Novel planar PCB (printed circuit board) integrated transformer

Abstract

A planar integrated transformer structure is presented. The transformer structure may include a top core, a bottom core, and one or more center posts interposed between the top core and the bottom core. The transformer structure may also include a transformer including a primary winding and a secondary winding, each of the primary winding and the secondary winding surrounding at least one of the one or more center posts. One of the primary winding or the secondary winding may be configured to function as an inductor. At least one of the one or more center posts may be shared between the transformer and the inductor.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 483,418, filed on February 6, 2023, entitled “NOVEL PLANAR PCB INTEGRATED TRANSFORMERS,” the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates to novel planar printed circuit board (PCB) integrated transformers. Background Art

[0004] PCB-based transformers can be used for low-power applications and signal processing applications. These transformers utilize PCB technology to achieve low-cost windings. Conventional PCB transformers can use discrete components. In most magnetic-based power converter topologies (such as LC resonant converters), discrete resonant inductors are typically required. There are journal publications on integrated transformer structures (for example, as listed below), but such structures do not address the problem of stray magnetic fields (whether from magnetic structures or passive shielding). 1. M. D'Antonio, S. Chakraborty, and A. Khaligh, "Planar Transformer With Asymmetric Integrated Leakage Inductance Using Horizontal Air Gap" (IEEE Transactions on Power Electronics, vol. 36, no. 12, pp. 14014-14028, Dec. 2021, doi: 10.1109 / TPEL.2021.3089606). Summary of the Invention

[0005] The embodiments disclosed herein each have several aspects, no single one of which is solely responsible for the desirable attributes of the present disclosure. Without limiting the scope of the present disclosure, its more salient features will now be briefly discussed. After considering this discussion, and particularly after reading the section entitled "Detailed Description," one will be able to understand how the features of the embodiments described herein provide advantages over existing transformers.

[0006] One aspect is an integrated magnetic structure comprising a top core, a bottom core, one or more pillars interposed between the top core and the bottom core, an inductor portion, and a transformer, the inductor portion comprising a center pillar, a first portion of a primary winding, and a first portion of a secondary winding, the center pillar being distinct from and spaced apart from the one or more pillars, the transformer being integrated with the inductor portion by sharing a pillar from the one or more pillars.

[0007] In the above integrated magnetic structure, the transformer includes a second portion of the primary winding and a second portion of the secondary winding.

[0008] In the above integrated magnetic structure, the second portion of the primary winding and the second portion of the secondary winding vertically overlap each other.

[0009] In the above integrated magnetic structure, the primary winding surrounds the secondary winding.

[0010] In the above integrated magnetic structure, at least one of the primary winding or the secondary winding includes an interleaved winding structure.

[0011] In the above integrated magnetic structure, the center post is vertically disposed at a central position of the bottom core of the inductor portion.

[0012] In the above integrated magnetic structure, the one or more columns, the transformer, the inductor portion and the central column are arranged in a fully enclosed housing.

[0013] In the above integrated magnetic structure, a flux shaping air gap is formed on each of the one or more legs and the center leg.

[0014] In the above integrated magnetic structure, the flux shaping air gap is formed on the central post.

[0015] In the above integrated magnetic structure, two or more symmetrical air gaps are formed on the inductor portion.

[0016] In the above integrated magnetic structure, the integrated magnetic structure further comprises a metal shielding plate disposed adjacent to the one or more pillars and configured to at least partially shield a stray magnetic field.

[0017] Another aspect is an integrated magnetic structure that includes a top core, a bottom core, one or more legs interposed between the top and bottom cores, an inductor portion including a center leg and a flux shaping plate disposed on top of the center leg, and a transformer integrated with the inductor portion by sharing one or more legs.

[0018] In the above integrated magnetic structure, the inductor portion further includes a first portion of the primary winding and a first portion of the secondary winding.

[0019] In the above integrated magnetic structure, the transformer includes a second portion of the primary winding and a second portion of the secondary winding.

[0020] In the above integrated magnetic structure, the primary winding surrounds the secondary winding.

[0021] In the above integrated magnetic structure, the second portion of the primary winding and the second portion of the secondary winding vertically overlap each other.

[0022] In the above integrated magnetic structure, a flux shaping air gap is formed on each of the one or more legs and the center leg.

[0023] In the above integrated magnetic structure, the flux shaping air gap is formed on the central post.

[0024] On the other hand, an integrated magnetic structure includes a top core, a bottom core, one or more pillars interposed between the top core and the bottom core, an inductor portion, and a transformer, wherein the top core includes a first portion and a second portion, the first portion and the second portion of the top core being arranged at different heights, the inductor portion includes a center pillar, a first portion of a primary winding, and a first portion of a secondary winding, the center pillar being different from and spaced apart from the one or more pillars, the transformer being arranged between the second portion of the top core and the bottom core, the transformer including a second portion of the primary winding and a second portion of the secondary winding.

[0025] In the above integrated magnetic structure, a flux shaping air gap is formed on each of the one or more legs and the center leg.

[0026] In the above integrated magnetic structure, the flux shaping air gap is formed on the central post.

[0027] In the above integrated magnetic structure, a first portion of the top core is disposed on top of the transformer, and wherein a second portion of the top core is disposed on top of the inductor portion.

[0028] Any feature of one aspect is applicable to all aspects described herein. In addition, any feature of one aspect can be independently combined with other aspects described herein in part or in whole in any manner. For example, one, two, three or more aspects can be combined in whole or in part. In addition, any feature of one aspect can become an optional feature of other aspects. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The above and other features of the present disclosure will become more apparent from the following description and the appended claims, taken in conjunction with the accompanying drawings. It should be understood that these drawings depict only several embodiments according to the present disclosure and should not be considered as limiting the scope thereof, and therefore the present disclosure will be described with additional specificity and detail using the accompanying drawings.

[0030] Figure 1A-1C The diagram shows a Litz-based transformer and inductor.

[0031] Figure 2A A non-planar magnetic structure is illustrated.

[0032] Figure 2B An example of a planar magnetic structure according to some embodiments is illustrated.

[0033] Figure 3A Another example of a non-planar magnetic structure is illustrated.

[0034] Figure 3B Another example of a planar magnetic structure according to some embodiments is illustrated.

[0035] Figure 4A A circuit model in which a transformer and an inductor have discrete structures is illustrated.

[0036] Figure 4B A circuit model in which a transformer and an inductor are partially integrated is illustrated according to some embodiments.

[0037] Figure 5 An example of an integrated transformer structure according to some embodiments is illustrated.

[0038] Figure 6A An example of a fully enclosed tank core integrated planar structure is illustrated in accordance with some embodiments.

[0039] Figure 6B A comparison graph is shown, where a discrete transformer / inductor section is compared to an integrated transformer.

[0040] Figure 6C Another example of a fully enclosed tank core integrated planar structure according to some embodiments is illustrated.

[0041] Figure 6D The diagram illustrates a method according to some embodiments Figure 6A or Figure 6C Perspective view of the fully enclosed tank core integrated planar structure.

[0042] Figure 6E Illustrates the near field reduction in a can core structure compared to an EE core structure according to some embodiments.

[0043] Figure 6F The figure shows the current density distribution of the closed pot core structure without flux shaping plates.

[0044] Figure 6G The figure shows the current density distribution of the closed pot core structure with flux shaping plates.

[0045] Figure 7AAn example of a hybrid tank core integrated planar structure is illustrated in accordance with some embodiments.

[0046] Figure 7B Another example of a hybrid tank core integrated planar structure is illustrated in accordance with some embodiments.

[0047] Figure 8A The concept of core laminations to minimize eddy currents is illustrated.

[0048] Figure 8B Illustrated are example structures to improve flux density sharing in a split core by using an air gap on the center leg in the magnetizing flux path, in accordance with some embodiments.

[0049] Figure 8C Illustrated is an example structure to improve magnetic flux density sharing in a split core by using consistent bond line thickness control in each laminated core, in accordance with some embodiments.

[0050] Figure 8D Examples of alternative structures are shown.

[0051] Figure 9A Illustrated is a high current termination in a non-planar magnetic component with wire windings.

[0052] Figure 9B Illustrated is a high current termination in a non-planar magnetic component with busbar windings.

[0053] Figure 9C and Figure 9D The diagram shows an example of low-loss, high-current PCB winding termination.

[0054] Figure 10A The diagram shows the PCB winding terminations (input and output) arranged side by side.

[0055] Figure 10B Shown are overlapping PCB winding terminations (input and output).

[0056] Figure 11A and Figure 11B A fully enclosed tank core integrated planar structure is illustrated according to some embodiments.

[0057] Figures 12A-12E An open EE 3-leg structure with or without flux shaping is illustrated according to some embodiments.

[0058] Figure 12F Illustration of simulation results for inductive losses in an adjacent metal heat sink.

[0059] Figure 13A An open EE 4-leg structure without flux shaping is illustrated in accordance with some embodiments.

[0060] Figure 13B An open EE 4-leg structure with flux shaping and symmetrical air gap is illustrated in accordance with some embodiments.

[0061] Figure 13C An open EE 4-leg structure with flux shaping and asymmetric air gap is illustrated in accordance with some embodiments.

[0062] Figure 14 Illustrated is near-field reduction in an open EE core structure with metal shielding according to some embodiments.

[0063] Figure 15A An example of an EE core structure with metal shielding according to some embodiments is illustrated.

[0064] Figure 15B An example of a metal shielding application according to some embodiments is illustrated.

[0065] Figure 15B Another example of an EE core structure with metal shielding according to some embodiments is illustrated.

[0066] Figures 16A-16D The diagram illustrates the concept of a partially interleaved winding structure between two power stages.

[0067] Figure 16E Pictured Figure 16C An example of the induced current density distribution for a winding structure without winding interleaving between two stages is shown.

[0068] Figure 16F Pictured Figure 16D An example of the induced current density distribution of a partially interleaved winding structure with winding interleaving between two stages is shown.

[0069] By referring to the detailed description below, the embodiments of the present disclosure and its advantages can be best understood. It should be understood that the same reference numerals are used to identify the same elements illustrated in one or more figures, wherein the illustrations therein are for illustrating embodiments of the present disclosure, not for limiting the present disclosure. DETAILED DESCRIPTION

[0070] Various embodiments of a novel planar PCB integrated transformer are provided herein. Magnetic components such as inductors and transformers typically include a conductor (e.g., winding) wound around a magnetic core. They come in many shapes and sizes and can be used for different functions (voltage conversion, isolation, electromagnetic interference (EMI) mitigation, etc.). Various embodiments provide novel planar PCB integrated transformer structures that use PCB traces as transformer windings to achieve low profile and high power density for high-frequency power converter applications. Planar structures are typically less expensive than wire-wound structures, and the planar structure can significantly reduce supply chain constraints by reducing the number of unique suppliers for assembling magnetic components from, for example, 6+ to about 1-2.

[0071] Examples of integrated transformer structures can include inductors integrated into the transformer structure. The integration of the inductor and transformer results in reduced winding losses and footprint compared to using discrete inductors and transformers. These structures offer the flexibility to locate the inductor entirely on the primary or secondary side. Furthermore, some structures offer the flexibility to distribute the inductance symmetrically or asymmetrically across both the primary and secondary windings. The proposed integrated transformer structures also include flux shaping features to minimize conduction losses.

[0072] Various embodiments can be used for onboard chargers in electric vehicles, stationary storage, powerwalls, megapacks, battery chargers, or autonomous driving hardware. Any power electronic converter that requires isolation / voltage step ratio and / or energy storage requires magnetic components. Various embodiments cover all different concepts / structures that can be used for any power converter designed for any of the above applications. In some embodiments, the core structure can be made of magnetic materials such as ferrite and powder cores.

[0073] High power, high frequency applications lead to large sized integrated transformer structures. Such high power integrated transformer structures may require lamination of the core to minimize eddy current losses in the core. Splitting the core can be used for high power integrated transformer structures, however, these split cores may present technical challenges in terms of flux density distribution between the various core split structures. As disclosed herein, some embodiments can improve the flux density distribution between different split cores. For example, by providing an air gap in the center column, the flux density distribution can be improved. As another example, by providing a uniform bond line thickness between the top core half and the bottom core half, the flux density distribution can be improved.

[0074] Integrated transformer structures can potentially generate significant stray magnetic fields, which can cause electromagnetic compatibility (EMC) issues with nearby components. To address these deficiencies, the present disclosure provides various integrated inductor and transformer structures that can confine strong magnetic fields within the core structure while minimizing the stray fields that exist. The present disclosure also provides other structures with metal shielding covers. Various embodiments can provide novel shielding structures to minimize the near field from a planar transformer structure with an integrated resonant inductor.

[0075] Various embodiments provide novel winding design techniques that overlap incoming and outgoing current-carrying PCB traces of the same winding to minimize stray field / termination losses. Various embodiments also provide the concept of overlapping windings from parallel power converter stages to achieve flux cancellation and reduce losses in the heat sink and / or reduce the overall footprint.

[0076] According to various embodiments, power converters designed using high-power planar magnetics can significantly increase power capabilities at a lower cost. Some embodiments can completely remove a portion of the supply chain (e.g., suppliers who assemble different components (such as cores, windings, bobbins, etc.) to manufacture transformers / inductors). This is crucial for achieving high-volume production rates at a lower cost.

[0077] Various embodiments may also provide manufacturing improvements. For example, LV termination using bolted connections requiring stringent micro-resistance measurements has proven challenging, but using planar magnetics, conductors on a PCB can be directly integrated into the PCB (e.g., a printed circuit board assembly (PCBA)).

[0078] Various embodiments provide a fully enclosed tank core integrated planar structure that minimizes stray magnetic fields compared to an open EE core structure. Various embodiments also provide a hybrid tank core integrated planar structure that further reduces weight and cost compared to a fully enclosed tank core structure while maintaining the benefits of minimized stray magnetic fields.

[0079] Various embodiments provide a closed can core structure (e.g., a fully closed can core integrated planar structure) that can include a smaller number of PCB layers than other structures with overlapping winding sections, in which resonant inductors can be integrated and distributed. Various embodiments provide an open EE core structure that can include a 3-leg open EE core and a 4-leg open EE core structure. The 3-leg open EE core structure can minimize core size and footprint. Compared to the 3-leg open EE core structure, the 4-leg open EE core structure can have lower stray fields and can also provide integrated resonant inductors that are symmetrically / asymmetrically distributed on the primary or secondary side.

[0080] Figure 1A-1CHigh frequency power magnetic components such as Litz based transformers and inductors are shown. Specifically, Figures 1A to 1C A conventional DCDC (DC to DC) converter and charger including an inductor and a transformer is shown, which can be used in various applications such as electric vehicles and chargers. For example, Figure 1A A DCDC converter is illustrated which may include a transformer and an inductor. Figure 1B The charger is shown to include a transformer and an inductor. Figure 1C An example of a DCDC converter that may include a transformer and an inductor is illustrated.

[0081] Conventional converters and / or chargers utilize Litz wire-based magnetics (transformers and inductors), which can provide low losses in certain frequency ranges (such as the 100kHz-500kHz frequency range) and low proximity / skin effect losses in Litz wire. However, there can be some technical challenges, including higher cost, high thermal resistance in the core and windings, limited supply chain (e.g., limited qualified Litz wire suppliers), power density (typically the highest component in the converter), and / or winding termination complexity / loss (high current Litz wire termination).

[0082] Figure 2A An example of an exploded view of a conventional non-planar magnetic structure 200 is shown. Typically, a non-planar magnetic structure 200 (such as a Litz wire-based magnetic element) may have a large number of parts, which may lead to a complex manufacturing assembly process. For example, the non-planar magnetic structure 200 may include a housing 202, a core 204, windings 206, 208, terminals 210, and a bobbin 212.

[0083] Figure 2B An example of a planar magnetic structure 250 according to some embodiments is shown. Compared to a non-planar magnetic structure 200 (e.g., a magnetic element based on Litz wire), a planar magnetic structure 250 can generally include a relatively small number of components and can eliminate the complexity of the manufacturing process, such as termination and winding. For example, the planar magnetic structure 250 can include a core 252, an insulator 254, and a PCB winding 256. Thus, the windings 206, 208, terminals 210, and bobbins 212 included in the conventional non-planar magnetic structure 200 can be integrated into the PCB winding 256 of the planar magnetic structure 250.

[0084] Figure 3AAnother example of a non-planar magnetic structure 300 is shown. In some embodiments, non-planar magnetic structure 300 may include non-planar magnetic structure 302, thin film capacitor 304, PCB 306, transistor (e.g., MOSFET) 308, thermal interface material 310, heat sink base 312, and heat sink 314. Figure 3B 3 shows another example of a planar magnetic structure 350 according to some embodiments. In some embodiments, the planar magnetic structure 350 may include non-planar magnetic structures 352A / 352B, a thin film capacitor 354, a PCB 356, a transistor (e.g., a MOSFET) 358, a thermal interface material 360, a heat sink base 362, and a heat sink 364. Figure 3A and Figure 3B As shown, the height of the non-planar magnetic structure 302 may be higher than the height of the planar magnetic structures 352A / 352B.

[0085] Figure 4A 4 shows a schematic diagram of a conventional discrete transformer and inductor 400. For example, the discrete transformer and inductor 400 may include an inductor 402, a transformer 404, and a capacitor 406. Figure 4A In the example shown, each of the inductor 402 and the transformer 404 may be discrete components. Figure 4B 4 shows a schematic diagram of an example of an integrated magnetic component 450 according to some embodiments. For example, the inductor 402 and the transformer 404 can be integrated into a component 408 (eg, an integrated magnetic), such as Figure 4B shown.

[0086] Figure 5 Examples of various integrated transformer structures 500 according to some embodiments are shown. The integrated transformer structure 500 may include a closed pot core structure 510 and an open EE core structure 520. The closed pot core structure 510 may include a pot core structure with or without flux shaping 512 (Example 1; see, for example, Figure 6A and Figure 6C ). The closed pot core structure 510 may also include a hybrid pot core structure plus EE core structure with or without flux shaping 514 (Example 2; see, for example, Figure 7A and Figure 7B ). The closed pot core structure 510 may also include a closed 5-leg pot core structure with or without flux shaping 516 (Example 3; FIG. 11 ). The open EE core structure 520 may include an open EE 3-leg with flux shaping 522 (Example 4; see, for example, Figures 12A-12E ). The open EE core structure 520 may also include an open EE 4-leg with or without flux shaping, having a resonant inductance independent distributed symmetric / asymmetric structure 524 (Example 5; see, for example, Figures 13A-13C ).

[0087] Figure 6A An example of a fully enclosed tank core integrated planar structure according to some embodiments is shown. Figure 6A , the inductor air gap 620 can be enclosed within the magnetic body 610 to provide minimal stray fields. Figure 6A An example of a fully enclosed tank core integrated planar structure 600 is illustrated in accordance with some embodiments. Figure 6A The closed can core integrated planar structure 600 does not include a flux shaping plate. In some embodiments, the closed can core integrated planar structure 600 may include an inductor portion 630 and a transformer portion 640. The inductor portion 630 may have an EE structure that may include a first side 632, a second side 634, and a core center column 636. In some examples, the core center column 636 may be disposed between the first side 632 and the second side 634. In some examples, the first side 632 and the second side 634 may surround the center column 636. In some embodiments, the first side 632 may include multiple layers of primary windings 638A (e.g., a first portion of the primary winding), and the second side 634 may include multiple layers of secondary windings 638B (e.g., a first portion of the secondary winding). The present disclosure is not limited to the above and Figure 6A The number of layers of each primary winding and secondary winding is shown. In some embodiments, the first side 632 can include a first portion of the primary winding 638A, and the second side 634 can include a first portion of the secondary winding 638B. The transformer portion 640 can include a second portion of the primary winding 638C and a second portion of the secondary winding 638D. In some embodiments, the second portion of the primary winding 638C and the second portion of the secondary winding 638D can be arranged vertically relative to each other. For example, as shown below Figure 6D As described, the primary winding can surround the inductor portion 630 and the transformer portion 640. A first portion of the primary winding can be disposed on the inductor portion 630 (e.g., the first side 632), and a second portion of the primary winding can be disposed on the transformer portion 640. Additionally, the secondary winding can surround the transformer portion 640. In this integrated planar structure (e.g., the transformer portion 640 and the inductor portion 630 can be integrated), a first portion of the secondary winding can be disposed on the inductor portion 630 (e.g., the second side 634), and a second portion of the secondary winding can be disposed on the transformer portion 640. In some embodiments, one or more posts 650 can be interposed between the top core 610A and the bottom core 610B. For example, as Figure 6A As shown, the posts 650, 650A may be interposed between the top cores 610A and 610B. Figure 6A As further shown, at least one of the one or more legs 650 (eg, leg 650A) may be shared between the inductor portion 630 and the transformer portion 640 .

[0088] like Figure 6A As shown, the magnetic body 610 may include a top core 610A and a bottom core 610B. The inductor portion 630 and the transformer portion 640 may be surrounded by the top core 610A, the bottom core 610B and the column 650 (as shown in FIG. Figure 6B In some embodiments, the inductor portion 630, the transformer portion 640, the center column 636 and the other columns ( Figure 6B 650) shown can be vertically positioned on top of the bottom core 610B and below the top core 610A.

[0089] Figure 6B A comparative diagram is shown in which a conventional discrete transformer / inductor structure 500 is compared to an integrated transformer 600. Figure 6B , the discrete transformer / inductor structure 500 may include discrete components of a transformer 502 and an inductor 504. Figure 6B As shown, the discrete transformer / inductor structure 500 may include three windings, while the integrated transformer 600 may include two windings because the inductor windings may be shared with the primary windings of the transformer portion of the integrated transformer 600. Furthermore, the discrete transformer / inductor structure 500 may include six legs (e.g., legs 550, 550A, and 550B), while the integrated transformer 600 may include four legs (e.g., legs 650 and 650A) because a shared leg (e.g., 650A) may be used between the inductor portion 630 and the transformer portion 640 of the integrated transformer 600. Consequently, the integrated transformer 600 may be more cost-effective to manufacture and operate than the discrete transformer / inductor structure 500.

[0090] Figure 6C Another example of a fully enclosed tank core integrated planar structure 650 is shown in FIG. Figure 6C , the inductor air gap 620 can be enclosed within the magnetic body 610 to achieve minimum stray fields. Figure 6B The closed tank core integrated planar structure 650 may include a flux shaping plate 670 disposed on a central column 660 . Figure 6CThe closed can core integrated planar structure 650 may include a flux shaping plate 670. In some embodiments, the closed can core integrated planar structure 650 may include an inductor portion 630 and a transformer portion 640. The inductor portion 630 may have an EE structure that may include a first side 632, a second side 634, and a core center column 660. In some examples, the core center column 660 may be disposed between the first side 632 and the second side 634. In some examples, the first side 632 and the second side 634 surround the center column 636. In some embodiments, the first side 632 may include multiple layers of a first portion of the primary winding 638A, and the second side 634 may include multiple layers of a first portion of the secondary winding 638B. However, the present disclosure is not limited to the above and Figure 6C The number of layers of each primary winding and secondary winding shown. In some embodiments, the transformer portion 640 may include a second portion of the primary winding 638C and a second portion of the secondary winding 638D. In some embodiments, the second portion of the primary winding 638C and the second portion of the secondary winding 638D may be vertically disposed relative to each other. In some embodiments, the inductor portion 630 may include a flux shaping plate 670. The flux shaping plate 670 may be disposed on top of the core center column 660. In some examples, the width of the flux shaping plate 670 may be greater than the width of the core center column 660. In some embodiments, an air gap 620 may be formed between the top of the flux shaping plate 670 and the magnetic body 610. In some examples, symmetrical air gaps may be formed in the first side 632 and the second side 634. In some embodiments, one or more columns 650 may be interposed between the top core 610A and the bottom core 610B. For example, as Figure 6A As shown, the posts 650, 650A may be interposed between the top cores 610A and 610B. Figure 6A As further shown, at least one of the one or more legs 650 (eg, leg 650A) may be shared between the inductor portion 630 and the transformer portion 640 .

[0091] Figure 6D The diagram illustrates a method according to some embodiments Figure 6A or Figure 6C A perspective view of the fully enclosed tank core integrated planar structure. Figure 6D Not shown, but Figure 6D The fully enclosed tank core integrated planar structure may include a flux shaping plate.

[0092] like Figure 6D As shown, in some embodiments, at least one of the closed tank core integrated planar structures 600 or 650 ( Figure 6D, a planar structure 600 (illustrated) may include an inductor portion (side) 630 and a transformer portion (side) 640, which may be integrated into a single structure 600 to have shared windings (e.g., a primary winding 638A and a secondary winding 638B). The windings 638A, 638B in the inductor portion 630 and the transformer portion 640 may at least partially overlap vertically with each other. For example, in the inductor portion 630, the primary winding 638A and the secondary winding 638B may overlap at portion 639A. Additionally, in the transformer portion 640, the primary winding 638A and the secondary winding 638B may overlap at a portion of 639B. In some embodiments, at portion 639B, portions of the primary winding 638A and portions of the secondary winding 638B may be stacked together such that portions of the primary winding 638A may be interposed between two layers of portions of the secondary winding 638B. In some embodiments, each of the primary winding 638A and the primary winding 638B can function as an inductor, and the combination of the primary winding and the secondary winding 638A can function as a transformer. In these embodiments, at least a portion of the primary winding can be disposed below or above the secondary winding 638B, such that at least a portion of the primary winding 638A can vertically overlap the secondary winding 638B (e.g., see FIG. Figure 6D In some embodiments, the secondary winding 638B can function as an inductor, and the combination of the primary winding 638A and the secondary winding 638B can function as a transformer. In these embodiments, at least a portion of the secondary winding 638B can be positioned below or above the primary winding such that at least a portion of the secondary winding 638B vertically overlaps the primary winding 638A. The description of this paragraph applies to at least Figure 7A 、 Figure 7B 、 Figure 8A 、 Figure 8C 、 Figure 8D 、 Figures 12B-12E or Figures 13A-13C Note that FIG11 shows at least a portion of the flux shaping plate vertically overlapping the primary and secondary windings, while the primary and secondary windings do not overlap each other.

[0093] Figure 6E The diagram shows the respective Figure 6A and Figure 6C The magnetic near fields of the EE core and the tank core structure are shown in Fig. Figure 6E , compared with traditional inductor and transformer structures, closed pot core structures (such as Figure 6E ) can provide near-field reduction.

[0094] Figure 6F The current density distribution of the closed pot core structure 600 without flux shaping (or flux shaping plates) is illustrated. Figure 6G The improved current density distribution of the closed pot core structure 650 which may include flux shaping (or flux shaping plates) is illustrated, which results in a minimum winding loss distribution. Figure 6F and Figure 6G The closed pot core structure with flux shaping plates can reduce winding losses. Table 1 shows the core loss and conduction loss of the straight inductor column structure 600 and the integrated planar structure with flux shaping 650.

[0095] Table 1

[0096] Core loss Conduction loss Straight inductor column (600) 1x 1.28 times With flux shaping plate (650) 1.1 times 1x

[0097] Figure 7A and Figure 7B Illustrated are example hybrid can-core integrated planar structures 700 and 750 according to some embodiments. The hybrid can-core integrated planar structures 700 and 750 may have a closed can-core structure on the inductor side and an open EE or EI structure on the transformer side. Figure 7A An example hybrid tank core integrated planar structure 700 is illustrated, in accordance with some embodiments. The hybrid tank core integrated planar structure 700 may include a flux shaping plate 670 .

[0098] In some embodiments, as Figure 7A As shown in the hybrid tank core integrated planar structure 700, the height of the transformer 640 can be reduced, so that the height of the transformer portion 640 can be less than the height of the inductor portion 630. For example, each of the inductor portion 630 and the transformer portion 640 can each include an inductor portion top core 610CC and a transformer portion top core 610AA. The transformer top core 610AA can be placed at a lower position than the inductor top core 610CC. Figure 7A The hybrid tank core integrated planar structure 700 may include a flux shaping plate 670. In some embodiments, the closed tank core integrated planar structure 650 may include an inductor portion 630 and a transformer portion 640. The inductor portion 630 may have an EE structure that may include a first side 632, a second side 634, and a core center column 660. In some examples, the core center column 660 may be disposed between the first side 632 and the second side 634. In some examples, the first side 632 and the second side 634 may surround the center column 636. In some embodiments, the first side 632 may include multiple layers of a first portion of the primary winding 638A, and the second side 634 may include multiple layers of a first portion of the secondary winding 638B. The present disclosure is not limited to the above and Figure 7AThe number of layers of each primary winding and secondary winding shown. In some embodiments, the transformer portion 640 may include a second portion of the primary winding 638C and a second portion of the secondary winding 638D. In some embodiments, the second portion of the primary winding 638C and the second portion of the secondary winding 638D may be arranged vertically. In some embodiments, the inductor portion 630 may include a flux shaping plate 670. The flux shaping plate 670 may be arranged on top of the core center column 660. In some examples, the width of the flux shaping plate 670 may be greater than the width of the core center column 660. In some embodiments, an air gap 620 may be formed between the top of the flux shaping plate 670 and the magnetic body 610. In some embodiments, the inductor portion 630, the transformer portion 640, the center column 660 and the other columns ( Figure 6B 650) can be vertically positioned on top of the bottom core 610B and below the top cores 610A and 610C. In some embodiments, one or more columns 650A-650C can be interposed between the top cores 610AA / 610CC and the bottom core 610B. For example, Figure 7A As shown, pillar 650B can be interposed between top cores 610AA and 610B. Additionally, pillars 650A and 650C can be interposed between top core 610CC and bottom core 610B of inductor portion 630. Figure 6A As further shown, leg 650A may be shared between the inductor portion 630 and the transformer portion 640 .

[0099] Figure 7B Another example of a hybrid tank core integrated planar structure 750 according to some embodiments is shown. The hybrid tank core integrated planar structure 750 can be formed from the example hybrid tank core integrated planar structure 700 to form a modified structure. For example, by removing the column 650B (e.g., Figure 7A ) and the top core of the transformer portion 610AA (as Figure 7B As shown), and adjusting the size of the bottom core 610B to the width of the top core 610CC of the inductor portion 630, a hybrid tank core integrated planar structure 750 can be formed from the hybrid tank core integrated planar structure 700. Figure 7B As further shown, the hybrid tank core integrated planar structure 750 can include a flux shaping plate 670 located on top of the center post 660. These hybrid structures 700 and 750 can minimize the weight / cost of the transformer core while minimizing the impact on the near field.

[0100] Figure 8A The concept of core laminations that minimize eddy currents is illustrated. For example, without a split, the eddy current core loss of a core can be 1.8 times greater than that of a design with two splits. Meanwhile, the core loss of a single split can be 1.4 times greater than that of a design with two splits. Figure 8A The core split shown is only an example, and the present disclosure is not limited thereto. For example, three or more splits (four or more cores) are also possible.

[0101] Figure 8B Illustrated is an example structure 800 to improve magnetic flux density sharing in split cores by controlling the reluctance of each split core using an air gap on the center leg, in accordance with some embodiments. Figure 8C An example structure 850 is illustrated that improves magnetic flux density sharing in a split core by using consistent bond line thickness control, according to some embodiments. Figure 8B and Figure 8C The example structures 800 and 850 can minimize the magnetic flux density sharing problem in the split core structure.

[0102] In some embodiments, as Figure 8B As shown, Figure 8B In the integrated planar structure 800 , the pillar 650A shared between the transformer portion 640 and the inductor portion 630 may include a flux shaping air gap 810 . Figure 8B The integrated planar structure 800 may include a flux shaping plate 670. In some embodiments, the closed-can core integrated planar structure 650 may include an inductor portion 630 and a transformer portion 640. The inductor portion 630 may have an EE structure that may include a first side 632, a second side 634, and a core center leg 660. In some examples, the core center leg 660 may be disposed between the first side 632 and the second side 634. In some examples, the first side 632 and the second side 634 may surround the center leg 636. In some embodiments, the first side 632 may include multiple layers of a first portion of the primary winding 638A, and the second side 634 may include multiple layers of a first portion of the secondary winding 638B. The present disclosure is not limited to a specific number of layers for each primary and secondary winding. The transformer portion 640 may include a second portion of the primary winding 638C and a second portion of the secondary winding 638D. In some embodiments, the inductor portion 630 may include a flux shaping plate 670. In some embodiments, the second portion of the primary winding 638C and the second portion of the secondary winding 638D can be arranged vertically. The flux shaping plate 670 can be arranged on top of the core center column 660. In some examples, the width of the flux shaping plate 670 can be greater than the width of the core center column 660. In some embodiments, the air gap 620 can be filled between the top of the flux shaping plate 670 and the magnetic body 610. In some embodiments, as shown in FIG. Figure 8C As described, columns 650 and 650A may include flux shaping air gaps 810. In some embodiments, as Figure 8DAs described above, the transformer portion 840 may be interposed between the two portions 830A, 830B of the inductor portion 830. In some embodiments, as Figure 8D As further described, the pillar 850A may be shared between a portion of the inductor portion 830A and the transformer portion 840 and between another portion of the inductor portion 830B and the transformer portion 840. In some embodiments, as shown in FIG. Figure 8D Further described, each of pillars 850A and 850B may include an air gap 855 .

[0103] Figure 9A Illustrated is a conventional high current termination in a planar magnetic component with wire windings. Figure 9A Conventional composite wire welding in a wire winding is shown. Figure 9B Illustration of conventional high current termination in a planar magnetic component with busbar windings. Figure 9B Showing a dangerous bolted joint in a busbar winding. Figure 9C and Figure 9D An example low-loss PCB winding termination according to some embodiments is shown. Figure 9C and Figure 9D The terminal 950 can be integrated into a portion of the PCB winding, which simplifies the manufacturing process and reduces the extra loss of termination (eg, welding). Figure 9C and Figure 9D In the structure of , the input and output terminals can overlap at 930, which can reduce AC winding losses at high frequencies due to stray magnetic field cancellation.

[0104] Figure 10A The diagram shows the winding terminations (input and output) side by side. Figure 10B Illustrated are overlapping winding terminations (input and output) according to some embodiments. Figure 10B The overlapping winding terminations shown in can significantly reduce current density hot spots and reduce AC winding losses.

[0105] Figure 11A and Figure 11B A fully enclosed tank core integrated planar structure 1100 is illustrated, according to some embodiments. Figure 11A and Figure 11B may include two inductor sections 630A and 630B (e.g., Figure 6C 950A). For example, inductor portions 630A and 630B may be integrated into structure 1100 by sharing pillar 950A. Figure 11A It is a side view of the fully enclosed tank core integrated planar structure 1100. Figure 11Bis a perspective view of a fully enclosed can core integrated planar structure 1100. In these embodiments, the primary winding 1160 and the secondary winding 1150 may not be stacked vertically on top of each other, but rather stacked side by side in the PCB. In this structure, an integrated inductor can be formed by the air gap between the two windings and the core leg (with or without a flux shaping plate). For example, Figure 11B As shown, the secondary winding 1150 may be wound around the column 950A, such as Figure 11B The secondary winding 1150 is shown. The primary winding 1160 can be wound around the core legs 1170A and 1170B of each inductor portion 630A and 630B, respectively. Thus, the primary winding 1160 can be as shown. Figure 11B Given the required number of turns, the number of PCB layers can be minimized in this structure.

[0106] Figures 12A-12E Various examples of open EE 3-leg structures with or without flux shaping according to some embodiments are illustrated. Figure 12A As shown, the open EE 3-leg structure 1200 may include a flux shaping air gap on the top core, while the open EE 3-leg structure 1250 may include an air gap without flux shaping on the face between the bottom and top cores. Figures 12B-12E It is shown that the secondary winding can be arranged above the primary winding, but the present disclosure is not limited thereto. For example, the primary winding can be arranged above the secondary winding. Similarly, the integrated inductor and transformer design allows for reduced size, and the flux shaping air gap can reduce winding losses. Figure 12F As shown, inductive losses in the heat sink can be a strong function of stray fields.

[0107] like Figure 12A As shown, the open EE 3-leg structure 1200 may include three legs 1210A-1210C vertically disposed on a bottom core 1220. Figure 12B As shown, the primary winding 1230 can be wrapped around leg 1210B (e.g., the center leg). Additionally, the secondary winding 1240 can be wrapped around leg 1210C (e.g., the side leg). Figure 12C As further shown, a top core 1250 can be disposed on top of the center leg 1210B and the side legs 1210C. In some embodiments, a flux shaping air gap 1260 can be formed on portions of the primary winding 1230 that may not be covered by the top core 1250.

[0108] The open EE 3-leg structure 1200 can be as Figure 12D and Figure 12E For example, Figure 12DAs shown, three legs (e.g., a first side leg 1210A, a middle leg 1210B, and a second side leg 1210C) may be formed between the top core 1250 and the bottom core 1220. An air gap 1250A may be formed between the first side leg 1210A and the middle leg 1210B on the top core 1250. In addition, the primary winding 1230 may be formed around the middle leg 1210B, and the secondary winding 1240 may be formed around the second side leg 1210C.

[0109] Figure 12E Another example of an open EE 3-leg structure 1200 is shown. Figure 12D As shown, three legs (e.g., a first side leg 1210A, a middle leg 1210B, and a second side leg 1210C) may be formed between a top core 1250 and a bottom core 1220. An air gap 1250B may be formed on the first side leg 1210A (e.g., between the top core 1250 and the bottom core 1220). In addition, a primary winding 1230 may be formed around the middle leg 1210B, and a secondary winding 1240 may be formed around the second side leg 1210C.

[0110] Figure 13A An open EE 4-leg structure 1300A without flux shaping is illustrated in accordance with some embodiments. The open EE 4-leg structure 1300A can minimize the losses in the base / heat sink due to low stray fields compared to a 3-leg EE core structure, and thus the open EE 4-leg structure 1300A is well suited for designs with heat sinks. In some embodiments, the open EE 4-leg structure 1300A can include a first leg 1310A to a fourth leg 1310D, respectively. These four legs 1310A-1310D can be inserted between a top core 1350 and a bottom core 1320. In some examples, a primary winding 1330 can be wrapped around the second leg 1310B, and a secondary winding 1340 can be wrapped around the third leg 1310C. In some embodiments, the secondary winding 1340 can be disposed on top of the primary winding 1330. In some applications, the secondary winding 1340 can also be disposed below the primary winding 1330. As Figure 13A As further shown, a first air gap can be formed on the first leg 1310A, and a second air gap 1350B can be formed on the fourth leg 1310D. In some examples, the open EE 4-leg structure 1300A can have a symmetrical design about a center 1360 of the open EE 4-leg structure 1300A.

[0111] Figure 13BAn open EE 4-leg structure 1300B with flux shaping and two or more symmetrical air gaps is illustrated in accordance with some embodiments. The open EE 4-leg structure 1300B can further reduce winding losses through the flux shaping air gap. In some embodiments, the open EE 4-leg structure 1300B can include a first leg 1310A to a fourth leg 1310D, respectively. The four legs 1310A-1310D can be inserted between the top core 1350 and the bottom core 1320. In some examples, the primary winding 1330 can be wrapped around the second leg 1310B, and the secondary winding 1340 can be wrapped around the third leg 1310C. In some embodiments, the secondary winding 1340 can be disposed on top of the primary winding 1330. In some applications, the secondary winding 1340 can also be disposed below the primary winding 1330. As Figure 13B As further shown, a first air gap 1350C can be formed between the first leg 1310A and the second leg 1310B on the top core 1350. A second air gap 1350D can be formed between the third leg 1310C and the fourth leg 1310D on the top core 1350. In some examples, the open EE 4-leg structure 1300B can have a symmetrical design about a center 1360 of the open EE 4-leg structure 1300A.

[0112] Figure 13C An open EE 4-leg structure 1300C with flux shaping and two or more asymmetric air gaps is illustrated in accordance with some embodiments. The open EE 4-leg structure 1300C can be implemented to have design flexibility with asymmetric resonant inductance on the primary and secondary windings. In some examples, the primary winding 1330 can be wrapped around the second leg 1310B, and the secondary winding 1340 can be wrapped around the third leg 1310C. In some embodiments, the secondary winding 1340 can be disposed on top of the primary winding 1330. In some applications, the secondary winding 1340 can also be disposed below the primary winding 1330. Figure 13B As further shown, a first air gap 1350E can be formed between the first leg 1310A and the second leg 1310F on the top core 1350. A second air gap 1350D can be formed between the third leg 1310C and the fourth leg 1310D on the top core 1350. In some examples, the air gaps 1350E and 1350F can be formed symmetrically about the center 1360 of the open EE 4-leg structure 1300A.

[0113] Figure 14 The diagram illustrates the near field reduction in an open EE core structure with metal shielding according to some embodiments. The open EE core structure can have large stray magnetic fields, which can cause problems for EMC. Figure 14 As shown, the near field can be greatly reduced in an open EE core structure with metal shielding.

[0114] Figure 15A An example of an EE core structure 1500 with a metal shield 1530 is shown in accordance with some embodiments. In an open EE core structure 1500, the metal shield 1530 may contact the heat sink 1510 at all points. For example, the open EE core structure 1500 may include features that may be pressed to ensure contact with the heat sink surface 1510 and have multiple small cross-sections to ensure coplanarity with the heat sink 1510 and the bottom core 1520. In some embodiments, a wall 1540 may be provided on top of the heat sink 1510 to compensate for any height difference between the bottom core 1520 and the heat sink 1510. Figure 15B As shown, the metal shield 1530 may include multiple small sections of notches.

[0115] Figure 15C Another example of an EE core structure 1550 with a metal shield 1530 according to some embodiments is shown. The open EE core structure 1550 may include one or more walls extending from the heat sink 1510, and the metal shield 1530 may be positioned to overlap the wall 1540, for example, in a horizontal direction. The open EE core structure 1550 may allow for the flexibility of having imperfect contact between the metal shield 1530 and the bottom of the heat sink 1510.

[0116] Figures 16A-16D The diagram illustrates the concept of a partially interleaved winding structure between two stages (A and B). Figure 16C The figure shows a winding structure without winding interleaving between the two stages. Figure 16D The diagram shows a partially interleaved winding structure with winding interleaving between two stages according to some embodiments. Figure 16D In an embodiment, the width of both the cover and the heat sink can be reduced by approximately 12%. This is merely an example, and depending on the embodiment, the width can be reduced by more than approximately 12%. In addition, due to the overlapping cancellation of stray magnetic fields, the induced current density of the intermediate base can be reduced. Figure 16E Pictured Figure 16C Example induced current density distribution for a winding structure with no winding interleaving between two stages is shown. Figure 16F Pictured Figure 16D An example inductive current density distribution of a partially interleaved winding with winding interleaving between two stages is shown. Table 2 below shows the inductive losses in the heat sink of the partially interleaved winding, which are lower than the inductive losses of the winding structure without winding interleaving.

[0117] Table 2

[0118]

[0119]

[0120] Features, materials, characteristics or groups described in conjunction with a particular aspect, embodiment or example should be understood to be applicable to any other aspect, embodiment or example described in this section or elsewhere in this specification unless incompatible therewith. All features disclosed in this specification (including any accompanying claims, abstract and drawings) and / or all steps of any method or process so disclosed may be combined in any combination, except combinations in which at least some of such features and / or steps are mutually exclusive. Protection is not limited to the details of any foregoing embodiments. Protection extends to any novel feature or any novel combination of features of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or any novel step or any novel combination of steps of any method or process so disclosed.

[0121] Furthermore, certain features described in this disclosure in the context of separate implementations may also be implemented in combination in a single implementation. Conversely, various features described in the context of a single implementation may also be implemented in multiple implementations individually or in any suitable subcombination. Furthermore, although the features described above may be described as functioning in certain combinations, in some cases one or more features of a claimed combination may be deleted from the combination, and the combination may be claimed as a subcombination or a variation of the subcombination.

[0122] In addition, although operations may be depicted in the drawings or described in the specification in a particular order, these operations do not need to be performed in the particular order shown or in sequence, nor do all operations need to be performed to achieve the desired results. Other operations not depicted or described may be incorporated into the example methods and processes. For example, one or more additional operations may be performed before, after, simultaneously with, or between any of the above operations. In addition, the operations may be rearranged or reordered in other implementations. Those skilled in the art will understand that in some embodiments, the actual steps taken in the illustrated and / or disclosed processes may be different from those shown in the drawings. Depending on the embodiment, some of the above steps may be deleted or other steps may be added. In addition, the features and attributes of the above-mentioned specific embodiments may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure. In addition, the separation of various system components in the above-mentioned implementations should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems may generally be integrated into a single product or packaged into multiple products. For example, any component of the energy storage system described herein may be provided separately or integrated together (e.g., packaged together or attached together) to form an energy storage system.

[0123] For the purposes of this disclosure, certain aspects, advantages, and novel features are described herein. Not all such advantages may be achieved according to any particular embodiment. Thus, for example, those skilled in the art will recognize that the present disclosure may be embodied or implemented in a manner that achieves one advantage or group of advantages taught herein without necessarily achieving other advantages taught or suggested herein.

[0124] Unless specifically stated otherwise, or understood otherwise in the context of use, conditional language such as "can," "could," "might," or "may" is generally intended to convey that some embodiments include, while other embodiments do not, certain features, elements, and / or steps. Thus, such conditional language generally does not imply that one or more embodiments require a feature, element, and / or step in any way, nor does it imply that one or more embodiments must include logic for deciding, with or without user input or prompting, whether to include or perform such features, elements, or steps in any particular embodiment.

[0125] Unless specifically stated otherwise, conjunctions such as the phrase "at least one of X, Y, and Z" may be understood with context generally used to convey that an item, term, etc. may be X, Y, or Z. Thus, such conjunctions do not generally indicate that certain embodiments require the presence of at least one of X, at least one of Y, and at least one of Z.

[0126] Language of degree used herein, such as the terms "approximately," "about," "generally," and "substantially" as used herein, means a value, amount, or characteristic that is close to the aforementioned value, amount, or characteristic and still performs a desired function or achieves a desired result.

[0127] The scope of the present disclosure is not limited by the specific disclosure of the embodiments in this section or elsewhere in this specification, but rather by the claims presented in this section or elsewhere in the specification or in the future. The claim language should be interpreted broadly based on the language used in the claims and not limited to the examples described in this specification or examples described during the prosecution of the application, which examples should be construed as non-exclusive.

[0128] Although certain embodiments have been described, these embodiments are presented as examples only and are not intended to limit the scope of the present disclosure. In fact, the novel methods and systems described herein can be embodied in various other forms. In addition, various omissions, substitutions, and changes can be made to the systems and methods described herein without departing from the spirit of the present disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications that fall within the scope and spirit of the present disclosure. Therefore, the scope of the present invention is limited only by reference to the accompanying claims.

Claims

1. An integrated magnetic structure comprising: Top core; bottom core; one or more posts interposed between the top core and the bottom core; an inductor portion comprising a center leg, a first portion of a primary winding, and a first portion of a secondary winding, the center leg being distinct from and spaced apart from the one or more legs; as well as A transformer is partially integrated with the inductor by sharing a column of the one or more columns. 2 . The integrated magnetic structure of claim 1 , wherein the transformer comprises a second portion of the primary winding and a second portion of the secondary winding. 4.

3. The integrated magnetic structure of claim 2, wherein the second portion of the primary winding and the second portion of the secondary winding vertically overlap each other. The integrated magnetic structure of any one of claims 1 to 3, wherein the primary winding surrounds the secondary winding. 3 . The integrated magnetic structure of claim 1 , wherein at least one of the primary winding or the secondary winding comprises an interleaved winding structure. 4 . The integrated magnetic structure according to claim 1 , wherein the center post is vertically disposed at a central position of the bottom core of the inductor portion.

5. The integrated magnetic structure of any one of claims 1 to 6, wherein the one or more pillars, the transformer, the inductor portion and the central pillar are disposed in a fully enclosed housing.

6. The integrated magnetic structure of any one of claims 1 to 7, wherein a flux shaping air gap is formed on each of the one or more pillars and the central pillar.

7. The integrated magnetic structure of any one of claims 1 to 8, wherein a flux shaping air gap is formed on the central post.

8. The integrated magnetic structure of any one of claims 1 to 9, wherein two or more symmetrical air gaps are formed on the inductor portion.

9. The integrated magnetic structure of any one of claims 1 to 10, further comprising a metal shield plate disposed adjacent to the one or more pillars and configured to at least partially shield against stray magnetic fields.

10. An integrated magnetic structure comprising: Top core; bottom core; one or more posts interposed between the top core and the bottom core; an inductor portion comprising a center post and a flux shaping plate disposed on top of the center post; as well as A transformer is partially integrated with the inductor by sharing a column of the one or more columns.

11. The integrated magnetic structure of claim 12, wherein the inductor portion further comprises a first portion of a primary winding and a first portion of a secondary winding, and wherein the transformer comprises a second portion of the primary winding and a second portion of the secondary winding. 12 . The integrated magnetic structure of claim 13 , wherein the primary winding is configured to surround the secondary winding.

13. The integrated magnetic structure of any one of claims 13 to 14, wherein the second portion of the primary winding and the second portion of the secondary winding vertically overlap each other.

14. The integrated magnetic structure of any one of claims 12 to 15, wherein a flux shaping air gap is formed on each of the one or more pillars and the central pillar.

15. The integrated magnetic structure of any one of claims 12 to 15, wherein a flux shaping air gap is formed on the central post.

16. An integrated magnetic structure comprising: a top core comprising a first portion and a second portion, the first portion and the second portion of the top core having different heights and being disposed at different levels; bottom core; one or more posts interposed between the top core and the bottom core; an inductor portion comprising a center leg, a first portion of a primary winding, and a first portion of a secondary winding, the center leg being distinct from and spaced apart from the one or more legs; as well as A transformer is disposed between the second portion of the top core and the bottom core, the transformer comprising a second portion of the primary winding and a second portion of the secondary winding.

17. The integrated magnetic structure of claim 18, wherein a flux shaping air gap is formed on each of the one or more pillars and the central pillar.

18. The integrated magnetic structure of claim 18, wherein a flux shaping air gap is formed on the center post.

19. The integrated magnetic structure of any one of claims 18 to 20, wherein the first portion of the top core is disposed on top of the transformer, and wherein the second portion of the top core is disposed on top of the inductor portion.

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