Conversion device and manufacturing method thereof

Abstract

A conversion device comprises: a transformer for generating an output voltage according to an input voltage; the current transformer is coupled to the first node of the transformer; one end of the resonant inductor is used for receiving the input voltage, and the other end of the resonant inductor is coupled to the current transformer at a second node; and the excitation inductor is coupled to the transformer at the third node, the excitation inductor is coupled to the resonant inductor at the second node and is adjacent to the resonant inductor, and the current transformer is arranged between the transformer and the resonant inductor along the first direction. According to the conversion device disclosed by the utility model, the occupied space on the printed wiring board is effectively reduced, and the magnetic flux generated by the resonant inductor and the excitation inductor to the transformer together is reduced. The disclosure also relates to a related manufacturing method.

Description

Technical Field

[0001] This disclosure relates to a conversion device, and more particularly to a conversion device for use in a resonant circuit that integrates magnetic components, and a method for manufacturing the same. Background Technology

[0002] Power supplies typically perform voltage conversion using an LLC resonant converter, which consists of a magnetizing inductor, resonant inductor, resonant capacitor, and transformer. When the LLC resonant converter is operating, it reduces power loss and improves conversion efficiency through soft-switching voltage transition (zero-voltage transition). In some converter designs, the LLC resonant converter may also include a current transformer (CT) to sense the current in the primary and secondary circuits. However, in current practice, the magnetizing inductor, resonant inductor, current transformer, and transformer are individually configured on a printed wiring board (PWB) to form the LLC resonant circuit. Typically, each magnetic component requires at least two pins, one for input and one for output. Therefore, these magnetic components occupy a significant amount of space on the PWB, reducing area utilization and consequently decreasing design flexibility. Summary of the Invention

[0003] This disclosure includes a conversion device comprising: a transformer for generating an output voltage based on an input voltage; a current transformer coupled to the transformer at a first node; a resonant inductor, one end of which receives the input voltage and the other end of which is coupled to the current transformer at a second node; and a magnetizing inductor coupled to the transformer at a third node and to the resonant inductor at the second node, and adjacent to the resonant inductor, wherein the current transformer is disposed between the transformer and the resonant inductor along a first direction.

[0004] In some embodiments, the conversion device further includes a magnetic core column disposed between the resonant inductor and the magnetizing inductor along a first direction, wherein when the conversion device is in operation, the first magnetic flux of the resonant inductor has a first maximum amplitude, and the second magnetic flux of the magnetizing inductor has a second maximum amplitude.

[0005] In some embodiments, the core column of the magnetic core is used to superimpose or cancel out the first magnetic flux of the resonant inductor and the second magnetic flux of the magnetizing inductor. When the winding direction of the coil of the resonant inductor is the same as that of the coil of the magnetizing inductor, the first magnetic flux and the second magnetic flux are superimposed. When the winding direction of the coil of the resonant inductor is not the same as that of the coil of the magnetizing inductor, the first magnetic flux and the second magnetic flux are canceled out.

[0006] In some embodiments, when the first magnetic flux and the second magnetic flux are superimposed, the first maximum amplitude increases to the third maximum amplitude, and when the first magnetic flux and the second magnetic flux cancel each other out, the first maximum amplitude decreases to the fourth maximum amplitude, and wherein the second maximum amplitude is less than each of the first maximum amplitude, the third maximum amplitude, and the fourth maximum amplitude.

[0007] In some embodiments, the resonant inductor and the magnetizing inductor have a void below a second direction perpendicular to the first direction, the void being used to configure one or more elements of the switching device.

[0008] This disclosure includes a method of manufacturing a switching device, comprising: coupling one end of a resonant inductor to one end of a current transformer; coupling the other end of the current transformer to one end of a transformer; coupling the other end of the transformer to one end of a magnetizing inductor and configuring the magnetizing inductor adjacent to the resonant inductor; and coupling the other end of the magnetizing inductor to the other end of the resonant inductor, wherein the current transformer is configured between the transformer and the resonant inductor along a first direction.

[0009] In some embodiments, when the conversion device is in operation, the first magnetic flux of the resonant inductor has a first maximum amplitude, and the second magnetic flux of the excitation inductor has a second maximum amplitude, and the first maximum amplitude is greater than the second maximum amplitude.

[0010] In some embodiments, the manufacturing method further includes: configuring a magnetic core column between the resonant inductor and the magnetizing inductor along a first direction, wherein the magnetic core column is used to superimpose or cancel the first magnetic flux of the resonant inductor and the second magnetic flux of the magnetizing inductor.

[0011] In some embodiments, when the winding direction of the resonant inductor's coil is the same as the winding direction of the magnetizing inductor's coil, the first magnetic flux and the second magnetic flux are superimposed on each other, and when the winding direction of the resonant inductor's coil is different from the winding direction of the magnetizing inductor's coil, the first magnetic flux and the second magnetic flux cancel each other out.

[0012] In some embodiments, when the first magnetic flux and the second magnetic flux are superimposed, the first maximum amplitude increases to the third maximum amplitude, and when the first magnetic flux and the second magnetic flux cancel each other out, the first maximum amplitude decreases to the fourth maximum amplitude, and wherein the second maximum amplitude is less than each of the first maximum amplitude, the third maximum amplitude, and the fourth maximum amplitude. Attached Figure Description

[0013] The nature of this disclosure can be best understood by reading the following detailed description in conjunction with the accompanying drawings. It should be noted that, in accordance with industry standard practice, the various features are not drawn to scale. In fact, for clarity of discussion, the dimensions of the various features may be arbitrarily increased or decreased.

[0014] Figure 1 The circuit diagrams are shown for some embodiments of the conversion device according to this disclosure.

[0015] Figure 2 This is a structural diagram of a conversion device illustrated according to some embodiments of the present disclosure.

[0016] Figure 3 This is a structural diagram of a conversion device illustrated according to some embodiments of the present disclosure.

[0017] Figure 4 The following is a timing waveform diagram of the magnetic flux of the magnetizing inductor and the resonant inductor, illustrated according to some embodiments of the present disclosure.

[0018] Figure 5 This is a flowchart illustrating a method of manufacturing a conversion device according to some embodiments of the present disclosure.

[0019] The reference numerals in the attached figures are explained below.

[0020] 1, 2, 5, 6, 7, 8, 9: Pins

[0021] 100: Conversion device

[0022] 500: Manufacturing Method

[0023] 510, 520, 530, 540: Operation

[0024] CT: Current Transformer

[0025] E1~E23: Edges

[0026] HL: Horizontal line

[0027] Lr: Resonant inductance

[0028] Lm: Magnetizing inductance

[0029] L1~L15: Length

[0030] m: Magnetic core column

[0031] ME: Metal-clad region

[0032] N1~N9: Nodes

[0033] Peak1~Peak4: Maximum amplitude

[0034] PRI: Primary side

[0035] SEC: Secondary Side

[0036] TR: Transformer

[0037] t: time

[0038] VL: Vertical line

[0039] VAC: Void

[0040] VIN: Input voltage

[0041] VOUT1, VOUT2: Output voltage

[0042] X, Y, Z: Direction

[0043] Φ Lr (t), Φ Lm (t): Magnetic flux Detailed Implementation

[0044] The following disclosure provides numerous different embodiments or examples for implementing various features of the provided subject matter. Specific examples of components and configurations are described below to simplify this disclosure. Of course, these components and configurations are merely examples and are not intended to be limiting. For example, in the following description, forming a first feature on or above a second feature may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which an additional feature may be formed between the first and second features such that the first and second features are not in direct contact. Additionally, reference numerals and / or letters may be repeated in various instances of this disclosure. This repetition is for simplicity and clarity and does not in itself determine the relationship between the various embodiments and / or configurations discussed.

[0045] Additionally, for ease of description, spatial relative terms such as “below,” “under,” “lower,” “above,” “upper,” “top,” “bottom,” and similar terms may be used herein to describe the relationship between one element or feature illustrated in the figures and one or more other elements or features. Besides the orientation depicted in the figures, spatial relative terms are intended to cover different orientations of elements in use or operation. Devices may be oriented in other ways (rotated 90 degrees or otherwise), and the spatial relative descriptors used herein will be interpreted accordingly.

[0046] In power supply technology, voltage converters typically perform voltage conversion using an inductor-capacitor (LLC) resonant converter, which consists of a magnetizing inductor, a resonant inductor, a resonant capacitor, and a transformer. This type of power supply topology is commonly found in server power supplies, computer power supplies, and electric vehicle power supplies.

[0047] During operation, the LLC resonant converter utilizes resonant elements (resonant inductor and resonant capacitor) and the magnetizing inductance of the transformer to achieve soft-switching voltage conversion with zero voltage switching (ZVS) and zero current switching (ZCS), thereby reducing power loss and improving conversion efficiency. In some topologies, the LLC resonant converter also includes a current transformer (CT) to detect the current in the primary and secondary circuits.

[0048] Figure 1 The circuit diagram is shown for some embodiments of the conversion device 100 according to this disclosure. Figure 1 As shown, the conversion device 100 includes a resonant inductor Lr, a magnetizing inductor Lm, a current transformer CT, and a transformer TR.

[0049] In some embodiments, the side of the transformer TR and current transformer CT used to receive the input voltage VIN is defined as the primary side PRI (also known as the primary side PRI). The side of the transformer TR and current transformer CT used to generate the transformed output voltages VOUT1 and VOUT2 respectively is defined as the secondary side SEC (also known as the secondary side SEC).

[0050] like Figure 1As shown, in the primary side PRI of the conversion device 100, one end of the resonant inductor Lr is coupled to node N1 and used to receive the input voltage VIN. The other end of the resonant inductor Lr is coupled to the non-signaled terminal of the current transformer CT at node N2. The signaled terminal of the current transformer CT is coupled to the non-signaled terminal of the transformer TR at node N3. The signaled terminal of the transformer TR is coupled to one end of the magnetizing inductor Lm at node N4. The other end of the magnetizing inductor Lm is coupled in parallel to one end of the resonant inductor Lr at node N2.

[0051] In the secondary side SEC of the conversion device 100, the dotted end of the current transformer CT is coupled to node N6, and the non-dotted end of the current transformer CT is coupled to node N5, and is used to generate the output voltage VOUT2 at nodes N5 and N6. The dotted end of the transformer TR is coupled to node N7, the intermediate end of the transformer TR is coupled to node N8, and the non-dotted end of the transformer TR is coupled to node N9, and is used to generate the output voltage VOUT1 at nodes N7 to N9.

[0052] In some embodiments, the output voltage VOUT1 indicates the output voltage generated after the input voltage VIN is transformed by the transformer TR. In some embodiments, the number of turns of the transformer TR on the primary side PRI and the secondary side SEC can be changed according to the actual application. For example, when the conversion device 100 is used to reduce the input voltage VIN, the number of turns of the transformer TR on the primary side PRI is greater than the number of turns of the transformer TR on the secondary side SEC, for example, the turns ratio of the primary side PRI to the secondary side SEC is 4:1. At this time, the voltage level of the output voltage VOUT1 is lower than the voltage level of the input voltage VIN. When the conversion device 100 is used to increase the input voltage, the number of turns of the transformer TR on the primary side PRI is less than the number of turns of the transformer TR on the secondary side SEC, for example, the turns ratio of the primary side PRI to the secondary side SEC is 1:4. At this time, the voltage level of the output voltage VOUT1 is higher than the voltage level of the input voltage VIN. However, the transformer TR disclosed herein is not limited to the above turns ratio, and the number of turns can be adjusted according to the actual application.

[0053] In some embodiments, the output voltage VOUT2 is used to indicate the current in the primary side PRI of the current transformer CT. Specifically, when current flows through the coil of the primary side PRI of the current transformer CT, an induced electromotive force (i.e., voltage VOUT2) is generated in the coil of the secondary side SEC of the current transformer CT. The current in the primary side PRI of the current transformer CT can be calculated by measuring the output voltage VOUT2 and based on the number of turns of the coil of the current transformer CT in the primary side PRI and the number of turns of the coil in the secondary side SEC. In some applications, the turns ratio of the coil of the primary side PRI to the coil of the secondary side SEC of the current transformer CT is 1:50. However, the current transformer CT disclosed herein is not limited to the above turns ratio and the number of coil turns can be adjusted according to the actual application.

[0054] In current practice, the magnetizing inductor, resonant inductor, current transformer, and transformer are individual and independent magnetic components. These magnetic components are arranged on a printed wiring board (PWB) and interconnected through the PWB to form an LLC resonant circuit. Typically, each magnetic device requires at least two pins, one for input and one for output. Because these magnetic components are individual and independent, when the magnetizing inductor, resonant inductor, current transformer, and transformer form an LLC resonant circuit, the connections and wiring of these magnetic components require at least eight pins and occupy a significant amount of space on the PWB.

[0055] Compared to the above methods, the conversion device 100 disclosed herein integrates the magnetizing inductor, resonant inductor, current transformer, and transformer into a single magnetic device, requiring only two pins as the input and output terminals, respectively. Therefore, the conversion device disclosed herein effectively reduces wiring in the PWB and the space it occupies.

[0056] In some embodiments, the conversion device 100 disclosed herein may include a transformer TR, a resonant inductor Lr, a magnetizing inductor Lm, and a current transformer CT. The transformer TR and resonant inductor Lr are essential components of the conversion device 100, while the magnetizing inductor Lm and current transformer CT can be added according to design requirements on the PWB. In other words, in one embodiment, the conversion device 100 disclosed herein may include a transformer TR and a resonant inductor Lr. In another embodiment, the conversion device 100 disclosed herein may also include a transformer TR, a resonant inductor Lr, and a magnetizing inductor Lm. In yet another embodiment, the conversion device 100 disclosed herein may also include a transformer TR, a resonant inductor Lr, a magnetizing inductor Lm, and a current transformer CT. In yet another embodiment, the conversion device 100 disclosed herein may also include a transformer TR, a resonant inductor Lr, a magnetizing inductor Lm, and a current transformer CT.

[0057] Figure 2 This is a structural diagram illustrating a conversion device 100 according to some embodiments of the present disclosure. Figure 2 As shown, Figure 2 This diagram illustrates a configuration of the conversion device 100 in the XZ plane formed by the X and Z directions.

[0058] Also refer to Figure 2 and Figure 1 Pin 1 corresponds to node N4 and is used to connect to the magnetizing inductor Lm and transformer TR. Pin 2 corresponds to node N1 and is used to connect to the resonant inductor Lr. Pins 5 and 6 correspond to nodes N5 and N6 respectively and are used to connect to the current transformer CT. Pins 7-9 correspond to nodes N7-N9 respectively and are used to connect to the transformer TR.

[0059] like Figure 2 As shown, the transformer TR, current transformer CT, magnetizing inductor Lm, and resonant inductor Lr are arranged sequentially along the X direction. Pins 1 and 2 are of the same size, and each of pins 1 and 2 has a length L1 of 3.0 ± 0.4 mm along the Z direction from its upper edge E1 to its lower edge E2. The switching device 100 has a maximum length L2 of 33.0 mm along the Z direction from its upper edge E3 to its lower edge E4 of the transformer TR. The switching device 100 has a maximum length L3 of 69.0 mm along the X direction from its left edge E5 of the transformer TR to its right edge E6 of the inductor Lr (containing the core material). The above values ​​are one embodiment of this disclosure; in various embodiments, the lengths L1 to L3 of the switching device 100 in the XZ plane are not limited to these values.

[0060] In some embodiments, the X, Y, and Z directions are perpendicular to each other.

[0061] In some embodiments, each of the resonant inductor Lr and the magnetizing inductor Lm is covered with a core material to increase the inductance values ​​of the resonant inductor Lr and the magnetizing inductor Lm. In some embodiments, the core material may be implemented using ferrite, such as manganese-zinc ferrite or nickel-zinc ferrite; however, this disclosure is not limited to the above materials.

[0062] In this disclosed example, a core column m is disposed between the resonant inductor Lr and the magnetizing inductor Lm along the direction X. In other words, the resonant inductor Lr and the magnetizing inductor Lm share the core column m as the covering core material along the direction X. The shared core column m can cancel out the magnetic flux generated by the resonant inductor Lr and the magnetizing inductor Lm, thereby reducing the magnetic flux jointly generated by the resonant inductor Lr and the magnetizing inductor Lm on the transformer. More details regarding the magnetic flux generated by the resonant inductor Lr and the magnetizing inductor Lm will be discussed later. Figure 4 Detailed explanations are provided in the corresponding paragraphs.

[0063] Figure 3 This is a structural diagram illustrating a conversion device 100 according to some embodiments of the present disclosure. Figure 3 As shown, Figure 3 The diagram illustrates a configuration of the conversion device 100 in the XY plane formed by the X and Y directions.

[0064] Similar to Figure 2 , Figure 3 Pin 1 corresponds to node N4. Pin 2 corresponds to node N1. Pins 5 and 6 correspond to nodes N5 and N6, respectively. Pins 7 through 9 correspond to nodes N7 through N9, respectively.

[0065] like Figure 3 As shown, the transformer TR, current transformer CT, magnetizing inductor Lm, and resonant inductor Lr are arranged sequentially along direction X. The conversion device 100 can be divided into left and right equal parts by a vertical line VL extending along direction Y, and into upper and lower equal parts by a horizontal line HL extending along direction X.

[0066] Also refer to Figure 3 and Figure 2 In the conversion device 100 disclosed herein, an empty region VAC is provided below the magnetizing inductor Lm and the resonant inductor Lr extending along the Z direction. The empty region VAC is located above pins 1 and 2 in the Z direction and below pins 1 and 2 in the Y direction.

[0067] In some embodiments, the vacant area (VAC) can be further used to configure additional components, such as capacitors, switches, circuit components, or other similar components. Alternatively, components used for other functions on the PWB can also be configured in the VAC to improve space utilization efficiency. In some embodiments, the conversion device 100 disclosed herein can improve the space utilization efficiency of the PWB and may have the aforementioned benefits, including increased power density during operation, improved heat dissipation efficiency during operation, reduced parasitic parameters resulting from the compact arrangement of individual components, and improved design flexibility and modularity.

[0068] like Figure 3As shown, the conversion device 100 has a length L4 of 22.2 mm along the direction Y from the upper edge E7 to the lower edge E8 of the transformer TR. The metal-clad region ME in the transformer TR has a length L5 of 14.0 ± 0.5 mm along the direction Y from the upper edge E9 to the lower edge E10. The metal-clad region ME has a length L6 of 7.875 ± 0.5 mm from the upper edge E9 to the horizontal line HL along the direction Y.

[0069] In some embodiments, the right side E11 of the metal-clad region ME to the left side E12 of the current transformer CT has a length L7 of 28.25 ± 0.5 mm along the X direction. The right side E11 of the metal-clad region ME to the right side E13 of the current transformer CT has a length L8 of 33.25 ± 0.5 mm along the X direction. The right side E11 of the metal-clad region ME to the right side E14 of the core material clad on the right side of the resonant inductor Lr has a length L9 of 61.5 ± 0.8 mm along the X direction. The right side E15 of the pin 5 to the right side E15 of the magnetizing inductor Lm has a length L10 of 14.4 ± 0.5 mm along the X direction.

[0070] In some embodiments, the upper edge E16 of the current transformer CT to the lower edge E17 of the resonant inductor Lr has a length L11 along the direction Y with a maximum value of 23.0 mm. The upper edge E18 to the lower edge E19 of the core material covering the right side of the resonant inductor Lr along the direction X has a length L12 of 19.5 ± 0.5 mm along the direction Y.

[0071] In some embodiments, the empty area VAC, extending from its upper edge E20 to its lower edge E21 in the direction Y and along the direction X, has a minimum length L13 of 6.0 mm along the direction Y. The horizontal line HL to the lower edge E21 of the empty area VAC has a length L14 of 4.0 ± 0.5 mm along the direction Y. The empty area VAC, extending from its left edge E22 to its right edge E23 in the direction X and along the direction Y, has a minimum length L15 of 15.5 mm along the direction X.

[0072] Figure 3 and Figure 4 The lengths L1 to L14 described herein are merely one example of the content disclosed herein; however, the content is not limited thereto. In various embodiments, the conversion device 100 disclosed herein can be designed and its spatial specifications adjusted according to converter functions, PWB specifications, compatibility, parameter requirements, or other relevant conditions. In other words, in various embodiments, the lengths L1 to L14 may also have different values.

[0073] Figure 4 The following are timing waveforms of the magnetic flux of the magnetizing inductor Lm and the resonant inductor Lr, as illustrated in some embodiments of this disclosure. Figure 4 As shown, Figure 4 Magnetic flux Φ including excitation inductance Lm Lm (t) and the magnetic flux Φ of the resonant inductor Lr Lr (t) changes with time t.

[0074] In the embodiments disclosed herein, the magnetic flux Φ Lr (t) and Φ Lm The unit of (t) is expressed in Weber (Wb), and time t is expressed in seconds (s), however, this disclosure is not limited to the above units.

[0075] In some embodiments, since the magnetizing inductor Lm and the resonant inductor Lr have circularly wound coils, when current flows through the magnetizing inductor Lm and the resonant inductor Lr, the magnetizing inductor Lm and the resonant inductor Lr will generate magnetic flux in a direction perpendicular to the direction of the coil winding. Therefore, as Figure 4 As shown, when the converter 100 is running, the input current flows through the excitation inductor Lm and the resonant inductor Lr, and generates magnetic flux Φ respectively. Lm (t) and Φ Lr (t).

[0076] For example, while referring to Figure 2 and Figure 4 When the coil of the magnetizing inductor Lm is wound counterclockwise along the ZY plane formed by directions Z and Y, the magnetizing inductor Lm generates a magnetic flux Φ along the X direction pointing towards the resonant inductor Lr. Lm (t). Accordingly, when the coil of the resonant inductor Lr is wound clockwise along the ZY plane formed by the directions Z and Y, the magnetizing inductor Lm generates a magnetic flux Φ along the direction X pointing towards the magnetizing inductor Lm. Lr (t).

[0077] Also refer to Figure 2 and Figure 4 The excitation inductor Lm and resonant inductor Lr disclosed herein share a common core m in their magnetic cores. Responding to the shared core m in the excitation inductor Lm and resonant inductor Lr, the magnetic flux Φ Lm (t) and magnetic flux Φ Lr (t) can be superimposed or canceled by each other depending on the direction of the winding of the excitation inductance Lm and the direction of the winding of the resonant inductance Lr.

[0078] Specifically, such as Figure 4 As shown, the magnetic flux Φ Lr (t) has the maximum amplitude Peak3 and magnetic flux Φ Lm(t) has the maximum amplitude Peak1. In some cases, when the winding direction of the resonant inductor Lr is different from that of the magnetizing inductor Lm, the magnetic flux Φ Lm (t) and magnetic flux Φ Lr (t) They cancel each other out. In other words, when the coil of the resonant inductor Lr is wound clockwise along the ZY plane, and the coil of the magnetizing inductor Lm is wound counterclockwise along the ZY plane, the magnetic flux Φ Lm (t) and magnetic flux Φ Lr (t) cancel each other out. Alternatively, when the coil of the resonant inductor Lr winds counterclockwise along the ZY plane and the coil of the magnetizing inductor Lm winds clockwise along the ZY plane, the magnetic flux Φ Lm (t) and magnetic flux Φ Lr (t) cancel each other out. When the magnetic flux Φ Lm (t) and magnetic flux Φ Lr When (t) cancel each other out, the magnetic flux measured at the core column m is equal to the magnetic flux Φ. Lr (t) minus magnetic flux Φ Lm (t), i.e., Φ Lr (t)-Φ Lm (t). Magnetic flux Φ Lr (t)-Φ Lm (t) has the maximum amplitude Peak2.

[0079] In other scenarios, when the winding direction of the resonant inductor Lr is the same as the winding direction of the magnetizing inductor Lm, the magnetic flux Φ Lm (t) and magnetic flux Φ Lr (t) They superimposed. In other words, when the coil of the resonant inductor Lr is wound clockwise along the ZY plane, and the coil of the magnetizing inductor Lm is wound clockwise along the ZY plane, the magnetic flux Φ Lm (t) and magnetic flux Φ Lr (t) They are superimposed. Alternatively, when the coil of the resonant inductor Lr winds counterclockwise along the ZY plane, and the coil of the magnetizing inductor Lm winds counterclockwise along the ZY plane, the magnetic flux Φ Lm (t) and magnetic flux Φ Lr (t) superimposed. When the magnetic flux Φ Lm (t) and magnetic flux Φ Lr When (t) are superimposed, the magnetic flux measured at the core column m is equal to the magnetic flux Φ. Lr (t) plus magnetic flux Φ Lm (t), i.e., Φ Lr (t)+Φ Lm (t). Magnetic flux Φ Lr (t)+Φ Lm(t) has the maximum amplitude Peak4.

[0080] For example, in the conversion device 100 disclosed herein, the magnetic flux Φ Lr The maximum amplitude Peak3 of (t) is approximately 2.3. 10 -5 The value of Wb, and the magnetic flux Φ Lm The maximum amplitude Peak1 of (t) is approximately 1.7. 10 -5 The value of Wb. In one scenario, when the winding direction of the resonant inductor Lr is different from the winding direction of the magnetizing inductor Lm, the magnetic flux Φ... Lr (t) and magnetic flux Φ Lm The t-axis cancels each other out, and the maximum amplitude Peak2 has approximately 2.1. 10 -5 The value of Wb. At this time, the value of the maximum amplitude Peak2 is less than the value of the maximum amplitude Peak3. In other words, in response to the magnetic flux Φ Lm (t) and magnetic flux Φ Lr (t) cancel each other out, magnetic flux Φ Lr The maximum amplitude Peak3 of (t) decreases to the maximum amplitude Peak2. In another scenario, when the winding direction of the resonant inductor Lr is the same as the winding direction of the magnetizing inductor Lm, the magnetic flux Φ Lr (t) and magnetic flux Φ Lm (t) are superimposed, and the maximum amplitude Peak4 has approximately 3.2. 10 -5 The value of Wb. At this point, the value of the maximum amplitude Peak4 is greater than the value of the maximum amplitude Peak3. In other words, in response to the magnetic flux Φ Lm (t) and magnetic flux Φ Lr (t) superimposed, magnetic flux Φ Lr The maximum amplitude Peak3 of (t) rises to the maximum amplitude Peak4.

[0081] In various embodiments, the maximum amplitude is an indication Figure 4 The maximum amplitude is the difference between the peak value and the value of 0 in the waveform of the magnetic flux. In other words, the maximum amplitude is the maximum value of the absolute value of the magnetic flux as a function of time. In the above example, the values ​​of the maximum amplitudes Peak1 to Peak4 are provided only as an illustrative embodiment, and this disclosure is not limited to these values.

[0082] In some embodiments, when the magnetic flux measured at the core column m is high, the permeability of the resonant inductor Lr and the magnetizing inductor Lm decreases, causing the current flowing through the transformer TR to increase, which in turn can damage the circuit or components. In the conversion device 100 disclosed herein, the magnetic flux of the resonant inductor Lr and the magnetizing inductor Lm is designed to be complementary, thus the magnetic flux measured at the core column m can be effectively reduced (e.g., maximum amplitude Peak2), thereby improving the conversion efficiency of the conversion device 100 and reducing power loss.

[0083] Figure 5 This is a flowchart illustrating a method 500 for manufacturing a conversion device 100 according to some embodiments of the present disclosure. Figure 5 As shown, manufacturing method 500 includes operations 510 to 540.

[0084] In operation 510, one end of the resonant inductor is coupled to one end of the current transformer.

[0085] For example, one end of the resonant inductor Lr is coupled to the non-pointed terminal of the current transformer CT. Operation 520 is performed after operation 510 is completed.

[0086] In operation 520, the other end of the current transformer is coupled to one end of the transformer, and the current transformer is positioned between the transformer and the resonant inductor along a first direction.

[0087] For example, the dotted terminal of the current transformer CT is coupled to the non-dotted terminal of the transformer TR, and the current transformer CT is positioned along direction X between the transformer TR and the resonant inductor Lr. Operation 530 is performed after operation 520 is completed.

[0088] In operation 530, the other end of the coupling transformer is connected to one end of the magnetizing inductor, and the magnetizing inductor is configured adjacent to the resonant inductor.

[0089] For example, the dotted terminal of the coupling transformer TR is connected to one end of the magnetizing inductor Lm, and the magnetizing inductor Lm is positioned adjacent to the resonant inductor Lr along the direction X. Operation 540 is performed after operation 530 is completed.

[0090] In operation 540, the other end of the magnetizing inductor is coupled to the other end of the resonant inductor. The magnetizing inductor and the resonant inductor are connected in parallel and share a common core.

[0091] For example, the other end of the magnetizing inductor Lm is coupled to the other end of the resonant inductor Lr. The magnetizing inductor Lm and the resonant inductor Lr are connected in parallel and share a common core m along the direction X. Manufacturing method 500 is completed when operation 540 is finished.

[0092] The foregoing outlines the features of several embodiments, enabling those skilled in the art to better understand the nature of this disclosure. Those skilled in the art will understand that they can readily use this disclosure as a basis for designing or modifying other processes and structures for implementing the same purpose and / or achieving the advantages of the embodiments described herein. Those skilled in the art will also recognize that such equivalent constructions do not depart from the spirit and scope of this disclosure, and that various changes, substitutions, and modifications can be made herein without departing from the spirit and scope of this disclosure.

Claims

1. A conversion device, characterized in that, include: A transformer is used to generate an output voltage based on an input voltage. A current transformer coupled to the transformer at a first node; A resonant inductor, one end of which is used to receive the input voltage, and the other end of which is coupled to the current transformer at a second node; as well as A magnetizing inductor is coupled to the transformer at a third node, and the magnetizing inductor is coupled to the resonant inductor at the second node, and is adjacent to the resonant inductor. The current transformer is positioned between the transformer and the resonant inductor along a first direction.

2. The conversion device as described in claim 1, characterized in that, Further includes: A magnetic core is disposed between the resonant inductor and the magnetizing inductor along the first direction. When the conversion device is running, the first magnetic flux of the resonant inductor has a first maximum amplitude, and the second magnetic flux of the excitation inductor has a second maximum amplitude.

3. The conversion device as described in claim 2, characterized in that, The central core of the magnetic core is used to superimpose or cancel out the first magnetic flux of the resonant inductor and the second magnetic flux of the excitation inductor. When the winding direction of one coil of the resonant inductor is the same as the winding direction of one coil of the magnetizing inductor, the first magnetic flux and the second magnetic flux are superimposed on each other, and When the winding direction of the resonant inductor is different from the winding direction of the magnetizing inductor, the first magnetic flux and the second magnetic flux cancel each other out.

4. The conversion device as described in claim 3, characterized in that, When the first magnetic flux and the second magnetic flux are superimposed, the first maximum amplitude rises to a third maximum amplitude. When the first magnetic flux and the second magnetic flux cancel each other out, the first maximum amplitude decreases to a fourth maximum amplitude, and The second maximum amplitude is less than each of the first maximum amplitude, the third maximum amplitude, and the fourth maximum amplitude.

5. The conversion device as claimed in claim 1, characterized in that, The resonant inductor and the magnetizing inductor have a void space below a second direction perpendicular to the first direction, the void space being used to configure one or more elements of the switching device.

6. A method for manufacturing a conversion device, characterized in that, include: One end of a resonant inductor is coupled to one end of a current transformer; The other end of the current transformer is coupled to one end of a transformer; The other end of the transformer is coupled to one end of a magnetizing inductor, and the magnetizing inductor is configured adjacent to the resonant inductor. as well as The other end of the magnetizing inductor is coupled to the other end of the resonant inductor. The current transformer is positioned between the transformer and the resonant inductor along a first direction.

7. The manufacturing method as described in claim 6, characterized in that, When the conversion device is operating, a first magnetic flux of the resonant inductor has a first maximum amplitude, and a second magnetic flux of the excitation inductor has a second maximum amplitude. The first maximum amplitude is greater than the second maximum amplitude.

8. The manufacturing method as described in claim 7, characterized in that, Further includes: A magnetic core is positioned along the first direction between the resonant inductor and the magnetizing inductor. The central core of the magnetic core is used to superimpose or cancel out the first magnetic flux of the resonant inductor and the second magnetic flux of the excitation inductor.

9. The manufacturing method as described in claim 7, characterized in that, When the winding direction of one coil of the resonant inductor is the same as the winding direction of one coil of the magnetizing inductor, the first magnetic flux and the second magnetic flux are superimposed on each other, and When the winding direction of the resonant inductor is different from the winding direction of the magnetizing inductor, the first magnetic flux and the second magnetic flux cancel each other out.

10. The manufacturing method as described in claim 7, characterized in that, When the first magnetic flux and the second magnetic flux are superimposed, the first maximum amplitude rises to a third maximum amplitude. When the first magnetic flux and the second magnetic flux cancel each other out, the first maximum amplitude decreases to a fourth maximum amplitude, and The second maximum amplitude is less than each of the first maximum amplitude, the third maximum amplitude, and the fourth maximum amplitude.

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