Inductive structure and power supply

Abstract

The application relates to the technical field of power supplies, and discloses an inductance structure and a power supply, wherein the inductance structure comprises a magnetic core group and a main winding unit; the magnetic core group comprises a first magnetic core and a second magnetic core which are arranged at intervals; the main winding unit is provided with n main winding units, the n main winding units are located between the first magnetic core and the second magnetic core, the main winding unit comprises a first magnetic column, a main winding is wound on the first magnetic column, one end of the first magnetic column is connected to the first magnetic core, the second magnetic core is arranged at an interval on the other end of the first magnetic column, the n main windings are connected in parallel, the two ends of each main winding are connected to a control unit and a load; and the intervals between part of the first magnetic columns and the second magnetic core are different from each other. Therefore, the application can balance the coupling coefficients between the main winding units, and the inductance can keep a stable and symmetrical magnetic coupling relationship when working in a multi-phase mode.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of power supply, in particular to an inductance structure. On this basis, the present application further includes a power supply comprising the inductance structure. BACKGROUND

[0002] With the continuous development of artificial intelligence, high-performance computing and cloud data centers, the operating frequency and power density of server processors are constantly increasing. The power supply system needs to complete the dynamic switching from light load to heavy load in a very short time to ensure the stability and reliability of the processor power supply. Therefore, power modules gradually evolve towards high frequency, miniaturization and high dynamic response. As the core energy storage element, the dynamic response capability and energy density of inductance become the key factors affecting the overall power performance.

[0003] The coupling inductance in the prior art, although it achieves a high power density by sharing the magnetic core and effectively suppresses the output current ripple to some extent, still has significant technical bottlenecks in terms of expansion capability and performance consistency. Specifically, the traditional n-phase coupling inductance usually adopts a layout method of transverse linear arrangement. This structure inevitably has physical asymmetry. For example, the distance between adjacent two phases is close, and the coupling is tight, while the physical distance between the phases at both ends and the farthest phase is too long, resulting in an increase in the length of the magnetic circuit and an increase in the coupling coefficient, which significantly reduces the inter-phase coupling coefficient. This uneven magnetic coupling directly destroys the current sharing characteristics of each phase system, thereby affecting the steady-state output performance and dynamic response capability of the power supply. SUMMARY

[0004] The present application provides an inductance structure to solve the problem of large differences in inter-phase coupling coefficients between phases.

[0005] In a first aspect, the present application provides an inductance structure, comprising a magnetic core group and a main winding unit, the magnetic core group comprising a first magnetic core and a second magnetic core arranged at intervals. The main winding unit is provided with n, and n main winding units are located between the first magnetic core and the second magnetic core, so that the plurality of main winding units can form a coupled magnetic circuit through the first magnetic core and the second magnetic core. Each main winding unit comprises a first magnetic column, and a main winding is wound on the first magnetic column. The first magnetic core is connected to one end of the first magnetic column, and the second magnetic core is arranged at an interval at the other end of the first magnetic column. At the same time, n main windings are connected in parallel between each main winding, and are respectively connected with a control unit and a load at both ends of each main winding, so that the second magnetic core can act as a shared magnetic circuit, and each main winding is coupled through the shared magnetic circuit.

[0006] As mentioned above, in the linear arrangement, the physical distance from the main winding units at both ends (e.g. the first main winding unit and the nth main winding unit) to other main winding units is different, resulting in different magnetic path lengths in the shared magnetic circuit (i.e. the secondary magnetic core and the primary magnetic column), thereby generating uneven path magnetic resistance.

[0007] Due to the interval between the secondary magnetic core and the primary magnetic column, the main winding units also have an additional interval magnetic resistance with the secondary magnetic core. Therefore, the total magnetic resistance of the mutual coupling between the main winding units is equal to the sum of the corresponding path magnetic resistance and the interval magnetic resistance between the corresponding main winding unit and the secondary magnetic core.

[0008] Meanwhile, the resistance value of the interval magnetic resistance of each main winding unit has a linear correlation with the interval size between the secondary magnetic core and the primary magnetic column. Based on this, the application can adjust the interval size between the primary magnetic column of the n main winding units and the secondary magnetic core, so that the interval size between part of the primary magnetic columns and the secondary magnetic core is different from each other, so as to compensate for the difference in path magnetic resistance by adjusting the interval magnetic resistance between each main winding unit and the secondary magnetic core, so that the coupling coefficient of the magnetic flux path coupled between each main winding unit tends to be consistent.

[0009] Therefore, through the above technical features, the embodiment can actively compensate and balance the total magnetic resistance (i.e. the sum of the path magnetic resistance and the interval magnetic resistance) of the mutual coupling between the main winding units 3, so that the distribution of the magnetic flux of different main winding units in the shared magnetic core tends to be consistent, thereby effectively balancing the coupling coefficient between the main winding units 3, so that the inductance remains stable and symmetric magnetic coupling relationship when working in multiple phases. Thus, not only the current sharing characteristics are improved, and the current bias phenomenon caused by the magnetic resistance deviation of a main winding unit is avoided, but also the multi-phase output current can maintain synchronous response under dynamic load change, significantly improving the overall stability and conversion efficiency of the power supply system. This scheme eliminates the uneven coupling problem caused by structural asymmetry from the magnetic circuit design level, and provides a favorable guarantee for the reliable operation of high dynamic inductance in high frequency and high response power supply system.

[0010] In a second aspect, the application also provides a power supply comprising the inductance structure as described above. BRIEF DESCRIPTION OF DRAWINGS

[0011] Figure 1 is a structural diagram of the inductance layout form of the application in a transverse arrangement;

[0012] Figure 2 is Figure 1 is a perspective view of the inductance layout form of the application in a transverse arrangement;

[0013] Figure 3 is a structural diagram of the inductance structure of the application without additional inductance;

[0014] Figure 4 A wiring schematic diagram of a transversely arranged inductor layout of the present application;

[0015] Figure 5 A structural perspective view of a side-by-side arranged inductor layout of the present application;

[0016] Figure 6 A sectional plan view of a side-by-side arranged inductor layout of the present application.

[0017] Explanation of reference numerals:

[0018] 1, primary magnetic core; 2, secondary magnetic core; 3, main winding unit; 301, primary magnetic column; 302, main winding; 4, auxiliary winding unit; 401, secondary magnetic column; 402, auxiliary winding; 5, tertiary magnetic core; 6, first solder pad; 7, second solder pad; 8, filling layer; 9, magnetic resistance layer; 10, additional inductor; 11, connecting wire. DETAILED DESCRIPTION

[0019] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work fall within the protection scope of the present application.

[0020] It should be noted that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application. The terms "mounting", "connecting", "connecting" should be understood broadly, for example, it can be fixed connection, or detachable connection, or integral connection. It can be mechanical connection, or electrical connection. It can be directly connected, or indirectly connected through intermediate medium, or the communication between two elements. The terms "parallel", "perpendicular", "equal" include the described case and the approximate case similar to the described case, and the approximate case is within the acceptable deviation range, wherein the acceptable deviation range is determined by the ordinary skilled in the art considering the measurement being discussed and the error related to the measurement of the specific quantity (i.e. the limitation of the measurement system). For example, "parallel" includes absolute parallel and approximate parallel, and the acceptable deviation range of approximate parallel can be within 5°, for example. "Perpendicular" includes absolute perpendicular and approximate perpendicular, and the acceptable deviation range of approximate perpendicular can also be within 5°, for example. "Equal" includes absolute equality and approximate equality, and the acceptable deviation range of approximate equality can be that the difference between the two equalities is less than or equal to 5% of either one, for example. The specific meaning of the above terms in the present application can be understood in specific cases by the ordinary skilled in the art.

[0021] In order for those skilled in the art to better understand the scheme of the present application, the present application will be further described in detail below in combination with the drawings and specific embodiments.

[0022] As described above, the conventional coupled inductors usually adopt a layout mode of transverse linear arrangement, and such structure inevitably has physical asymmetry. Specifically, the distance between two adjacent phases is close, and the coupling is tight, while the physical distance between the phases at both ends is too long, resulting in increased magnetic path length and reduced coupling coefficient, which significantly reduces the inter-phase coupling coefficient.

[0023] For example, if the coupling inductance includes four phases in the form of a transverse linear arrangement, the length of the magnetic circuit between the first phase and the fourth phase is inevitably greater than the length of the magnetic circuit between the first phase and the second phase, which results in a higher coupling coefficient between the first phase and the fourth phase than between the first phase and the second phase. Ultimately, the coupling coefficient between the first phase and the second phase is greater than that between the first phase and the fourth phase. Such uneven magnetic coupling between the phases directly destroys the current sharing characteristics of the phase system, thereby affecting the steady-state output performance and dynamic response capability of the power supply.

[0024] To this end, with reference to Figure 1 and Figure 2 In the present embodiment, the inductance structure includes a magnetic core group and a main winding unit 3.

[0025] The magnetic core group includes a first magnetic core 1 and a second magnetic core 2 arranged at intervals. The main winding unit 3 is provided in n, and each of the n main winding units 3 is located between the first magnetic core 1 and the second magnetic core 2, so that the coupling magnetic circuit between the plurality of main winding units 3 is formed by the first magnetic core 1 and the second magnetic core 2.

[0026] Specifically, each main winding unit 3 includes a first magnetic column 301, and a main winding 302 is wound on the first magnetic column 301. The first magnetic core 1 is connected to one end of the first magnetic column 301, and the second magnetic core 2 is arranged at intervals at the other end of the first magnetic column 301. Meanwhile, the n main windings 302 are connected in parallel between them, and each main winding 302 is connected to a control unit and a load at both ends, respectively, in combination Figure 2 so that the second magnetic core 2 can serve as a shared magnetic circuit, and each main winding 302 is coupled through the shared magnetic circuit.

[0027] As mentioned earlier, referring to Figure 1 In the linear arrangement, the physical distance of the main winding units 3 located at both ends (such as the first main winding unit 3 and the nth main winding unit 3) to other main winding units 3 is different, resulting in different magnetic circuit lengths in the shared magnetic circuit (i.e., the second magnetic core 2 and the first magnetic core 1), thereby generating uneven path reluctance.

[0028] In the present embodiment, due to the interval between the second magnetic core 2 and the first magnetic column 301, the main winding unit 3 and the second magnetic core 2 additionally have an interval reluctance. Therefore, the total magnetic reluctance of the mutual coupling between each main winding unit 3 is equal to the sum of the corresponding path reluctance and the interval reluctance between the corresponding main winding unit 3 and the second magnetic core 2.

[0029] Meanwhile, the resistance value of the spacing magnetic reluctance of each main winding unit 3 is linearly correlated with the spacing between the secondary magnetic core 2 and the primary magnetic column 301. Based on this, this embodiment can make the spacing between the primary magnetic column 301 and the secondary magnetic core 2 of the main winding unit 3 adjustable, so that the spacing between some primary magnetic columns 301 and the secondary magnetic core 2 is different from each other. In other words, among the n primary magnetic columns 301, the spacing between some primary magnetic columns 301 and the secondary magnetic core 2 is different from the spacing between other primary magnetic columns 301 and the secondary magnetic core 2, thus forming different spacing magnetic reluctances. Therefore, by differentially adjusting the spacing magnetic reluctance between each main winding unit 3 and the secondary magnetic core 2, this embodiment can effectively compensate for the total magnetic reluctance difference between each magnetic flux path, making the magnetic flux coupling relationship between each main winding unit 3 more balanced, and thus making its coupling coefficient tend to be consistent.

[0030] It should be noted that if there are only two main winding units 3, the structure is symmetrical and no adjustment is needed. Therefore, in this embodiment, n is greater than 3.

[0031] In this embodiment, reference is made to... Figure 1 The first spacing between the first primary magnetic column 301 and the secondary magnetic core 2, and the second spacing between the nth (i.e. the last) primary magnetic column 301 and the secondary magnetic core 2, are both smaller than the third spacing between the other (i.e. the primary magnetic column 301 located between the first and the last) primary magnetic columns 301 and the secondary magnetic core 2. This is to ensure that the spacing magnetic resistance between the main winding units 3 located at both ends and the secondary magnetic core 2 is smaller than the spacing magnetic resistance between the main winding units 3 located in the middle position and the secondary magnetic core 2, so that the total coupling magnetic resistance between each main winding unit 3 is approximately equal.

[0032] Understandably, with Figure 1 Taking four main winding units 3 as an example, for the main winding units 3 at both ends (e.g., the first main winding unit 3 and the fourth main winding unit 3) with longer magnetic paths, larger inherent path magnetic reluctance, and therefore smaller inherent coupling coefficients, the spacing between the primary magnetic pillar 301 and the secondary magnetic core 2 of the first and fourth main winding units 3 (as described above, the first and second spacing) can be set to be smaller than the spacing between the second and third main winding units 3 (e.g., the third spacing). This makes the first and fourth main winding units 3 have a smaller spacing magnetic reluctance than the second and third main winding units 3.

[0033] By the above technical features, the embodiment can actively compensate and balance the total magnetic resistance (i.e., the sum of the path magnetic resistance and the interval magnetic resistance) of the mutual coupling between each main winding unit 3, so that the magnetic flux distribution of different main winding units 3 in the shared magnetic core tends to be consistent, thereby effectively balancing the coupling coefficients between each main winding unit 3 and keeping the inductance stable and symmetric magnetic coupling relationship when working in multiple phases. Thus, not only the current sharing characteristics are improved, and the current bias phenomenon caused by the magnetic resistance deviation of a main winding unit 3 is avoided, but also the multi-phase output current can remain synchronous response under dynamic load changes, significantly improving the overall stability and conversion efficiency of the power supply system. This scheme eliminates the uneven coupling problem caused by structural asymmetry from the magnetic circuit design level, providing a favorable guarantee for the reliable operation of high dynamic inductance in high frequency and high response power supply systems.

[0034] In addition, since the main winding 302 of each main winding unit 3 generates the same magnetic flux flow direction after being energized, the magnetic flux flows into the secondary magnetic core 2. Therefore, the magnetic flux emitted by each main winding unit 3 can cancel each other in the secondary magnetic core 2 (as a common magnetic circuit), thereby reducing the ripple current in the inductance structure and improving the efficiency of voltage conversion.

[0035] Based on the above structural features, the embodiment can effectively compress the volume through the magnetic core sharing design between multiple main winding units 3, thereby having more main winding units 3 to have good steady-state energy storage characteristics. At the same time, the embodiment can also significantly reduce the current ripple through the magnetic flux coupling effect, and to some extent, solve the problem of uneven inter-phase coupling coefficients caused by traditional linear arrangement.

[0036] However, when the power supply system faces ns-level transient changes in equal load, the coupled inductance needs to pass and redistribute the magnetic flux through its shared magnetic core (such as the secondary magnetic core 2) to achieve transient coupling response between each main winding unit 3. In this process, although the main winding units 3 can transfer energy through mutual coupling between each other, due to the above-mentioned total magnetic resistance of the mutual coupling between each main winding unit 3, the response time of each main winding unit 3 to the sudden load change will be different. The lag phenomenon of magnetic flux flow makes the dynamic adjustment of current not completely synchronized, thereby causing the current response of part of the main winding units 3 to be insufficient or overshoot when the load changes suddenly.

[0037] To this end, in one embodiment, referring to Figure 1 The inductance structure further includes a secondary winding unit 4, the secondary winding unit 4 is provided with n, and the n secondary winding units 4 are in one-to-one correspondence with the n main winding units 3 in magnetic communication, and the n secondary winding units 4 are provided with a shared magnetic circuit.

[0038] The secondary winding unit 4 comprises a secondary magnetic column 401, and the secondary winding 402 is wound on the secondary magnetic column 401. The n secondary windings 402 are connected in series, and the corresponding response mechanism is formed by the magnetic communication between each primary winding unit 3 and the corresponding secondary winding unit 4. That is, the primary winding unit 3 in the embodiment is coupled with the primary winding unit 3 and the corresponding secondary winding unit 4.

[0039] Specifically, in combination with Figure 3 Each primary winding unit 3 (for example, the primary winding 1 of the primary winding unit 3) and the corresponding secondary winding unit 4 (for example, the secondary winding 1-1 of the secondary winding unit) are coupled by the magnetic core to form a transformer. When the current of any primary winding 302 suddenly changes due to load transients, the changed magnetic flux has two moving paths after entering the second magnetic core: one is from the second magnetic core into the secondary magnetic column 401 of the corresponding secondary winding unit 4 (for example, the secondary winding 1-1 of the secondary winding unit), so as to pass through the secondary winding 402 wound on the secondary magnetic column 401 to generate an induced current on the secondary winding 402.

[0040] Since the n secondary windings 402 are connected in series, the transient change (that is, the induced voltage) is immediately transmitted to all other secondary windings 402 (for example, the secondary winding 402 of the secondary winding unit 2-1 to the secondary winding 402 of the secondary winding unit n-1) through the series path. Then, the magnetic flux is generated in the secondary magnetic column 401 wound thereon, and this part of the magnetic flux is transmitted to the primary winding unit 3 to the primary winding unit n which is in magnetic communication with the secondary winding unit 2-1 to the secondary winding unit n-1, thereby utilizing the high transmission rate of the current, so that all the primary winding units 3 participate in the response together and immediately. Therefore, in the embodiment, the load transient of a single primary winding unit 3 is forced to make all the primary windings 302 participate in the response together and immediately, which overcomes the problem that the coupled inductance depends on the slow flow of magnetic flux in the shared magnetic circuit, thereby greatly improving the response problem between the primary winding units 3.

[0041] Referring to Figure 1 Although the energy transmission between the primary winding unit 3 and the secondary winding unit 4 is realized by the coupled magnetic flux, which can quickly respond to the load change in the transient stage, this strong coupling design also compresses the equivalent energy storage space of the inductance, resulting in a decrease in the steady-state energy storage capacity, which is difficult to maintain sufficient energy reserve under continuous working conditions.

[0042] To solve this problem, in the related art, an additional inductance 10 (also called compensation inductance) is usually connected in series in the secondary winding unit 4 loop, for example, after at least one secondary winding unit 4 located at the end. The additional inductance 10 not only effectively makes up for the problem of insufficient energy storage of the secondary winding unit 4, but also maintains the continuity of the secondary winding 402 current, making the output current change more smooth, thereby preventing current spikes or output voltage fluctuations caused by insufficient energy reserve during load transients.

[0043] However, the introduction of the additional inductor 10, although it can compensate for the energy storage capability of the secondary winding unit 4 to some extent, also brings many problems in system design. For example, the additional inductor 10 needs additional installation space and magnetic material as an independent element, which significantly increases the volume and manufacturing cost of the overall structure, which is not conducive to the miniaturization and high power density layout of the power supply module. In addition, the introduction of the additional inductor 10 may also destroy the overall magnetic circuit continuity of the system, making the path separation between the primary and secondary magnetic fluxes more obvious, the magnetic flux sharing capability decreasing, and the energy transmission efficiency correspondingly decreasing.

[0044] In terms of electrical connection, the presence of the additional inductor 10 makes the system wiring more complex, not only requiring additional soldering points and connection lines 11, but also lengthening the wire length of the secondary side circuit. This structure will cause an increase in parasitic resistance, parasitic inductance and distributed capacitance, thereby causing additional power loss and voltage spikes at high frequency operation, affecting the transient response characteristics and signal integrity of the power supply. At the same time, due to the increase in the number of connection points, the thermal stress and mechanical fatigue risk of the soldering points also increases, and failure problems such as virtual welding, wire breakage or poor contact are more likely to occur under long-term operation.

[0045] In addition, the additional inductor 10 will also introduce the problem of mismatching of magnetic saturation characteristics. Since its magnetic core material, size and air gap design are independent of the main inductor structure, it may produce different magnetic flux responses under different temperature or load conditions, leading to uneven overall magnetic field distribution, thereby affecting the decoupling effect between the primary and secondary windings 402 and weakening the dynamic compensation capability.

[0046] In this regard, in one embodiment, the secondary magnetic columns 401 are spaced apart from the secondary magnetic core 2 to form a fourth spacing. It can be understood that due to the fourth spacing between the secondary magnetic columns 401 and the secondary magnetic core 2, there is a certain magnetic flux resistance between each secondary magnetic column 401 and the secondary magnetic core 2. It is precisely because of the existence of these magnetic flux resistances that there is a part of the magnetic flux (not coupled to the primary winding unit 3) backflow when the magnetic flux of the secondary magnetic column 401 is transmitted to the secondary magnetic core 2, resulting in leakage inductance.

[0047] In one embodiment, the leakage inductance between the plurality of secondary winding units 4 and the secondary magnetic core 2 is superimposed to form a protection inductor, and the inductance of the protection inductor is not less than a predetermined value, which can be the inductance of the additional inductor 10 that needs to be supplemented.

[0048] Based on this, in the embodiment, the inductance of the leakage inductance between the secondary magnetic core 2 and the corresponding secondary winding unit 4 is adjusted by adjusting the fourth gap size between each secondary magnetic column 401 and the secondary magnetic core 2. This makes the inductance of the protection inductance formed by the superposition of the leakage inductance between the plurality of secondary winding units 4 and the secondary magnetic core 2 not less than (or reach) the preset value.

[0049] Through the above technical features, the embodiment uses the gap between the secondary magnetic column 401 of the secondary winding unit 4 and the secondary magnetic core 2 to regulate the sum of the inductance of the leakage inductance between the plurality of secondary winding units 4 and the secondary magnetic core 2 (i.e. the inductance of the protection inductance), so as to replace the above-mentioned additional inductance 10, thereby saving cost and space occupation.

[0050] In the embodiment, the gap between each secondary magnetic column 401 and the secondary magnetic core 2 can be set to be equal, so that the inductance of the leakage inductance possessed by each secondary magnetic core 2 is the same. At the same time, it is also convenient for the production of the secondary winding 402 of the secondary unit. Of course, in another embodiment, the gap between the secondary unit and the secondary magnetic core 2 can also be unequal or partially equal, for example, the inductance of the leakage inductance of one of them is increased, and the inductance of the leakage inductance of the rest is reduced.

[0051] In one embodiment, the fourth gap is filled with a magnetic resistance layer 9, and the magnetic resistance layer 9 has a magnetic permeability lower than that of the secondary magnetic core 2, so as to ensure that the fourth gap area can provide high magnetic resistance, thereby accurately controlling the leakage inductance generated by the gap. If the magnetic permeability of the filling material is higher than or close to that of the secondary magnetic core 2, the gap will lose its high magnetic resistance characteristic and cannot form the required leakage inductance.

[0052] Further, the magnetic resistance layer 9 can be made of a material with zero magnetic permeability. For example, the magnetic resistance layer 9 can be air, that is, the fourth gap is not filled with any solid material, but only an air gap is left.

[0053] The gap between the secondary magnetic column 401 and the secondary magnetic core 2 can be determined by the following formula.

[0054] If the gap between each secondary magnetic column 401 and the secondary magnetic core 2 is set to be equal, the following formula is used:

[0055]

[0056] Wherein, L is the inductance of the leakage inductance; Lc is the inductance of the compensation inductance to be replaced; M is the number of secondary windings 402 of the secondary unit; N is the number of turns of the secondary winding 402; A is the cross-sectional area of the secondary magnetic column 401; C is a constant; lgap is the value of the fourth gap; μ e is the complex permeability in the magnetic circuit.

[0057] The composite permeability is used to characterize the equivalent permeability of the magnetic circuit, and it is determined by equivalent calculation of the vacuum permeability and the permeability of the secondary magnetic core 2 along the path of the magnetic circuit. When other materials are filled between the secondary magnetic column 401 and the secondary magnetic core 2, the composite permeability is determined by a comprehensive equivalent calculation of the vacuum permeability, the permeability of the material, and the permeability of the secondary magnetic core 2.

[0058] Based on this, this embodiment calculates the leakage inductance of the secondary winding 402 averaged to each secondary unit based on the inductance of the compensation inductor, and calculates the value of the fourth interval according to the calculation formula between the fourth interval and the leakage inductance of L.

[0059] If the spacing between each secondary magnetic post 401 and the secondary magnetic core 2 is not equal, then it is necessary to determine the leakage inductance that each secondary winding unit 4 needs to carry. Based on the aforementioned formula relating the fourth spacing to the leakage inductance (L), the fourth spacing value between each secondary winding unit 4 should be calculated.

[0060] In one embodiment, at least one of the secondary winding units 4 located at the end is grounded, such that a closed loop is formed between the secondary windings 402 of each secondary winding unit 4.

[0061] Among them, reference Figure 1 In this embodiment, if an additional inductor 10 is connected, the other end of the additional inductor 10 can be grounded. Combined with... Figure 3 If the above leakage inductance is used to replace the additional inductance 10, the secondary windings 402 of the secondary winding unit 4 at both ends are grounded to form a closed loop.

[0062] In one embodiment, the gap between the primary magnetic post 301 and the secondary magnetic core 2 is filled with a filler layer 8, the permeability of which is lower than that of the magnetic material of the secondary magnetic core 2. Alternatively, the filler layer 8 may also be composed of other materials with low permeability (e.g., non-magnetic materials such as ceramics or epoxy resins) to form the desired high magnetic reluctance at the filler layer 8.

[0063] Furthermore, the filling layer 8 can be made of a material with zero magnetic permeability. For example, the magnetic blocking layer 9 can be considered as air, meaning that the filling layer 8 is not filled with any solid material, but only retains air gaps.

[0064] In this embodiment, different materials with different permeabilities can be filled in the gap between each primary magnetic column 301 and the secondary magnetic core 2, so that each primary winding unit 3 and the secondary magnetic core 2 have different spacing magnetic resistance.

[0065] For example, with Figure 1For example, the four main winding units 3 in the gap between the first main winding unit 3 and the fourth main winding unit 3 and the second level magnetic core 2 are filled with a material with high magnetic permeability. The gap between the second main winding unit 3 and the third main winding unit 3 and the second level magnetic core 2 is filled with a material with low magnetic permeability.

[0066] This design can also reduce the gap reluctance of the first main winding unit 3 and the fourth main winding unit 3, thereby being lower than the gap reluctance between the second main winding unit 3 and the third main winding unit 3 and the second level magnetic core 2, achieving the effect of compensating the path reluctance.

[0067] That is, in this embodiment, when the air gap width of the fourth gap at some positions needs to be adjusted and exceeds the maximum physical size that the inductance structure can accommodate, the corresponding reluctance adjustment can be achieved by adjusting the magnetic permeability of the filling material. By filling materials with different magnetic permeabilities in the gap, the equivalent reluctance of the magnetic circuit can be optimized and balanced without changing the overall structure size. This method can achieve more accurate magnetic circuit adjustment under size constraints, effectively overcoming the problem of insufficient adjustment range when simply compensating by changing the air gap distance.

[0068] Through the above structure design, the total reluctance (including the sum of the path reluctance and the gap reluctance) between the main winding units 3 can be actively balanced, and the magnetic flux paths of different main winding units 3 can be kept consistent, thereby achieving balanced magnetic coupling between the main winding units 3. This balanced design not only improves the magnetic flux distribution of the multi-phase inductor during operation, but also effectively suppresses the current unbalanced flow phenomenon caused by the asymmetry of the magnetic circuit, improving the current distribution accuracy and response consistency of the system.

[0069] From a technical effect point of view, the differential filling material combined with the gap can make the magnetic flux distribution between the main winding units 3 more uniform, improve the concentration of the magnetic field, and suppress the leakage inductance deviation, thereby improving the response characteristics of the multi-phase anti-coupling inductor under high-speed dynamic load changes.

[0070] At the same time, since the magnetic permeability of the filling material is controllable, designers can flexibly fine-tune the magnetic circuit parameters according to different application scenarios, achieving comprehensive optimization of the magnetic field concentration area, coupling strength, and thermal distribution. Therefore, under the premise of ensuring the stability of the overall magnetic performance of the inductor, this scheme further improves the manufacturability, consistency, and thermal reliability of the structure, providing a more engineering feasible magnetic circuit regulation method for multi-phase high dynamic inductors in high frequency and high power density application scenarios.

[0071] In addition, since the energized primary winding 302 of each primary winding unit 3 generates magnetic flux in the same direction on each primary magnetic column 301, the magnetic flux generated by each primary winding unit 3 flows into the secondary magnetic core 2. Therefore, the magnetic flux generated by each primary winding unit 3 can cancel each other in the secondary magnetic core 2 (as a common magnetic circuit), thereby reducing the ripple current in the inductance structure and improving the efficiency of voltage conversion.

[0072] In one embodiment, the filling layer 8 and the magnetic blocking layer 9 can be used as a structure for fixing the secondary magnetic core 2.

[0073] Specifically, the material used to form the filling layer 8 and the magnetic blocking layer 9 can be selected to have adhesive properties while meeting the above-mentioned low magnetic permeability requirement (e.g., the magnetic permeability is lower than that of the secondary magnetic core 2, or the magnetic permeability is zero). For example, epoxy resin or other non-magnetic potting adhesive can be used as the material of the filling layer 8 and the magnetic blocking layer 9. Such materials are not only excellent electrical insulators and non-magnetic media (meeting the magnetic permeability requirement), but also have strong adhesive ability. Of course, in another embodiment, the secondary magnetic core 2 can be fixed by mechanical connection. Therefore, this document will not be described in more detail.

[0074] Based on the above technical features, the layout of the inductance structure can have, but is not limited to, two layout forms.

[0075] The first arrangement form is (i.e., transversely placed): in one embodiment, referring to Figure 1 and Figure 3 , the magnetic core group further includes a tertiary magnetic core 5, which is spaced apart from the secondary magnetic core 2 and arranged in parallel with the primary magnetic core 1, the secondary magnetic core 2, and the tertiary magnetic core 5. The tertiary magnetic core 5 is located on the side of the secondary magnetic core 2 away from the primary magnetic core 1.

[0076] The secondary winding unit 4 (including a secondary magnetic column 401 and a secondary winding 402) is arranged between the tertiary magnetic core 5 and the secondary magnetic core 2. The tertiary magnetic core 5 is connected to one end of the secondary magnetic column 401 away from the secondary magnetic core 2, and forms a shared magnetic circuit between the secondary winding units 4.

[0077] Based on this, the present embodiment can realize the separation design of the primary winding 302 of the primary winding unit 3 and the secondary winding 402 of the secondary winding unit 4 by arranging the secondary magnetic core 2 between the primary winding unit 3 (on the side of the primary magnetic core 1) and the secondary winding unit 4 (on the side of the tertiary magnetic core 5). This increases the distance between the primary winding 302 of the primary winding unit 3 and the secondary winding 402 of the secondary winding unit 4, significantly improves the insulation withstand capability, and completely avoids the risk of breakdown of the primary winding 302 of the primary winding unit 3 and the secondary winding 402 of the secondary winding unit 4.

[0078] Further, the tertiary magnetic core 5 can be an integral part of the plurality of secondary magnetic columns 401.

[0079] Meanwhile, in the present embodiment, the n primary winding units 3 and the n secondary winding units 4 can be arranged at equal intervals along the long side direction of the secondary magnetic core 2. Moreover, the primary winding units 3 and the secondary winding units 4 in one-to-one correspondence have the center lines of the primary magnetic columns 301 and the secondary magnetic columns 401 in line, thereby ensuring that the primary magnetic columns 301 and the secondary magnetic columns 401 in one-to-one correspondence can establish an optimized coupling magnetic circuit.

[0080] It can be understood that the coupling magnetic circuit can have the shortest path and the lowest magnetic resistance (for example, through the secondary magnetic core 2), reducing the magnetic leakage not in the design, thereby ensuring that the primary winding units 3 and the secondary winding units 4 can achieve excellent dynamic response capability.

[0081] In the transverse arrangement, the first magnetic core and the second magnetic core can be configured as a strip-shaped magnetic core. The long side direction is the extension direction of the strip-shaped magnetic core.

[0082] In one embodiment, referring to Figure 4 , the inductance structure further comprises n first pads 6. In the manufacturing process, the lead-out ends of the n primary windings 302 of the n primary winding units 3 are respectively connected to the n first pads 6, for example, by welding to complete the termination.

[0083] In one embodiment, the inductance structure further comprises n second pads 7, and the n second pads 7 are respectively connected to the lead-out ends of the n secondary windings 402 of the secondary winding units 4. Adjacent second pads 7 are connected to each other through a connecting line 11, which can be a conductive metal strip, a wire or a PCB trace, for realizing the electrical connection between the secondary windings 402 and ensuring the reliable transmission of current and the stability of the overall structure.

[0084] Therefore, in the present embodiment, the first arrangement form has the advantage that since the primary winding units 3 and the secondary winding units 4 are respectively located on the two sides of the secondary magnetic core 2, the spacing between the primary winding units 3 and the secondary winding units 4 can be directly increased in the spacing between the primary magnetic columns 301 and the secondary magnetic columns 401 and the secondary magnetic core 2. Further, the insulation bearing capacity between the primary windings 302 and the secondary windings 402 is significantly improved, effectively avoiding the risk of breakdown easily occurring at high voltage levels due to the too close distance between the two.

[0085] The second arrangement form (i.e., the parallel arrangement) is as follows:

[0086] In one embodiment, referring to Figure 5, the secondary winding units 4 are also arranged between the primary magnetic core 1 and the secondary magnetic core 2. Specifically, the n primary winding units 3 and the n secondary winding units 4 are arranged in an array structure, and are sequentially distributed according to a set geometric rule in space. More specifically, the winding units are sequentially and spacedly arranged along a first direction, thereby forming a double-row structure as shown in Figure 5 , i.e., a 2xN matrix array with two rows arranged side by side and corresponding to each other. This arrangement enables each primary winding unit 3 to obtain a corresponding secondary winding unit 4 at its adjacent position, and the spatial distribution relationship between the two is clear, facilitating subsequent magnetic flux path control and electrical interconnection design.

[0087] In one embodiment, referring to Figure 6 , the n primary magnetic columns 301 are spacedly arranged along a second direction, the n secondary magnetic columns 401 are spacedly arranged along the second direction, and the first direction is perpendicular to the second direction. Based on this, the side-by-side scheme of the present embodiment effectively distinguishes the magnetic flux paths between different winding units through the orthogonal arrangement, and the primary magnetic column 301 and the secondary magnetic column 401 jointly participate in constructing a stable magnetic flux path.

[0088] Further, the n secondary magnetic columns 401 and the n primary magnetic columns 301 are fixedly connected to the primary magnetic core 1, and jointly form a closed magnetic circuit with the secondary magnetic core 2, so that each group of primary and secondary winding units 4 can realize magnetic flux sharing and magnetic field coupling through the magnetic core, thereby reducing the number of magnetic cores and significantly saving the manufacturing cost of inductors.

[0089] Meanwhile, the side-by-side scheme of the present embodiment adjusts the spatial layout of the primary magnetic core 1 and the secondary magnetic core 2 to make them jointly undertake the magnetic flux guiding function of the original center magnetic core, thereby realizing the simplification of the magnetic circuit. This improvement reduces the total number of magnetic cores from three to two, directly bringing about the improvement of space compactness and the reduction of manufacturing cost. Due to the reduction of the number of magnetic cores, the number of magnetic columns, magnetic yokes and insulation gaps is also compressed, making the entire magnetic circuit system more concise.

[0090] In the present embodiment, when adopting the side-by-side arrangement form, the first magnetic core and the second magnetic core need to provide a large enough area to accommodate the n primary winding units 3 and the n secondary winding units 4 side by side. Therefore, the primary magnetic core 1 and the secondary magnetic core 2 can adopt a plate-shaped magnetic core structure.

[0091] According to Figure 5 It can be seen that the magnetic flux generated by the primary winding unit 3 (the primary winding unit 3 with an arrow in the figure) flows upwards and enters the top secondary magnetic core 2. Then it is divided into two magnetic fluxes in the secondary magnetic core 2. The two magnetic fluxes move towards other primary winding units 3 along the length direction of the secondary magnetic core 2. The other magnetic flux moves towards the corresponding secondary winding unit 4 along the width direction of the secondary magnetic core 2.

[0092] As Figure 5 As shown by the arrow at the top of the secondary magnetic core 2, the magnetic flux from one primary winding unit 3 flows in the length direction of the secondary magnetic core 2 to one side, while the magnetic flux from the primary winding unit 3 adjacent to it flows in the opposite direction in the secondary magnetic core 2, thereby canceling each other out. Therefore, this structure can also constitute a reverse coupling.

[0093] Based on this, the first direction described above can be the width direction of the primary magnetic core 1. The second direction described above can be the length direction of the primary magnetic core 1.

[0094] In an embodiment, n said secondary windings 402 are sequentially wound by a first wire around n said secondary magnetic columns 401. Based on this, the embodiment can significantly reduce the number of solder joints by forming n secondary windings 402 with a first wire, and only needs to solder at the starting point and the ending point of the wire to complete the electrical connection of the whole secondary winding 402, thereby reducing the assembly complexity, reducing the risk of false welding, de-welding and other defects, and improving the production consistency and reliability.

[0095] In addition, the winding mode of the continuous wire keeps the magnetic flux path between each secondary magnetic column 401 continuous and smooth, which can effectively reduce the unevenness of the magnetic flux distribution and the interphase coupling deviation, improve the magnetic coupling consistency and current transmission balance of the whole secondary winding 402, thereby reducing the leakage inductance error and improving the dynamic response performance. At the same time, since the wire is continuous and the conductor cross section is complete, the current conduction path has no interruption node, the overall direct current resistance is lower, and the electrical conductivity is better. Finally, this structure also has good space utilization and mechanical stability, and the arrangement of the wire between the magnetic columns is more compact and regular, which is not only conducive to the concentration of the magnetic field and the conduction of heat, but also improves the stability of the inductance structure in long-term operation and high-frequency vibration environment. In summary, this continuous winding method takes into account the manufacturing convenience, magnetic performance balance and structural reliability, and provides better comprehensive performance for the inductance structure.

[0096] In this parallel arrangement scheme, the most core structural feature is to cancel the center magnetic core in the traditional scheme. The above-mentioned transverse arrangement scheme adopts a three-magnetic-core structure, that is, the secondary magnetic core 2 is used for magnetic flux convergence and path adjustment, while in the parallel arrangement scheme, the spatial layout of the primary magnetic core 1 and the secondary magnetic core 2 is reasonably adjusted, so that they jointly bear the magnetic flux guiding function of the original center magnetic core, thereby realizing the simplification of the magnetic circuit. This improvement reduces the total number of magnetic cores from three to two, directly bringing about the improvement of the space compactness and the reduction of the manufacturing cost. Since the number of magnetic cores is reduced, the number of magnetic columns, magnetic yokes and insulation gaps is also compressed, making the whole magnetic circuit system more simple.

[0097] It is noted that the parallel arrangement can avoid the breakdown by adjusting the distance between the primary winding unit 3 and the secondary winding unit 4.

[0098] In the embodiment, the control unit is an electronic control module for regulating or managing the current, voltage and inductance operating states.

[0099] In the embodiment, it is noted that the adjustment of the distance between the primary magnetic column 301 and the secondary magnetic core 2 (for adjusting the gap reluctance) and the adjustment of the distance between the secondary magnetic column 401 and the secondary magnetic core 2 (i.e. the fourth gap, for adjusting the leakage inductance) do not interfere with each other. This is because the two distances are physically separated and functionally completely independent.

[0100] Specifically, the gap reluctance is determined by the distance between the primary magnetic column 301 and the secondary magnetic core 2, which measures the magnetic flux resistance of the primary magnetic column 301 (the primary winding unit 3) into the secondary magnetic core 2 (the shared magnetic path of the primary winding unit 3). The purpose of the adjustment is to balance the path reluctance difference between different primary winding units 3 due to different physical layouts (such as linear arrangement), so as to achieve the uniform current distribution and the equal coupling coefficient of the primary winding 302.

[0101] The leakage inductance (i.e. the protection inductance) is determined by the fourth gap between the secondary magnetic column 401 (the secondary winding unit 4) and the secondary magnetic core 2, which controls the magnetic flux path of the secondary winding unit 4 itself (i.e. the part of the magnetic flux that does not couple to the corresponding primary winding unit 3 or can be said to not enter the secondary magnetic core 2). The purpose of the adjustment is to form a specific inductance in the series loop of the secondary winding 402 to compensate for the energy storage and replace the additional inductance 10 required in the traditional scheme.

[0102] Therefore, adjusting the gap reluctance is to regulate the inter-phase coupling characteristics between the primary windings 302, and adjusting the leakage inductance is to regulate the energy storage characteristics of the series loop of the secondary winding 402. Since the two are designed for different magnetic path parts and different physical targets, adjusting one distance will not interfere with the magnetic characteristics controlled by the other distance.

[0103] Therefore, in the embodiment, based on the above parallel scheme in realizing the series connection of the secondary winding, the secondary magnetic column 401 (such as 1-1) can be wound first, and then directly connected to the adjacent next secondary magnetic column 401 (such as 2-1) for continuous winding, and so on. The path is very direct.

[0104] On the contrary, in the transverse scheme (such as Figure 3 and Figure 4 shown), an additional connecting line 11 (such as Figure 4The jumper wires 11 are shown in FIG. 1 as being external to the core assembly 10, and are connected between the respective secondary side pads 12. Thus, the side-by-side arrangement, due to its compact magnetic column arrangement, reduces or eliminates the need for such external jumpers, and the wiring is simpler, i.e., its physical structure allows for a more direct, more continuous winding path, simplifying the manufacturing process and reducing the complexity caused by the external connection wires 11.

[0105] The above provides a kind of inductance structure and power supply provided in the application in detail.This paper applies specific example to the principle and implementation of the application are described, the above example is only used to help understand the method of the application and its core idea.It should be pointed out that, for the ordinary skill in the art, without departing from the principle of the application, the application can be improved and modified in several ways, these improvements and modifications also fall within the scope of the claims of the application.

Claims

1. An inductor structure, characterized in that, include: The magnetic core assembly includes a primary magnetic core (1) and a secondary magnetic core (2) spaced apart. The main winding unit (3) is provided in n units. All n main winding units (3) are located between the first-stage magnetic core (1) and the second-stage magnetic core (2). The main winding unit (3) includes a first-stage magnetic column (301). The first-stage magnetic column (301) is wound with a main winding (302). The first-stage magnetic core (1) is connected to one end of the first-stage magnetic column (301). The second-stage magnetic cores (2) are spaced apart at the other end of the first-stage magnetic column (301). The n main windings (302) are connected in parallel. Both ends of each main winding (302) are connected to the control unit and the load. Among them, the spacing between some of the primary magnetic pillars (301) and the secondary magnetic cores (2) is different; the inductor structure also includes a secondary winding unit (4), and there are n secondary winding units (4), which are magnetically connected to the n primary winding units (3) in a one-to-one correspondence; The secondary winding unit (4) includes a secondary magnetic column (401), on which a secondary winding (402) is wound. n secondary windings (402) are connected in series. The ends of the secondary windings (402) located at both ends are not connected to the ground.

2. The inductor structure according to claim 1, characterized in that, The first distance between the first primary magnetic column (301) and the second secondary magnetic core (2), and the second distance between the nth primary magnetic column (301) and the second secondary magnetic core (2) are both smaller than the third distance between the other primary magnetic columns (301) and the second secondary magnetic core (2), where n is greater than 3.

3. The inductor structure according to claim 1, characterized in that, The secondary magnetic column (401) and the secondary magnetic core (2) are spaced apart to form a fourth gap.

4. The inductor structure according to claim 3, characterized in that, The leakage inductance between multiple secondary winding units (4) and the secondary magnetic core (2) is superimposed to form a protective inductor, and the inductance of the protective inductor is not lower than a preset value.

5. The inductor structure according to claim 4, characterized in that, The fourth interval is filled with a magnetic blocking layer (9), which has a magnetic permeability lower than that of the secondary magnetic core (2).

6. The inductor structure according to claim 5, characterized in that, The magnetic blocking layer (9) is made of a material with zero magnetic permeability.

7. The inductor structure according to claim 3, characterized in that, The fourth interval in each of the secondary winding units (4) is the same.

8. The inductor structure according to claim 1 or 2, characterized in that, The gap between the primary magnetic column (301) and the secondary magnetic core (2) is filled with a filling layer (8), the permeability of which is lower than that of the magnetic material of the secondary magnetic core (2).

9. The inductor structure according to claim 8, characterized in that, The filling layer (8) is made of a material with zero magnetic permeability.

10. The inductor structure according to claim 3, characterized in that, The magnetic core assembly also includes a third-level magnetic core (5), which is spaced apart from the second-level magnetic core (2) and located on the side of the second-level magnetic core (2) away from the first-level magnetic core (1). The auxiliary winding unit (4) is located between the third-level magnetic core (5) and the second-level magnetic core (2), and the third-level magnetic core (5) is located at the end of the second-level magnetic post (401) away from the second-level magnetic core (2).

11. The inductor structure according to claim 10, characterized in that, The centerline of the secondary magnetic column (401) is collinear with the centerline of the primary magnetic column (301).

12. The inductor structure according to claim 10, characterized in that, The inductor structure also includes n first pads (6), each of which is connected to the main winding (302) of the n main winding units (3) in a one-to-one correspondence, and the first pads (6) are respectively connected to the control unit and the load.

13. The inductor structure according to claim 10, characterized in that, The inductor structure includes n second pads (7), each of which is connected to one of the n secondary windings (402) of the secondary winding unit (4). Adjacent second pads (7) are connected by a first connecting line (11).

14. The inductor structure according to claim 3, characterized in that, The secondary winding unit (4) is disposed between the primary magnetic core (1) and the secondary magnetic core (2), the n primary winding units (3) and the n secondary winding units (4) are spaced apart along the first direction, and the n secondary magnetic columns (401) are connected to the primary magnetic core (1).

15. The inductor structure according to claim 14, characterized in that, The n primary magnetic pillars (301) are spaced apart along the second direction, and the n secondary magnetic pillars (401) are spaced apart along the second direction, wherein the first direction and the second direction are perpendicular to each other.

16. The inductor structure according to claim 14, characterized in that, The n secondary windings (402) are formed by sequentially winding the n secondary magnetic pillars (401) around a first conductor.

17. The inductor structure according to claim 16, characterized in that, The n main windings (302) are formed by winding the n primary magnetic columns (301) with the n second conductors in a one-to-one correspondence.

18. A power supply, characterized in that, Including the inductor structure as described in any one of claims 1-17.

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