111 and the winding magnetic column group 112 smaller, and the magnetic flux of the top and bottom of the magnetic integrated structure 10 between the two winding magnetic column groups 112 is larger. Please refer to Figure 2 , Figure 2 for Figure 1 Schematic diagram of magnetic flux of magnetic integrated structure 10. Figure 2 As shown in the figure, the darker the color, the smaller the magnetic flux; the lighter the color, the larger the magnetic flux. It can be seen from the figure that the uneven magnetic flux of the magnetic integrated structure 10 makes the local magnetic density of the magnetic integrated structure 10 large, which easily causes the problem of large loss of the magnetic core 11 of the magnetic integrated structure 10, and because the local magnetic flux at the top and bottom of the magnetic integrated structure 10 is large, in order to reduce the risk of local saturation of the magnetic integrated structure 10, the thickness of the top and bottom of the magnetic integrated structure 10 needs to be increased, which will cause the volume of the magnetic integrated structure 10 to become larger, which is not conducive to the development trend of device miniaturization.

[0037] In order to solve the above technical problems, this application proposes a magnetic integration structure. Figure 3 , Figure 3 The schematic diagram of the structure of an embodiment of the magnetic integration structure of the present application is shown in FIG. In a specific embodiment, the magnetic integration structure 20 includes a top magnetic column 21 , a bottom magnetic column 22 , at least one group of winding magnetic columns 210 , and two side magnetic columns 25 .

[0038] The top magnetic column 21 and the bottom magnetic column 22 are arranged relatively spaced apart along the first direction m. At least one group of winding magnetic column groups 210 is arranged between the top magnetic column 21 and the bottom magnetic column 22, and one group of winding magnetic column groups 210 includes two winding magnetic column groups 210. The two winding magnetic column groups 210 are arranged spaced apart along the second direction n; each side magnetic column 25 includes an upper magnetic column 211 arranged at the end of the top magnetic column 21 and a lower magnetic column 212 arranged at the end of the bottom magnetic column 22, and a first air gap 220 is provided between the upper magnetic column 211 and the lower magnetic column 212 of the same side magnetic column 25; the top magnetic column 21 and / or the bottom magnetic column 22 are provided with a second air gap 230, and the second air gap 230 is located in the area between the two winding magnetic column groups 210.

[0039] In this embodiment, the magnetic integrated structure 20 includes a first magnetic core 23 and a second magnetic core 24. In order to clearly describe the structural position relationship, the direction of the line connecting the center point of the top magnetic column 21 and the center point of the bottom magnetic column 22 is defined as the first direction m, and the first magnetic core 23 and the second magnetic core 24 are arranged relatively along the first direction m. The first magnetic core 23 and the second magnetic core 24 act as conductors of magnetic flux to help guide and limit magnetic flux and form a magnetic flux loop. Among them, the two winding magnetic column groups 210 are respectively the first excitation coil magnetic column group 260 and the second excitation coil magnetic column group 270. The first excitation coil magnetic column group 260 includes a first coil winding magnetic column 261 located at the first magnetic core 23 and a second coil winding magnetic column 262 located at the second magnetic core 24. The first coil winding magnetic column 261 and the second coil winding magnetic column 262 are arranged at intervals along the first direction m. The first coil winding magnetic column 261 and the second coil winding magnetic column 262 are used to wind the first excitation coil. The second excitation coil magnetic column group 270 includes a third coil winding magnetic column 271 located on the second magnetic core 24 and a fourth coil winding magnetic column 272 located on the first magnetic core 23. The third coil winding magnetic column 271 and the fourth coil winding magnetic column 272 are used to wind the second excitation coil. The first excitation coil and the second excitation coil form magnetic fluxes in opposite directions in the upper and lower directions on the first excitation coil magnetic column group 260 and the second excitation coil magnetic column group 270 respectively. The two winding magnetic column groups 210 are arranged at intervals along the second direction n. Among them, the first magnetic core 23 is composed of a top magnetic column 21, an upper magnetic column 211 located on both sides of the top magnetic column 21, and a first coil winding magnetic column 261 and a fourth coil winding magnetic column 272 on the top magnetic column 21. The second magnetic core 24 is composed of a bottom magnetic column 22, a lower magnetic column 212 located on both sides of the bottom magnetic column 22, and a second coil winding magnetic column and a third coil winding magnetic column 271 on the bottom magnetic column 22.

[0040] The first excitation coil magnetic column group 260 is used to wind the first excitation coil, and the second excitation coil magnetic column group 270 is used to wind the second excitation coil. Figure 4 , Figure 4 for Figure 3 Schematic diagram of the transmission path of magnetic flux in the magnetic integrated structure 20. Figure 4 The solid line in the middle is a schematic diagram of the magnetic flux transmission path generated by the first excitation coil on the first excitation coil magnetic column group 260 on the left. Figure 4The middle dotted line is a schematic diagram of the magnetic flux transmission path generated by the second excitation coil on the second excitation coil magnetic column group 270 on the right. The transmission path of the magnetic flux in the magnetic integrated structure 20 is: the first excitation coil generates magnetic flux, and the magnetic flux is transmitted from the first excitation coil magnetic column group 260 to the top magnetic column 21. After the magnetic flux is transmitted to the top magnetic column 21, a part of it is transmitted to the side magnetic column 25 away from the second excitation coil magnetic column group 270 and returns to the first excitation coil magnetic column group 260, and the other part is transmitted on the top magnetic column 21 in the direction of the second excitation coil magnetic column group 270, and a part of it passes through the second excitation coil magnetic column group 270 and returns to the first excitation coil magnetic column group 260, and the other part passes through the side magnetic column 25 close to the second excitation coil magnetic column group 270 and returns to the first excitation coil magnetic column group 260. The second excitation coil also generates magnetic flux, which is transferred from the second excitation coil magnetic column group 270 to the bottom magnetic column 22. After the magnetic flux is transferred to the bottom magnetic column 22, a portion of it is transferred to the edge magnetic column 25 in the direction away from the first excitation coil magnetic column group 260 and returns to the second excitation coil magnetic column group 270, and another portion is transferred on the bottom magnetic column 22 toward the first excitation coil magnetic column group 260, and a portion of it passes through the first excitation coil magnetic column group 260 and then returns to the second excitation coil magnetic column group 270, and another portion passes through the edge magnetic column 25 close to the first excitation coil magnetic column group 260 and then returns to the second excitation coil magnetic column group 270. It can be seen from the above-mentioned magnetic flux transmission path that the magnetic flux of the magnetic integrated structure 20 in the area between the top magnetic column 21 and the bottom magnetic column 22 in the side magnetic column 25 and the winding magnetic column group 210 and the magnetic flux of the side magnetic column 25 are relatively small, and the magnetic flux of the magnetic integrated structure 20 in the area between the top magnetic column 21 and the bottom magnetic column 22 in the two winding magnetic column groups 210 is relatively large, and the magnetic integrated structure 20 has the problem of uneven magnetic flux. In addition, in the existing magnetic integrated structure 20, the side magnetic columns 25 are spliced, and the air gaps between the side magnetic columns 25 generate magnetic resistance, so the magnetic flux of the magnetic integrated structure 20 at the two side magnetic columns 25 becomes smaller, and the uneven magnetic flux easily causes the loss of the magnetic core of the magnetic integrated structure 20. In this embodiment, the top magnetic column 21 and / or the bottom magnetic column 22 is provided with a second air gap 230, and the second air gap 230 is located in the area between the two winding magnetic column groups 210. The second air gap 230 can generate magnetic resistance, thereby reducing the magnetic flux in the area between the two winding magnetic column groups 210 of the top magnetic column 21 and the bottom magnetic column 22, thereby reducing the magnetic flux difference of the magnetic integrated structure 20 and reducing the loss of the magnetic core of the magnetic integrated structure 20.

[0041] Different from the prior art, the present application provides a magnetic integrated structure 20, a magnetic integrated device and a power supply device. The top magnetic column 21 and / or the bottom magnetic column 22 of the magnetic integrated structure 20 are provided with a second air gap 230, and the second air gap 230 is located in the area between the two winding magnetic column groups 210. As mentioned above, the second air gap 230 reduces the magnetic flux in the area between the two winding magnetic column groups 210 on the top magnetic column 21 and the bottom magnetic column 22, increases the magnetic flux of the edge magnetic column 25 and the magnetic flux of other areas on the top magnetic column 21 and the bottom magnetic column 22, and can reduce the magnetic flux difference at various locations of the magnetic integrated structure 20. On the other hand, the magnetic flux in the area between the two winding magnetic column groups 210 on the top magnetic column 21 and the bottom magnetic column 22 becomes smaller, reducing the risk of magnetic flux saturation, and can reduce the thickness of the top magnetic column 21 and the bottom magnetic column 22, which can reduce the volume of the magnetic integrated device.

[0042] In some embodiments, the top magnetic column 21 and the bottom magnetic resistance respectively include a plurality of sub-magnetic columns, the plurality of sub-magnetic columns are arranged along the second direction, the plurality of sub-magnetic columns are spliced, and a second air gap 230 is provided between two adjacent sub-magnetic columns. Specifically, the second direction n is perpendicular to the first direction m. The second direction n on the top magnetic column 21 and the bottom magnetic column 22 is the direction of transfer of magnetic flux on the top magnetic column 21 and the bottom magnetic column 22. The plurality of sub-magnetic columns are arranged along the second direction n, so that the second air gap 230 between the sub-magnetic columns can block the transfer of magnetic flux on the top magnetic column 21 and the bottom magnetic column 22, and reduce the magnetic flux between the top magnetic column 21 and the bottom magnetic column 22 between the two winding magnetic column groups 210. In this embodiment, the top magnetic column 21 and the bottom magnetic column 22 are both composed of a plurality of sub-magnetic columns spliced ​​together. Among them, the top magnetic column 21 and the bottom magnetic column 22 can each be composed of two, three, or any other reasonable number of sub-magnetic columns. In some other embodiments, the top magnetic column 21 may be composed of a plurality of sub-magnetic columns, and the bottom magnetic column 22 may be a complete magnetic column. Or the top magnetic column 21 may be a complete magnetic column, and the bottom magnetic column 22 may be composed of a plurality of sub-magnetic columns.

[0043] In some embodiments, the top magnetic column 21 and the bottom magnetic column 22 each include two sub-magnetic columns. Specifically, the top magnetic column 21 and the bottom magnetic column 22 each consist of two sub-magnetic columns, which can not only generate magnetic resistance through the second air gap 230 to reduce the magnetic flux of the top magnetic column 21 and the bottom magnetic column 22, but also reduce the second air gap 230 between the top magnetic column 21 and the bottom magnetic column 22 as much as possible, thereby improving the integrity of the magnetic integrated structure 20.

[0044] In some embodiments, the top magnetic column 21 and the bottom magnetic column 22 include an integrally formed sub-magnetic column, and a notch groove is provided on the sub-magnetic column to form a second air gap 230. Specifically, in this embodiment, the top magnetic column 21 and the bottom magnetic column 22 are not formed by splicing sub-magnetic columns, and the top magnetic column 21 and the bottom magnetic column 22 are both integrally formed structures. The second air gap 230 is formed by forming a notch groove, which can improve the integrity of the magnetic integrated structure 20. In some other embodiments, one of the top magnetic column 21 and the bottom magnetic column 22 can also form the second air gap 230 by providing a notch groove, and the other of the top magnetic column 21 and the bottom magnetic column 22 can form the second air gap 230 by splicing sub-magnetic columns.

[0045] In some embodiments, the top magnetic column 21, the bottom magnetic column 22 and the side magnetic column 25 are all made of magnetic materials, and the first air gap 220 on the side magnetic column 25, the second air gap 230 on the top magnetic column 21 and the bottom magnetic column 22 are filled with a binder (not shown), and the magnetic permeability of the binder is less than the magnetic permeability of the magnetic material. Specifically, the materials used to make the first magnetic core 23 and the second magnetic core 24 may include magnetic materials such as ferrite, metal magnetic powder, and amorphous alloy. The binder may be glass bead glue, magnetic powder glue, resin glue, or low magnetic permeability magnetic material glue.

[0046] In some embodiments, the sum of the magnetic resistance of a side magnetic column 25, the magnetic resistance of the area from the side magnetic column 25 to the winding magnetic column group 210 on the top magnetic column 21 on one side of the side magnetic column 25, and the magnetic resistance of the area from the side magnetic column 25 to the winding magnetic column group 210 on the bottom magnetic column 22 on the other side of the side magnetic column 25 is the first magnetic resistance; the sum of the magnetic resistance of the area between the two winding magnetic column groups 210 on the top magnetic column 21 and the magnetic resistance of the area between the two winding magnetic column groups 210 on the bottom magnetic column 22 is the second magnetic resistance, and the second magnetic resistance is greater than the first magnetic resistance. Specifically, the magnetic resistance of the side magnetic column 25 specifically includes the magnetic resistance of the upper magnetic column 211 of the side magnetic column 25, the magnetic resistance of the lower magnetic column 212 of the side magnetic column 25, and the sum of the magnetic resistance generated by the first air gap 220 between the upper magnetic column 211 and the lower magnetic column 212. Two first magnetic resistances are generated on both sides of the magnetic integrated structure 20 in the second direction. The sum of the magnetic resistance of the area between the two winding magnetic column groups 210 on the top magnetic column 21 and the magnetic resistance of the area between the two winding magnetic column groups 210 on the bottom magnetic column 22 includes the magnetic resistance generated by the second air gap 230. The transmission path of the magnetic flux in the magnetic integrated structure 20 is: the first excitation coil generates magnetic flux, and the magnetic flux is transmitted from the first excitation coil magnetic column group 260 to the top magnetic column 21. After the magnetic flux is transmitted to the top magnetic column 21, a part of it is transmitted to the side magnetic column 25 away from the second excitation coil magnetic column group 270 and returns to the first excitation coil magnetic column group 260, and the other part is transmitted on the top magnetic column 21 in the direction of the second excitation coil magnetic column group 270, and a part of it passes through the second excitation coil magnetic column group 270 and returns to the first excitation coil magnetic column group 260, and the other part passes through the side magnetic column 25 close to the second excitation coil magnetic column group 270 and returns to the first excitation coil magnetic column group 260. The second excitation coil coil also generates magnetic flux, which is transferred from the second excitation coil magnetic column group 270 to the bottom magnetic column 22. After the magnetic flux is transferred to the bottom magnetic column 22, a part of it is transferred to the edge magnetic column 25 away from the first excitation coil magnetic column group 260 and returns to the second excitation coil magnetic column group 270, and the other part is transferred on the bottom magnetic column 22 toward the first excitation coil magnetic column group 260, and a part of it passes through the first excitation coil magnetic column group 260 and then returns to the second excitation coil magnetic column group 270, and the other part passes through the edge magnetic column 25 close to the first excitation coil magnetic column group 260 and then returns to the second excitation coil magnetic column group 270. It can be seen from the magnetic flux transfer path that when the first magnetic resistance and the second magnetic resistance exist and the first magnetic resistance and the second magnetic resistance are of the same size, although the magnetic flux in the area between the two winding magnetic column groups 210 on the top magnetic column 21 and the bottom magnetic column 22 of the magnetic integrated structure 20 becomes smaller due to the second air gap 230, the magnetic flux in the area between the two winding magnetic column groups 210 on the top magnetic column 21 and the bottom magnetic column 22 is still greater than the magnetic flux in the area of ​​the magnetic column 25 on the upper edge of the top magnetic column 21 and the bottom magnetic column 22.Only when the second magnetic resistance is greater than the first magnetic resistance, the magnetic flux in the area between the two winding magnetic column groups 210 on the top magnetic column 21 and the bottom magnetic column 22 can be equal to the magnetic flux in the area of ​​the upper edge magnetic column 25 of the top magnetic column 21 and the bottom magnetic column 22.

[0047] Further, in a preferred embodiment, the magnetic integrated structure 20 is a four-column magnetic integrated structure 20, and the second magnetic resistance is twice the first magnetic resistance. Figure 6 , Figure 6 for Figure 3 Schematic diagram of magnetic resistance and magnetic flux distribution on the magnetic integrated structure. In this embodiment, the first magnetic core 23 and the second magnetic core 24 have the same shape and size, the first excitation coil magnetic column group 260 and the second excitation coil magnetic column group 270 have the same number of coil turns, and the magnetic flux transfer path of the magnetic integrated structure 20 can be simplified as follows: Figure 6As shown. Since the first magnetic core 23 and the second magnetic core 24 have the same shape and size, and the number of coil turns of the first excitation coil magnetic column group 260 and the second excitation coil magnetic column group 270 are the same, the magnetic flux and magnetic resistance at the corresponding positions on the top magnetic column 21 and the bottom magnetic column 22 are the same, and the magnetic resistance of the top magnetic column 21 and the bottom magnetic column 22 in the area between the two side magnetic columns 25 and the winding magnetic column group 210 is defined as Rmd1, the magnetic resistance of the top magnetic column 21 and the bottom magnetic column 22 in the area between the two winding magnetic column groups 210 is Rmd2, and the magnetic resistance of the two side magnetic columns 25 is Rmb, wherein the magnetic resistance of the side magnetic column 25 includes the magnetic resistance of the upper magnetic column 211, the magnetic resistance of the lower magnetic column 212, and the sum of the magnetic resistance generated by the first air gap 220 between the upper magnetic column 211 and the lower magnetic column 212. Then Rmc1=Rmb+Rmd1*2; Rmc2=Rmd2*2. In the above formula, Rmc1 is the first magnetic resistance, and Rmc1 includes the magnetic resistance of a side magnetic column 25, the magnetic resistance of the area from the side magnetic column 25 to the winding magnetic column group 210 on the top magnetic column 21 on one side of the side magnetic column 25, and the magnetic resistance of the area from the side magnetic column 25 to the winding magnetic column group 210 on the bottom magnetic column 22 on the other side of the side magnetic column 25. The magnetic resistance of the side magnetic column 25 specifically includes the magnetic resistance of the upper magnetic column 211 of the side magnetic column 25, the magnetic resistance of the lower magnetic column 212 of the side magnetic column 25, and the sum of the magnetic resistance generated by the first air gap 220 between the upper magnetic column 211 and the lower magnetic column 212. There are two Rmc1 on both sides of the magnetic integrated structure 20 in the n direction. Rmc2 is the second magnetic resistance, and Rmc2 includes the sum of the magnetic resistance of the area between the two winding magnetic column groups 210 on the top magnetic column 21 and the magnetic resistance of the area between the two winding magnetic column groups 210 on the bottom magnetic column 22. The sum of the magnetic resistance of the area between the two winding magnetic column groups 210 on the top magnetic column 21 and the magnetic resistance of the area between the two winding magnetic column groups 210 on the bottom magnetic column 22 also includes the magnetic resistance generated by the second air gap 230. According to the expression of the magnetomotive force, there is a formula F = (N ÷ 2) * i; wherein F is the magnetomotive force of the magnetic integrated structure 20, N is the sum of the number of turns of the coil on the first excitation coil magnetic column group 260 and the coil on the second excitation coil magnetic column group 270, and i is the current passing through the coil. Then Figure 6 In the magnetic integrated structure 20, the magnetic flux calculation formula on the winding magnetic column group 210 is: It is the total magnetic flux independently generated by the excitation coil on any of the two winding magnetic column groups 210. The magnetic flux calculation formula of the area between the top magnetic column 21 or the upper edge magnetic column 25 of the bottom magnetic column 22 and the winding magnetic column group 210 is:

[0048]

[0049] The magnetic flux of the area between the upper edge magnetic column 25 of the top magnetic column 21 or the bottom magnetic column 22 and the winding magnetic column group 210. The magnetic flux calculation formula of the area between the two winding magnetic column groups 210 on the top magnetic column 21 or the bottom magnetic column 22 is: is the magnetic flux in the area between the two winding magnetic column groups 210 on the top magnetic column 21 or the bottom magnetic column 22. When the magnetic flux of the magnetic integrated structure 20 is uniform, there is Substitute the above formula and simplify it to get the formula: That is, 2Rmc1-Rmc2=0, then Rmc2=2Rmc1; that is, when the second magnetic resistance is twice that of the first magnetic column, the magnetic flux in the area between the two winding magnetic column groups 210 on the top magnetic column 21 and the bottom magnetic column 22 is the same as the magnetic flux in other areas on the top magnetic column 21 and the bottom magnetic column 22 and the magnetic flux of the edge magnetic column 25. Please refer to Figure 5 , Figure 5 for Figure 3 Schematic diagram of magnetic flux of the top magnetic column 21 of the magnetic integrated structure 20. Figure 5 As shown in the figure, it can be seen that the magnetic flux of the area between the two winding magnetic column groups 210 on the top magnetic column 21 of the magnetic integrated structure 20 is nearly equal to the magnetic flux of other areas of the top magnetic column 21 and the magnetic flux of the edge magnetic column 25. In this embodiment, the second magnetic resistance is twice the first magnetic resistance. In other embodiments, the second magnetic resistance is greater than the first magnetic resistance. The second magnetic resistance can also be 1.5 times, 1.8 times, or other reasonable multiples of the first magnetic resistance. The above-mentioned second magnetic resistance can also play a role in reducing the magnetic flux difference of the magnetic integrated structure 20.

[0050] In this embodiment, a winding magnetic column group 210 includes a first winding magnetic column 201 and a second winding magnetic column 202; two adjacent first winding magnetic columns 201 are arranged on the top magnetic column 21 at intervals along the second direction; two adjacent second winding magnetic columns 202 are arranged on the bottom magnetic column 22 at intervals along the second direction; a first winding magnetic column 201 and a second winding magnetic column 202 are arranged opposite to each other to form a winding magnetic column group 210, and the air gap between the first winding magnetic column 201 and the second winding magnetic column 202 forms a third magnetic resistance, and the third magnetic resistance is used to adjust the main inductance of the magnetic integrated structure 20.

[0051] In this embodiment, two side magnetic columns 25 and a group of winding magnetic column groups 210 are arranged on the top magnetic column 21 and the bottom magnetic column 22. The magnetic integrated structure 20 is a magnetic integrated structure 20 in the form of four columns. In other embodiments, the magnetic integrated structure 20 can also be provided with two groups, three groups, or other groups of winding magnetic column groups 210, wherein each group of winding magnetic column groups 210 includes two winding magnetic column groups 210, and each group of winding magnetic column groups 210 can be provided with coils with different numbers of turns, so that the magnetic integrated structure 20 can form magnetic motive forces of different sizes. In addition, when the magnetic integrated structure 20 is provided with multiple groups of winding magnetic column groups 210, the number of the second air gaps 230 on the top magnetic column 21 and / or the bottom magnetic column 22 can be multiple, and the area between any two winding magnetic column groups 210 on the top magnetic column 21 and / or the bottom magnetic column 22 can be provided with a second air gap 230.

[0052] In some embodiments, the first magnetic core 23 and the second magnetic core 24 have the same shape and size. Specifically, in the present embodiment, the top magnetic column 21 and the bottom magnetic column 22 are both in the shape of a rectangle, and the length of the top magnetic column 21 and the bottom magnetic column 22 in the second direction n and the thickness in the first direction m are the same. The side magnetic column 25 on the top magnetic column 21 and the side magnetic column 25 on the bottom magnetic column 22 are both in the shape of a rectangle, and the length and thickness of the side magnetic column 25 are the same. The first winding magnetic column on the top magnetic column 21 and the second winding magnetic column on the bottom magnetic column 22 are also in the shape of a rectangle and have the same size. In some other embodiments, the length and thickness of the top magnetic column 21 and the bottom magnetic column 22 may also be different. In addition, the length and thickness of the side magnetic column 25 on the top magnetic column 21 and the bottom magnetic column 22 may also be different, and the length and thickness of the first winding magnetic column and the second winding magnetic column may also be different.

[0053] In this embodiment, the second air gap 230 on the top magnetic column 21 and / or the bottom magnetic column 22 is centered between the two winding magnetic column groups 210. In other embodiments, the two second air gaps 230 may be arranged non-centered between the two winding magnetic column groups 210. That is, the second air gap 230 between the two winding magnetic column groups 210 may be close to the winding magnetic column group 210 on the left, or close to the winding magnetic column group 210 on the right.

[0054] In addition, in the present embodiment, the side magnetic pillars 25 on both sides of the magnetic integrated structure 20 are perpendicular to the top magnetic pillar 21 and the bottom magnetic pillar 22, that is, the angle between the side magnetic pillar 25 and the top magnetic pillar 21, and the angle between the side magnetic pillar 25 and the bottom magnetic pillar 22 are both 90 degrees. In some other embodiments, the side magnetic pillars 25 may not be perpendicular to the top magnetic pillar 21 and the bottom magnetic pillar 22, and the side magnetic pillars 25 may be rotated at a certain angle relative to the winding magnetic pillar group 210 and the top magnetic pillar 21. For example, the angle between the side magnetic pillar 25 and the top magnetic pillar 21, and the angle between the side magnetic pillar 25 and the bottom magnetic pillar 22 may also be 60 degrees, 80 degrees, 120 degrees, 100 degrees, or other reasonable angles.

[0055] In a specific application scenario, the length of the magnetic integrated structure 20 in the second direction n is 70 mm, the height in the first direction m is 30 mm, and the height in the third direction is 25 mm. Among them, the third direction is perpendicular to the first direction m, and the third direction is also perpendicular to the second direction n. The magnetic integrated structure 20 is the magnetic integrated structure 20 described in any of the above embodiments. The excitation current frequency of the magnetic integrated structure 20 is 250 kHz, and the magnetic material used to make the magnetic integrated structure 20 is DMR96A, which is a manganese-zinc ferrite material with high saturation magnetic induction intensity and low core loss. Among them, the peak value of the magnetic flux density of the magnetic integrated structure 20 is 0.15 Tesla. The magnetic integrated structure 20 is composed of a plurality of sub-magnetic columns spliced ​​together by the top magnetic column 21 and the bottom magnetic column 22, and the thickness of the top magnetic column 21 and the thickness of the bottom magnetic column 22 can be reduced from 6.5 mm to 5 mm. The cross-sectional area of ​​the magnetic integrated structure 20 in the first direction m can be reduced by about 23%, and the volume of the magnetic integrated structure 20 can be reduced by about 13.5%. Through the above, the core loss of the magnetic integrated structure 20 can be reduced by 40%.

[0056] Different from the prior art, the present application provides a magnetic integrated structure 20, a magnetic integrated device and a power supply device. The edge magnetic column 25 of the magnetic integrated structure 20 has a first air gap 220, and the top magnetic column 21 and / or the bottom magnetic column 22 are provided with a second air gap 230, and the second air gap 230 is located in the area between the two winding magnetic column groups 210. As mentioned above, the second air gap 230 is introduced in the area between the two winding magnetic column groups 210 on the top magnetic column 21 and the bottom magnetic column 22, and the second air gap 230 reduces the magnetic flux in the area between the two winding magnetic column groups 210 on the top magnetic column 21 and the bottom magnetic column 22, increases the magnetic flux of the edge magnetic column 25 and the magnetic flux of other areas on the top magnetic column 21 and the bottom magnetic column 22, and can reduce the magnetic flux difference of the magnetic integrated structure 20. On the other hand, the magnetic flux in the area between the two winding magnetic column groups 210 on the top magnetic column 21 and the bottom magnetic column 22 becomes smaller, reducing the risk of magnetic flux saturation, and the thickness of the top magnetic column 21 and the bottom magnetic column 22 can be thinned, which can reduce the volume of the magnetic integrated device.

[0057] Correspondingly, the present application also proposes a magnetic integrated device, which includes a magnetic integrated structure, a first excitation coil and a second excitation coil; wherein the magnetic integrated structure is the magnetic integrated structure described above; the first excitation coil and the second excitation coil are respectively wound on two winding magnetic column groups of a group of winding magnetic columns. In this embodiment, the magnetic integrated device is a magnetic integrated transformer. In some other embodiments, the magnetic integrated structure can also be other devices such as a magnetic integrated inductor, a magnetic integrated mutual inductor, a magnetic integrated magnetic amplifier, and a magnetic integrated solenoid valve.

[0058] In some embodiments, the magnetic integrated device includes a PCB, the PCB is arranged between the top magnetic column and the bottom magnetic column, the winding magnetic column group passes through the PCB, and the first excitation coil and the second excitation coil are integrated on the PCB. In this embodiment, the number of PCBs is one, and the first excitation coil and the second excitation coil are all integrated on the PCB.

[0059] In some other embodiments, see Figure 7 , Figure 7 It is a structural schematic diagram of an embodiment of the magnetic integrated device of the present application. In this embodiment, the PCB includes a first PCB31 and a second PCB32, wherein the first PCB31 and the second PCB32 are arranged opposite to each other, the first PCB31 is close to the top magnetic column, and the second PCB32 is close to the bottom magnetic column; the winding magnetic column group passes through the first PCB31 and the second PCB32. Among them, the first excitation coil and the second excitation coil are integrated on the first PCB31 and the second PCB32. Specifically, it can be: the first PCB31 and the second PCB32 are both integrated with the first excitation coil and the first secondary coil on the side of the first excitation coil magnetic column group, and the first excitation coil magnetic column group is wound by the first excitation coil and the first secondary coil. The first PCB31 and the second PCB32 are both integrated with the second excitation coil and the second secondary coil on the side of the second excitation coil magnetic column group, and the second excitation coil magnetic column group is wound by the second excitation coil and the second secondary coil. Among them, the two groups of first excitation coils on the first PCB31 and the second PCB32 are connected in parallel and have the same number of turns. The two groups of second excitation coils are connected in parallel and have the same number of turns. In some embodiments, the first excitation coil and the second excitation coil of the first PCB 31 and the second PCB 32 may also be connected in parallel or in series.

[0060] Correspondingly, the present application also proposes a power supply device, which includes the magnetic integrated device described in the above embodiment.

[0061] The above description is only an embodiment of the present application and does not limit the patent scope of the present application. Any equivalent structure or equivalent process transformation made using the contents of the present application specification and drawings, or directly or indirectly used in other related technical fields, are also included in the patent protection scope of the present application.

Claims

1. A magnetic integrated structure, characterized in that: The magnetic integrated structure comprises: A top magnetic column and a bottom magnetic column arranged relatively spaced apart along a first direction; At least one group of winding magnetic column groups, wherein the group of winding magnetic column groups includes two winding magnetic column groups, the winding magnetic column group is arranged between the top magnetic column and the bottom magnetic column, and the two winding magnetic column groups are arranged at intervals along the second direction; Two side magnetic pillars, each of the side magnetic pillars comprises an upper magnetic pillar arranged at the end of the top magnetic pillar and a lower magnetic pillar arranged at the end of the bottom magnetic pillar, and a first air gap is provided between the upper magnetic pillar and the lower magnetic pillar of the same side magnetic pillar; The top magnetic column and / or the bottom magnetic column is provided with a second air gap, and the second air gap is located in the area between the two winding magnetic column groups.

2. The magnetic integrated structure according to claim 1, characterized in that: The top magnetic column and the bottom magnetic resistor respectively include a plurality of sub-magnetic columns, the plurality of sub-magnetic columns are arranged along the second direction, the plurality of sub-magnetic columns are spliced, and the second air gap is provided between two adjacent sub-magnetic columns.

3. The magnetic integrated structure according to claim 2, characterized in that: The top magnetic column and the bottom magnetic column each include two sub-magnetic columns.

4. The magnetic integrated structure according to claim 1, characterized in that: The top magnetic column and the bottom magnetic column include an integrally formed sub-magnetic column, and a notch groove is arranged on the sub-magnetic column to form the second air gap.

5. The magnetic integrated structure according to claim 1, characterized in that: The top magnetic column, the bottom magnetic column and the side magnetic column are all made of magnetic material; The first air gap on the edge magnetic column, the top magnetic column, and the second air gap on the bottom magnetic column are all filled with an adhesive, and the magnetic permeability of the adhesive is less than the magnetic permeability of the magnetic material.

6. The magnetic integrated structure according to claim 5, characterized in that: The adhesive includes one or more of glass bead adhesive, magnetic powder adhesive and resin adhesive.

7. The magnetic integrated structure according to claim 1, characterized in that: The magnetic integrated structure includes a first magnetic core and a second magnetic core; each of the winding magnetic column groups includes a first winding magnetic column and a second winding magnetic column; The first magnetic core comprises: Top magnetic column; Upper magnetic pillars, two upper magnetic pillars are arranged on both sides of the top magnetic pillar; First winding magnetic columns, two adjacent first winding magnetic columns are arranged on the top magnetic column at intervals along the second direction; The second magnetic core comprises: Bottom magnetic column; Lower magnetic pillars, two lower magnetic pillars are arranged on both sides of the bottom magnetic pillar; A second winding magnetic column, two adjacent second winding magnetic columns are arranged on the bottom magnetic column at intervals along a second direction; Wherein, a first winding magnetic column and a second winding magnetic column are arranged opposite to each other to form the winding magnetic column group, a third air gap is provided between the first winding magnetic column and the second winding magnetic column, and the third air gap is filled with an adhesive.

8. The magnetic integrated structure according to claim 7, characterized in that: The first magnetic core and the second magnetic core have the same shape and size.

9. The magnetic integrated structure according to claim 8, characterized in that: The sum of the magnetic resistance of one edge magnetic column, the magnetic resistance of the region from the edge magnetic column to the winding magnetic column group on the top magnetic column on one side of the edge magnetic column, and the magnetic resistance of the region from the edge magnetic column to the winding magnetic column group on the bottom magnetic column on the other side of the edge magnetic column is the first magnetic resistance; the sum of the magnetic resistance of the region between the two winding magnetic column groups on the top magnetic column and the magnetic resistance of the region between the two winding magnetic column groups on the bottom magnetic column is the second magnetic resistance, and the second magnetic resistance is greater than the first magnetic resistance.

10. The magnetic integrated structure according to claim 9, characterized in that: The second magnetic resistance is twice the first magnetic resistance.

11. A magnetic integrated device, characterized in that: The magnetic integrated device includes a magnetic integrated structure, a first excitation coil and a second excitation coil; wherein the magnetic integrated structure is the magnetic integrated structure described in any one of claims 1 to 10; the first excitation coil and the second excitation coil are respectively wound on two of the winding magnetic column groups of the group of winding magnetic column groups.

12. The magnetic integrated device according to claim 11, characterized in that: The magnetic integrated device comprises a PCB, the PCB is arranged between the top magnetic column and the bottom magnetic column, the winding magnetic column group passes through the PCB, and the first excitation coil and the second excitation coil are integrated on the PCB.

13. The magnetic integrated device according to claim 12, characterized in that: The PCB includes a first PCB and a second PCB, wherein the first PCB and the second PCB are arranged opposite to each other, the first PCB is close to the top magnetic column, and the second PCB is close to the bottom magnetic column; the winding magnetic column group passes through the first PCB and the second PCB.

14. The magnetic integrated device according to claim 13, characterized in that: The first excitation coil and the second excitation coil are integrated on the first PCB and the second PCB.

15. A power supply device, characterized in that: The power supply device comprises the magnetic integrated device according to any one of claims 11-14.

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