Integrated magnetic component and LLC resonant converter

Abstract

The invention relates to an integrated magnetic component for a converter, comprising: at least one magnetic core element of a first type comprising a yoke and at least three legs, where a first total number of legs is defined as the number of legs of each of the at least one magnetic core element of the first type; at least one second type of magnetic core element comprising a yoke and at least three legs, where a second total number of legs is defined as a number of legs of each of the at least one second type of magnetic core element; wherein at least one magnetic core element of the first type and at least one magnetic core element of the second type are stacked one after the other in a stacking direction such that the legs are arranged in rows, a first total number of the legs and a second total number of the legs being the sum of the number of corresponding winding legs and the number of return legs, no electrical winding is wound around the return legs, and the first total number of legs and the second total number of legs are not equal. The invention also relates to a unidirectional LLC resonant converter and a bidirectional LLC resonant converter.

Description

Technical Field

[0001] The present invention relates to an integrated magnetic component and an LLC resonant converter, and in particular to a unidirectional LLC resonant converter and a bidirectional LLC resonant converter including an integrated magnetic component. Background Art

[0002] Conventionally, an integrated magnetic component comprising a plurality of magnetic core elements and its implementation in LLC (unidirectional or bidirectional) is known, for example, from EP 3 401 935 A1. Figure 5 a and Figure 5 As shown in FIG. 1 , this integrated magnetic component includes a single magnetic core having three stacked E-cores, wherein each E-core includes a flange (also commonly referred to as a “yoke” or “main body”) and three legs. In its implementation in an LLC converter, the top E-core and its electrical winding act as a choke, wherein the other two E-cores and their windings act as the primary and secondary sides of a transformer, respectively. In addition, its Fig.13 and Fig.14 A five-leg magnetic core arrangement is shown, which is also referred to as a "W-core".

[0003] CN 218182007 U also shows a transformer structure with multiple magnetic cores. Figure 5 a and Figure 5 In b, it is shown or Arrangement of multiple E cores.

[0004] However, conventional magnetic components have disadvantages. Previously known stacked E-core arrangements cannot be used for three-phase converters (each three-phase converter has currents with a 120° phase shift). Further, current imbalances and the magnetic flux imbalances they produce are not adequately compensated by the return legs. On the other hand, previously known stacked W-core arrangements for three-phase converters have the disadvantage of requiring expensive, large amounts of magnetic material as well as high volume and weight. Summary of the invention

[0005] The object of the present invention is to overcome these drawbacks. In particular, one object of the present invention is to provide an integrated magnetic component of reduced weight and volume, which is easy to assemble and cost-effective. Another object of the present invention is to provide a unidirectional or bidirectional LLC resonant converter of reduced weight and volume, which is easy to assemble and cost-effective, and in which current imbalance and magnetic flux imbalance are fully compensated, thereby improving both thermal efficiency and electrical / power efficiency and reducing losses, especially iron losses.

[0006] In particular, the solution of these objects is achieved by an integrated magnetic component according to claim 1 and below. The integrated magnetic component according to claim 1 and below is configured for use in a converter. The integrated magnetic component comprises at least one first type core element and at least one second type core element. At least one first type core element comprises a yoke and at least three legs, a first total number of legs being defined as the number of legs of each of the at least one first type core element. At least one second type core element comprises a yoke and at least three legs, a second total number of legs being defined as the number of legs of each of the at least one second type core element. At least one first type core element and at least one second type core element are stacked one after another in a stacking direction such that their legs are arranged in a row. The first total number of legs and the second total number of legs are each the sum of the number of corresponding winding legs around which an electrical winding is wound and the number of return legs around which no electrical winding is wound. The first total number of legs and the second total number of legs are not equal.

[0007] A yoke connects the legs of each core element, wherein the legs extend from one side of the yoke. A return leg, around which no winding is wound, together with the yoke closes a magnetic circuit created by the magnetic flux created by the windings of the winding legs.

[0008] In other words, in the integrated magnetic component at least two (at least one of the first type and at least one of the second type) magnetic core elements are stacked one after the other, wherein the two magnetic core elements have different total numbers of legs.

[0009] In the above and below, the term "integrated" with respect to an "integrated magnetic component" means that together with the windings, multiple functions of a converter or transformer are integrated with the magnetic core elements and the windings in the integrated magnetic component. For example, the first type of magnetic core element and the second type of magnetic core element together with appropriate windings may form part of a choke and a transformer.

[0010] For example, in one example, the two core elements can be in an EW or WE arrangement. Compared to the WW arrangement, the current imbalance is better compensated, resulting in lower losses and higher efficiency. In addition, the weight, volume and cost are reduced compared to the WW arrangement.

[0011] In some embodiments, more than the aforementioned at least one first type core element and at least one second type core element may be used. For example, at least one I core may be further inserted or arranged at the end of the stack of the aforementioned first and second type core elements. In addition, more than one first type core element and / or second type core element may be used. For example, the integrated magnetic component includes EIW, EWI, WEI, WIE, EWIE, WEIW, WIEW, EIWE, etc., as long as at least one first type and at least one second type with different numbers of legs are provided.

[0012] For illustration purposes, in an EW arrangement, an E core (a first type having a total of three legs) may form part of the primary side, while a W core (a second type having a total of five legs) may form part of the secondary side of the transformer (together with the windings). Here and hereinafter, when it is mentioned that a core element (or E core, W core, etc.) forms part of a choke or transformer (primary side, secondary side), this preferably refers to its magnetic flux. In some examples, the windings forming the primary side and the secondary side and thus insulated from each other may be arranged, for example, in a bifilar configuration. Thus, one core element may form part of the primary side and part of the secondary side in terms of the magnetic flux flowing therethrough.

[0013] In an exemplary three-phase arrangement, the E core will include three winding legs (three windings, each winding around a leg), and the W core will include three winding legs (three windings, each winding around a leg) and two return legs. The return legs of the W core advantageously compensate for the current imbalance, which also induces magnetic flux in the E core. In addition, by providing an EW instead of, for example, a WW, the weight, volume and cost of such magnetic components are reduced.

[0014] In particular, a first type of core element has more legs than a second type of core element and vice versa.The core element having more legs than the other core element advantageously provides compensation for current imbalance and magnetic flux.

[0015] In an advantageous embodiment, the number of winding legs of the first type core elements is equal to the number of winding legs of the second type core elements. For example, in a three-phase embodiment, each of the first type core elements and the second type core elements comprises three winding legs.

[0016] Advantageously, the number of return legs of the first type of core element is not equal to the number of return legs of the second type of core element. For example, in a three-phase EW arrangement, the first type of core element (E core) has no return legs (only winding legs) and the second type of core element (W core) has two return legs.

[0017] In some advantageous embodiments, the integrated magnetic component includes one first type magnetic core element and two second type magnetic core elements in sequence along the stacking direction, wherein the second second type magnetic core element of the two second type magnetic core elements is opposite to the first second type magnetic core element of the two second type magnetic core elements. An illustrative example of this situation is Another illustrative example of this is the EWW arrangement (or "EWM" arrangement for opposing second type core elements).

[0018] Here and hereinafter, the term "opposite", in particular "opposite in the stacking direction" means that the legs of one core element extend from the respective yoke of the core element opposite (with respect to the stacking direction) to the legs of the other core element extending from the yoke of the other core element. In a non-opposite arrangement, the legs of one core element extend in the same direction as the legs of the other core element with respect to the stacking direction. An illustrative example of "opposite" is arrangement, and an illustrative example of "not relative" is EE or Arrangement.

[0019] In some embodiments, the first total number of legs is three and the second total number of legs of each of the two second type core elements is five. This is also referred to as an EWW or EWM arrangement, where "WM" means that two W cores are opposite each other. Of course, at least one I core can be additionally inserted or arranged at the end of this exemplary arrangement. This configuration has the particular advantage that current imbalances can be particularly effectively compensated by the second type core elements, while also reducing the overall weight and size of the device by the first type core elements.

[0020] Preferably, the first type core element comprises three winding legs and no return legs. Each second type core element comprises three winding legs and two return legs. This embodiment is particularly suitable for a three-phase configuration.

[0021] Preferably, in the yoke extension direction perpendicular to the stacking direction, the winding legs of the second type of core element are the two outermost legs and the middle leg of the second type of core element. The winding legs and the return legs are arranged alternately along the yoke extension direction (i.e., in the yoke extension direction: winding leg, return leg, winding leg, return leg, winding leg). This has the particular advantage that cooling of the integrated magnetic component can be easily implemented on the outermost legs of the second type of core element (i.e., on its outer surface).

[0022] In a preferred alternative, the return legs of the second type of core element are the two outermost legs in the direction of yoke extension. The winding legs are the middle three legs of the second type of core element (i.e., in the direction of yoke extension: return leg, winding leg, winding leg, winding leg, return leg). This has the particular advantage that the electromagnetic field is shielded by the outer return legs and is prevented from extending far outside the integrated magnetic component, reducing undesirable EMI (electromagnetic interference).

[0023] In some embodiments, the first total number of legs is five and the second total number of legs is three. Of course, at least one I-core can be additionally inserted or arranged at the end of this exemplary arrangement. This configuration has the particular advantage that the second type core element reduces the overall weight and size of the device, while the first type core element also compensates for current imbalance.

[0024] Preferably, the first type core element comprises three winding legs and two return legs. Further, each second type core element comprises three winding legs and no return leg. This embodiment is particularly suitable for a three-phase configuration.

[0025] In a preferred embodiment, in the yoke extension direction perpendicular to the stacking direction, the winding legs of the first type of magnetic core element are the two outermost legs and the middle leg, and in particular the winding legs and the return legs are arranged alternately along the yoke extension direction (i.e., in the yoke extension direction: winding leg, return leg, winding leg, return leg, winding leg). This configuration has the particular advantage that cooling can be easily and effectively implemented on the outer surface of the first type of magnetic core element.

[0026] Preferably, in the yoke extension direction perpendicular to the stacking direction, the return legs of the first type of core element are the two outermost legs. The winding legs of the first type of core element are its three middle legs (i.e., in the yoke extension direction: return leg, winding leg, winding leg, winding leg, return leg). This has the particular advantage that the electromagnetic field is shielded by the outer return legs and is prevented from extending far outside the integrated magnetic component, reducing undesirable EMI (electromagnetic interference).

[0027] Preferably, the height of the first type magnetic core element along the extension direction of the yoke is smaller than the height of at least one second type magnetic core element. Therefore, the volume, size and cost of the integrated magnetic component can be further reduced.

[0028] Preferably, at least part of the winding legs of the first type core element and at least part of the winding legs of the second type core element are arranged in a colinear manner along the stacking direction and parallel to the stacking direction. For example, in one embodiment, the first type core element includes five legs, wherein the winding legs are the two outermost legs and the middle leg, and the second type core element each includes three legs (all winding legs). The size (especially the height) of the first type core element and the second type core element is such that their winding legs are colinear, i.e., on a line along the stacking direction. In addition, for example, the first type core element includes three legs, and the second type core element each includes five legs. In the example where the winding of the second type core element is on the two outermost legs and the middle leg, in the colinear arrangement, the size (especially their height) of the first type core element and the second type core element along the yoke extension direction is the same or similar, so that all the winding legs are colinear. In the example where the windings of the second type of core element are on three middle legs, in a collinear arrangement, the first type of core element (with three legs) is smaller in the yoke extension direction, in particular has a smaller height, so that all winding legs are collinear. These collinear examples have the particular advantage that the windings can be easily arranged in an integrated magnetic component.

[0029] In a preferred alternative, the two winding legs of the first type of core element and the two winding legs of the second type of core element are arranged non-collinearly along the stacking direction and parallel to the stacking direction, respectively. An illustrative example of this situation (especially compared with the collinear arrangement) is that the first type of core element includes a total of three legs, the second type of core element includes five legs, wherein the outermost legs and the middle legs of the five legs have windings, and the first type of core element is smaller in size than the second type of core element in the yoke extension direction, especially having a smaller height, so that the two outermost windings of the first type of core element are not collinear with the two outermost windings of the second type of core element. The middle windings of the first type of core element and the second type of core element are collinear. Further, the outermost windings of the first type of core element are preferably collinear with the return legs of the second type of core element. This configuration has the particular advantage that the weight and volume can be further reduced, especially due to the smaller height of the first type of core element, while also providing windings on the outermost legs of all core elements, so that cooling can be effectively implemented.

[0030] Preferably, in some embodiments, the winding of a first type core element is connected in series with the winding of a second type core element. In such examples, the first type core element and its winding are preferably part of a choke, and the second type core element and its winding are preferably part of the primary side and / or secondary side of a transformer.

[0031] Advantageously, with respect to the first type core element and the second type core element, the integrated magnetic component preferably comprises only one first type core element and two second type core elements as mentioned above. This configuration is preferably suitable for a unidirectional converter, which will be explained below.

[0032] Advantageously, in some embodiments, the integrated magnetic component further comprises another first type magnetic core element. The other first type magnetic core element is opposite to the above-mentioned first type magnetic core element (i.e., the aforementioned at least one first type magnetic core element) along the stacking direction. The two first type magnetic core elements sandwich the two second type magnetic core elements along the stacking direction. Examples of such a configuration include or Also as described above, one or more I-cores may be inserted or arranged at the ends of such a configuration in the stacking direction. Preferably, with respect to the first type core elements and the second type core elements, the integrated magnetic component comprises only two first type core elements and two second type core elements. Such a configuration is preferably suitable for a bidirectional converter, which will be described below.

[0033] Preferably, an air gap may be provided between one or more legs of opposing core elements, or between one or more legs of a core element and the yoke of another adjacent core element. In particular, the winding legs are separated by air gaps between the individual core elements. In some embodiments, all winding legs of a first type core element or a second type core element and adjacent yokes or adjacent winding legs of another adjacent first type core element or second type core element have air gaps between them. In some embodiments, a return leg of a first type core element or a second type core element and adjacent yokes or adjacent return legs of another adjacent first type core element or second type core element are not separated by an air gap.

[0034] The invention also relates to an LLC resonant converter comprising an integrated magnetic converter according to the aforementioned embodiments.

[0035] In particular, the present invention also relates to a unidirectional LLC resonant converter, which includes an input converter, an output converter and an integrated magnetic component, wherein the integrated magnetic component includes a first type magnetic core element and two second type magnetic core elements. The input converter is connected to the winding of the first type magnetic core element. The output converter is connected to the winding of the second second type magnetic core element in the stacking direction of the second type magnetic core element.

[0036] Preferably, in a unidirectional LLC resonant converter, the first type core element and its windings form part of a choke. The second type core element and its windings form part of the primary and secondary sides of a transformer. In other words, the first second type core element is part of the primary side of the transformer and the second second type core element is part of the secondary side of the transformer. Preferably, the windings of the first type core element are connected in series with the windings of the first second type core element (i.e., the primary side).

[0037] The present invention also relates to a bidirectional LLC resonant converter, which includes an input converter, an output converter and an integrated magnetic component, wherein the integrated magnetic component includes two first-type magnetic core elements and two second-type magnetic core elements. The input converter is connected to the winding of the first first-type magnetic core element along the stacking direction of the first-type magnetic core element, and the output converter is connected to the winding of the second first-type magnetic core element along the stacking direction of the first-type magnetic core element.

[0038] Preferably, in the bidirectional LLC resonant converter, the two first type core elements and their windings respectively constitute a part of a choke, and the second type core element and its windings constitute a part of the primary side and the secondary side of a transformer.

[0039] Therefore, the LLC resonant converter (unidirectional or bidirectional) has the aforementioned advantages of weight, volume and cost reduction, and in particular has high maximum power transfer and efficiency.

[0040] In particular, the LLC resonant converter (unidirectional or bidirectional) is a three-phase LLC converter.

[0041] It should be noted that the previously described embodiments of the E-core and the W-core are preferred embodiments. The above configurations can be correspondingly applied to cores having, for example, more than a total of five legs, wherein at least one first type and at least one second type have a different number of legs. For example, configurations with five-leg cores and six-leg cores or other multiples of two and three can be used. In addition, any number of the aforementioned configurations can be stacked along the aforementioned stacking direction, or additionally stacked in the yoke extension direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Further details, advantages and features of preferred embodiments of the present invention are described in detail with reference to the accompanying drawings.

[0043] Figure 1 A diagram showing an integrated magnetic component according to a first embodiment of the invention is shown.

[0044] Figure 2 A diagram showing an integrated magnetic component according to a second embodiment of the invention is shown.

[0045] Figure 3A diagram showing an integrated magnetic component according to a third embodiment of the present invention is shown.

[0046] Figure 4 A diagram showing an integrated magnetic component according to a fourth embodiment of the present invention is shown.

[0047] Figure 5 A view showing an integrated magnetic component according to a fifth embodiment of the present invention is shown.

[0048] Figure 6 A view showing an integrated magnetic component according to a sixth embodiment of the present invention is shown.

[0049] Figure 7 A view showing an integrated magnetic component according to a seventh embodiment of the present invention is shown.

[0050] Figure 8 A view showing an integrated magnetic component according to an eighth embodiment of the present invention is shown.

[0051] Fig. 9 A diagram showing a unidirectional LLC resonant converter according to a ninth embodiment of the present invention.

[0052] Fig.10 A diagram showing a unidirectional LLC resonant converter according to a tenth embodiment of the present invention.

[0053] Fig.11 A diagram showing a unidirectional LLC resonant converter according to an eleventh embodiment of the present invention.

[0054] Fig.12 A diagram showing a bidirectional LLC resonant converter according to a twelfth embodiment of the present invention.

[0055] Fig.13 A diagram showing a bidirectional LLC resonant converter according to a thirteenth embodiment of the present invention.

[0056] Fig.14 A diagram showing a bidirectional LLC resonant converter according to a fourteenth embodiment of the present invention.

[0057] Reference Mark List

[0058] 1Integrated magnetic components

[0059] 2. The first type of magnetic core element

[0060] 3. Second type of magnetic core element

[0061] 4 Yoke

[0062] 5 winding legs

[0063] 6 Return Leg

[0064] 7Electric winding

[0065] 8 Stacking direction

[0066] 9 Yoke extension direction

[0067] 10 Magnetic Flux

[0068] 11 Air Gap

[0069] 12 Height

[0070] 100 unidirectional LLC resonant converter

[0071] 101 Input Converter

[0072] 102 Output Converter

[0073] 110 Bidirectional LLC Resonant Converter DETAILED DESCRIPTION

[0074] First, before describing the configuration of the LLC resonant converters 100 , 110 of the present invention, the configuration of the integrated magnetic component 1 of the present invention will be described.

[0075] Figure 1 A view showing an integrated magnetic component 1 according to a first embodiment of the invention is shown.

[0076] The integrated magnetic component 1 of this embodiment comprises one first type magnetic core element 2 and two second type magnetic core elements 3. Further, the integrated magnetic component 1 comprises an electric winding 7. Here, the electric winding 7 is shown in a schematic cross-sectional manner.

[0077] The first type core element 2 comprises a yoke 4 and three legs 5. A first total number of legs 5 is defined as the number of legs 5 of the first type core element 2. The second type core elements 3 comprise a yoke 4 and five legs 5, 6, respectively. A second total number of legs 5, 6 is defined as the number of legs 5, 6 of each second type core element 3. The yoke 4 connects the legs 5, 6 of each core element 2, 3, wherein the legs 5, 6 extend from one side of the yoke 4.

[0078] As shown herein, one first type core element 2 and two second type core elements 3 are stacked on top of each other along a stacking direction 8 such that their legs 5, 6 are arranged in a row. Here, the second of the two second type core elements 3 is opposite to the first of the two second type core elements 3. This embodiment may also be referred to as an EWW or EWM configuration, where "M" means "opposite to W".

[0079] The first total number of legs 5 and the second total number of legs 5, 6 are each the sum of the number of corresponding winding legs 5 around which an electric winding 7 is wound and the number of return legs 6 around which no electric winding 7 is wound. The return legs 6 around which no winding 7 is wound, together with the yoke 4, close the magnetic circuit generated by the magnetic flux 10 generated by the winding 7 of the winding leg 5.

[0080] In this embodiment, the first total number of legs 5 is three, and the second total number of legs 5, 6 is five. Therefore, the first total number of legs 5 and the second total number of legs 5, 6 are not equal.

[0081] The number of winding legs 5 of the first type magnetic core element 2 and the number of winding legs 5 of the second type magnetic core element 3 are equal, specifically three.

[0082] The number of return legs 6 of the first type core element 2 and the number of return legs 6 of the second type core element 3 are not equal. Here, the first type core element 2 (E core) has no return legs 6 and the second type core element 3 (W core) has two return legs 6.

[0083] Further, here, in the yoke extension direction 9 perpendicular to the stacking direction 8, the winding legs 5 of the second type core element 3 are the two outermost legs 5 and the middle leg 5 of the second type core element 3. The winding legs 5 and the return legs 6 are arranged alternately along the yoke extension direction 9 (i.e., in the yoke extension direction: winding leg, return leg, winding leg, return leg, winding leg).

[0084] Furthermore, an air gap 11 is provided between all winding legs 5 of a core element 2, 3 and an adjacent yoke 4 or an adjacent winding leg 5 of another core element 2, 3. Preferably, the return legs 6 are not separated by an air gap 11.

[0085] As shown here, the electric windings 7 of the two second type core elements 3 span or surround the corresponding air gap 11. However, the electric windings 7 of the adjacent and opposite winding legs 5 of the two second type core elements 3 are separate electric windings 7, i.e., not directly electrically connected to each other, in other words, insulated from each other, thereby constituting the primary side and the secondary side of the transformer. Preferably, the windings 7 can be a bifilar arrangement, or can be provided, for example, layer by layer in the stacking direction 8 (i.e., alternating layers).

[0086] In addition, if Figure 1 As shown, all winding legs 5 of the first type core elements 2 and all winding legs 5 of the second type core elements 3 are arranged colinearly along the stacking direction 8 and parallel to the stacking direction 8 .

[0087] This exemplary configuration has the particular advantage that cooling of the integrated magnetic component 1 can be easily implemented on the outermost legs 5 of the second type magnetic core element 3 (i.e., on its outer surface), while providing three legs 5 for the first type magnetic core element 2, reducing the weight, volume and cost of the integrated magnetic component 1. In addition, Conversely configured, the magnetic flux 10 is compensated in the return legs 6 of the two second type core elements 3 so that current imbalances that may occur in a three-phase 120° phase-shifted current application can be balanced or compensated.

[0088] The exemplary configuration shown is particularly suitable for a unidirectional LLC resonant converter as shown below.

[0089] Figure 2 A view showing an integrated magnetic component 1 according to a second embodiment of the invention is shown.

[0090] Here, compared with the first embodiment, in the yoke extension direction 9 , the return legs 6 of the second type core element 3 are respectively the two outermost legs 6 (ie the top and the bottom).

[0091] Here, the winding legs 5 are the middle three legs 5 of the second type core element 3, so that these legs are arranged from top to bottom along the yoke extension direction as return leg 6, winding leg 5, winding leg 5, winding leg 5, return leg 6.

[0092] In addition to the foregoing, this embodiment has the particular advantage that the electromagnetic field is shielded by the outer return leg 6 and is prevented from extending far outside the integrated magnetic component 1, which reduces undesirable EMI (Electromagnetic Interference).

[0093] In addition, the two winding legs 5 of the first type core element 2 and the two winding legs 5 of the second type core element 3 are arranged non-collinearly along the stacking direction 8 and parallel to the stacking direction 8. The corresponding middle legs 5 as the winding legs 5 are arranged collinearly along the stacking direction 8 and parallel to the stacking direction 8. Further, the outermost winding legs 5 of the first type core element 2 are arranged collinearly with the outermost return legs 6 of the second type core element 3.

[0094] Figure 3 A view showing an integrated magnetic component 1 according to a third embodiment of the invention is shown. Figure 4 A view showing an integrated magnetic component 1 according to a fourth embodiment of the invention is shown.

[0095] Compared with the first and second embodiments, in the third and fourth embodiments, the height 12 of the first type core element 2 along the yoke extension direction 9 is smaller than the height of the two second type core elements 3 .

[0096] In the third embodiment, the winding legs 5 of the second type core element 3 are the middle three legs 5, and the return legs 6 are the two outermost legs 6. Due to the height 12 of the first type core element 2, the winding legs 5 of the first type core element 2 are collinear with the winding legs 5 of the second type core element 3. Therefore, particularly high EMI suppression and reduction in size, weight and volume can be achieved.

[0097] In the fourth embodiment, the winding legs 5 of the second type core element 3 are the two outermost legs 5 and the middle leg 5, with the return leg 6 located between them in the yoke extension direction 9. Therefore, the winding legs 5 of the first type core element 2 are colinear with the two return legs 6 and one (middle) winding leg 5 of the second type core element 3. Therefore, particularly effective cooling and reduction in size, weight and volume can be achieved.

[0098] Now, a configuration example in which the first total number of legs 5, 6 is five and the second total number of legs 5, 6 is three is described below. For example, this configuration is also referred to as Arrangement.

[0099] Figure 5 A view showing an integrated magnetic component 1 according to a fifth embodiment of the invention is shown. Figure 6 A view showing an integrated magnetic component 1 according to a sixth embodiment of the invention is shown.

[0100] In the fifth and sixth embodiments, the first type core element 2 includes five legs 5, 6, and the second type core element 3 includes three legs 5. In other words, the second type core element 3 does not include the return leg 6, but only the winding leg 5.

[0101] In the fifth embodiment, in the yoke extension direction 9, the winding legs 5 of the first type core element 2 are the two outermost legs 5 and the middle leg 5, and in particular, the winding legs 5 and the return legs 6 are alternately arranged along the yoke extension direction 9. This configuration has a particular advantage that cooling can be easily and effectively implemented on the outer surface of the first type core element 2, while by providing two E-core second type core elements 3, the size, weight and cost are advantageously reduced.

[0102] In the sixth embodiment, in the yoke extension direction 9, the return legs 6 of the first type core element 2 are the two outermost legs 6. The winding legs 5 of the first type core element 2 are the three middle legs 5 thereof.

[0103] Furthermore, in the fifth embodiment, all winding legs 5 are collinear. In the sixth embodiment, two winding legs 5 of the first type core element 2 are not collinear with two winding legs 5 of the second type core element 3 .

[0104] As will be discussed below, the aforementioned embodiments are particularly suitable for unidirectional LLC resonant converter configurations.In the following, embodiments of an integrated magnetic component 1 are discussed that are particularly suitable for bidirectional LLC resonant converter applications.

[0105] Figure 7 A view showing an integrated magnetic component 1 according to a seventh embodiment of the invention is shown. Figure 8 A view showing an integrated magnetic component 1 according to an eighth embodiment of the invention is shown.

[0106] In the seventh and eighth embodiments, the integrated magnetic component 1 further comprises another first type magnetic core element 2 .

[0107] Here, the other (or "second") first type magnetic core element 2 is opposite to the one (or "first") first type magnetic core element 2 along the stacking direction. The two first type magnetic core elements 2 sandwich the two second type magnetic core elements 3 along the stacking direction 8. This configuration is also called WEEW or

[0108] Figure 7 The seventh embodiment shown corresponds to Figure 5 The fifth embodiment shown has an additional first type magnetic core element 2 . Figure 8 The eighth embodiment shown corresponds to Figure 1 The first embodiment shown in FIG. 1 has an additional first type magnetic core element 2. It should be understood that any of the aforementioned embodiments can be combined with an additional first type magnetic core element 2, such as Figure 7 and Figure 8 shown.

[0109] In combination with the fifth and sixth embodiments, this configuration is also referred to as (or ).

[0110] Now, refer to Figures 9 to 14 The LLC resonant converter of the present invention using the aforementioned integrated magnetic component 1 is described. In these figures, the circuits of these LLC resonant converters are shown, as well as the inductor L rxx (result of the electrical winding 7 and the magnetic core elements 2, 3), capacitor C rxx (the subscript "r" stands for "resonance" or "resonance"), the primary winding 7 (P xx )、Secondary winding 7(S xx ) and air gap 11(g xxx ).

[0111] Fig. 9 A diagram showing a unidirectional LLC resonant converter 100 according to a ninth embodiment of the present invention is shown.

[0112] Fig.10 A diagram showing a unidirectional LLC resonant converter 100 according to a tenth embodiment of the present invention is shown. Fig.11 A diagram showing a unidirectional LLC resonant converter 100 according to an eleventh embodiment of the present invention.

[0113] The unidirectional LLC resonant converter 100 of the ninth to eleventh embodiments includes an input converter 101 , an output converter 102 , and an integrated magnetic component 1 . The integrated magnetic component 1 includes one first-type magnetic core element 2 and two second-type magnetic core elements 3 .

[0114] The input converter 101 is connected to the winding 7 of the one first type core element 2. The output converter 102 is connected to the winding 7 of the second second type core element 3 of the second type core elements 3 along the stacking direction 8.

[0115] Further, the electrical winding 7 of the first type core element 2 is connected in series with the electrical winding 7 of the first second type core element 3. Thus, the first type core element 2 with the winding 7 is part of a choke. The two second type core elements 3 are part of the primary and secondary sides of a transformer.

[0116] In other words, the first second type core element 3 is part of the primary side of the transformer and the second second type core element 3 is part of the secondary side of the transformer. With respect to the electrical winding 7 and the magnetic flux it generates, the first second type core element 3 is also part of the secondary side of the transformer and the second second type core element 3 is also part of the primary side of the transformer. The primary side and the secondary side of the transformer are electrically insulated from each other.

[0117] In the unidirectional LLC resonant converter 100 of the ninth embodiment, the integrated magnetic component 1 of the first embodiment is implemented.

[0118] In the unidirectional LLC resonant converter 100 of the tenth embodiment, the integrated magnetic component 1 of the fifth embodiment is implemented.

[0119] In the unidirectional LLC resonant converter 100 of the eleventh embodiment, the integrated magnetic component 1 of the third embodiment is implemented.

[0120] The above implementation examples of the unidirectional LLC resonant converter 100 are illustrative. The unidirectional LLC resonant converter 100 may adopt any one of the embodiments of the integrated magnetic component 1 , in particular the first to sixth embodiments.

[0121] Fig.12 A diagram showing a bidirectional LLC resonant converter 110 according to a twelfth embodiment of the present invention is shown. Fig.13 A diagram showing a bidirectional LLC resonant converter 110 according to a thirteenth embodiment of the present invention. Fig.14A diagram showing a bidirectional LLC resonant converter 110 according to a fourteenth embodiment of the present invention is shown.

[0122] The bidirectional LLC resonant converter 110 of the twelfth to fourteenth embodiments includes an input converter 101 , an output converter 102 , and an integrated magnetic component 1 . The integrated magnetic component 1 includes two first-type magnetic core elements 2 and two second-type magnetic core elements 3 .

[0123] Here, the input converter 101 is connected to the winding 7 of the first one of the first type core elements 2 in the stacking direction 8 , and the output converter 102 is connected to the winding 7 of the second one of the first type core elements in the stacking direction 8 .

[0124] Preferably, in the bidirectional LLC resonant converter 110 , both first type core elements 2 and their windings 7 are part of a choke, while the second type core element 3 is part of the transformer (primary and secondary sides thereof) of the converter 110 .

[0125] In the bidirectional LLC resonant converter 110 of the twelfth embodiment, the integrated magnetic component 1 of the first embodiment with an additional first type magnetic core element 2 is implemented.

[0126] In the bidirectional LLC resonant converter 110 of the thirteenth embodiment, the integrated magnetic component 1 of the third embodiment with an additional first type magnetic core element 2 is implemented.

[0127] In the bidirectional LLC resonant converter 110 of the fourteenth embodiment, the integrated magnetic component 1 of the seventh embodiment is implemented.

[0128] The foregoing implementation examples of the bidirectional LLC resonant converter 110 are illustrative. The bidirectional LLC resonant converter 110 may adopt any embodiment of the integrated magnetic component 1 , in particular the seventh and eighth embodiments, in particular with additional first type magnetic core elements 2 in the case of the first to sixth embodiments.

[0129] Thus, the LLC resonant converter 100, 110 (unidirectional or bidirectional) has the aforementioned advantages of weight, volume and cost reduction, in particular with high maximum power transfer and efficiency, and with easily achievable and effective cooling and reduced EMI.

[0130] In addition to the foregoing written instructions, explicit reference to Figures 1 to 14 , wherein these figures show in detail the circuit diagram and configuration examples of the present invention.

Claims

1. An integrated magnetic component (1) for a converter (100, 110), comprising: at least one first type core element (2) comprising a yoke (4) and at least three legs (5, 6), wherein a first total number of legs (5, 6) is defined as the number of legs (5, 6) of each first type core element (2) of the at least one first type core element (2); At least one second type magnetic core element (3) comprising a yoke (4) and at least three legs (5, 6), wherein a second total number of legs (5, 6) is defined as the number of legs (5, 6) of each second type magnetic core element (3) of the at least one second type magnetic core element (3); The at least one first type magnetic core element (2) and the at least one second type magnetic core element (3) are stacked one after the other in a stacking direction (8) such that the legs (5, 6) of the at least one first type magnetic core element (2) and the at least one second type magnetic core element (3) are arranged in a row, The first total number of legs (5, 6) and the second total number of legs (5, 6) are each the sum of the number of corresponding winding legs (5) around which an electric winding (7) is wound and the number of return legs (6) around which no electric winding (7) is wound, and The first total number of legs (5, 6) and the second total number of legs (5, 6) are not equal.

2. An integrated magnetic component (1) according to claim 1, wherein the number of winding legs (5) of the first type of magnetic core element (2) is equal to the number of winding legs (5) of the second type of magnetic core element (3), and the number of return legs (6) of the first type of magnetic core element (2) is not equal to the number of return legs (6) of the second type of magnetic core element (3).

3. An integrated magnetic component (1) according to claim 1, wherein the integrated magnetic component (1) comprises a first type magnetic core element (2) and two second type magnetic core elements (3) in sequence along the stacking direction (8), wherein the second second type magnetic core element (3) of the two second type magnetic core elements (3) is opposite to the first second type magnetic core element (3) of the two second type magnetic core elements (3).

4. An integrated magnetic component (1) according to claim 3, wherein a first total number of the legs (5, 6) is three and a second total number of the legs (5, 6) of each of the two second type core elements (3) is five.

5. An integrated magnetic component (1) according to claim 4, wherein the first type core element (2) comprises three winding legs (5) and no return legs (6), and each of the second type core elements (3) comprises three winding legs (5) and two return legs (6).

6. An integrated magnetic component (1) according to claim 5, wherein in a yoke extension direction (9) perpendicular to the stacking direction (8), the winding legs (5) of the second type of magnetic core element (3) are two outermost legs (5) and a middle leg (5), and the winding legs (5) and the return legs (6) of the second type of magnetic core element (3) are alternately arranged along the yoke extension direction (9).

7. An integrated magnetic component (1) according to claim 5, wherein in a yoke extension direction (9) perpendicular to the stacking direction (8), the return legs (6) of the second type core element (3) are the two outermost legs (6).

8. An integrated magnetic component (1) according to claim 3, wherein the first total number of the legs (5, 6) is five, the second total number of the legs (5, 6) is three, wherein the first type of core element (2) includes three winding legs (5) and two return legs (6), and each of the second type of core elements (3) includes three winding legs (5) and no return legs (6).

9. The integrated magnetic component (1) according to claim 8, wherein in a yoke extension direction (9) perpendicular to the stacking direction (8), the first type magnetic core element (2) is configured as one of the following: The winding legs (5) of the first type magnetic core element (2) are two outermost legs (5) and a middle leg (5), and the winding legs (5) and the return legs (6) of the first type magnetic core element (2) are alternately arranged along the yoke extension direction (9); or The return legs (6) of the first type magnetic core element (2) are the two outermost legs (6).

10. An integrated magnetic component (1) according to claim 3, wherein at least part of the winding legs (5) of the first type of magnetic core element (2) and at least part of the winding legs (5) of the second type of magnetic core element (3) are arranged collinearly along the stacking direction (8) and parallel to the stacking direction (8).

11. The integrated magnetic component (1) according to claim 3 further includes another first type magnetic core element (2), wherein the other first type magnetic core element (2) is opposite to the one first type magnetic core element (2) along the stacking direction (8), and wherein the two first type magnetic core elements (2) sandwich the two second type magnetic core elements (3) along the stacking direction (8).

12. The integrated magnetic component (1) according to claim 1, wherein a winding (7) of a first type of magnetic core element (2) is connected in series with a winding (7) of a second type of magnetic core element (3).

13. An integrated magnetic component (1) according to claim 1, wherein there is an air gap (11) between all winding legs (5) of the first type magnetic core element (2) or the second type magnetic core element (3) and the adjacent yoke (4) or adjacent winding legs (5) of another adjacent first type magnetic core element (2) or the second type magnetic core element (3).

14. An integrated magnetic component (1) according to claim 1, wherein the return leg (6) of the first type magnetic core element (2) or the second type magnetic core element (3) and the adjacent yoke (4) or adjacent return leg (6) of another adjacent first type magnetic core element (2) or the second type magnetic core element (3) are not separated by an air gap (11).

15. A unidirectional LLC resonant converter (100), comprising an input converter (101), an output converter (102) and an integrated magnetic component (1) according to claim 4, wherein the integrated magnetic component (1) comprises a first type magnetic core element (2), wherein the input converter (101) is connected to the winding (7) of the first type magnetic core element (2), and the output converter (102) is connected to the winding (7) of the second second type magnetic core element (3) in the second type magnetic core element (3) along the stacking direction (8).

16. The unidirectional LLC resonant converter (100) of claim 15, wherein the first type core element (2) and its winding (7) constitute part of a choke, and the second type core element (3) and its winding (7) constitute part of the primary side and the secondary side of a transformer.

17. A bidirectional LLC resonant converter (110), comprising an input converter (101), an output converter (102) and an integrated magnetic component (1) according to claim 11, wherein the input converter (101) is connected to the winding (7) of the first first type of magnetic core element (2) in the first type of magnetic core element (2) along the stacking direction (8), and the output converter (102) is connected to the winding (7) of the second first type of magnetic core element (2) in the first type of magnetic core element (2) along the stacking direction (8).

18. The bidirectional LLC resonant converter (110) according to claim 17, wherein the two first-type core elements (2) and their windings (7) respectively constitute a part of a choke, and the second-type core element (3) and its windings (7) constitute a part of the primary side and the secondary side of a transformer.

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