Magnetic integrated inductor and magnetic integrated circuit applying magnetic integrated inductor

Abstract

The embodiment of the invention discloses a magnetic integrated inductor and a magnetic integrated circuit applying the magnetic integrated inductor, which are applied to the technical field of electromagnetism, the magnetic integrated inductor is characterized in that a first magnetic core and a second magnetic core are oppositely arranged in parallel, and N wrapping posts and M middle posts are integrally integrated between a first magnet yoke and a second magnet yoke which are shared; the multi-phase winding wound on the wrapping post realizes high-efficiency energy transmission and interphase coupling through a closed magnetic circuit, and the middle post with shorter axial length naturally forms an air gap inside the magnetic core when the two magnetic cores are butted, so that a stable filter inductance path is formed; the filtering function does not depend on an external independent inductor any more, but is embedded in the middle column area of the main magnetic core, so that an extra magnetic core, a framework and a packaging space are omitted, and the overall size is remarkably reduced; meanwhile, all the windings are tightly adjacent to the middle column in the physical layout, and the wiring path is greatly shortened and concentrated on the same end face of the magnetic core.

Description

Technical Field

[0001] This invention relates to the field of electromagnetic technology, and more specifically to a magnetic integrated inductor and a magnetic integrated circuit using the magnetic integrated inductor. Background Technology

[0002] In electronic devices, magnetic integrated inductors are important magnetic components, widely used in switching power supplies, voltage regulation modules, and new energy power systems, where they can achieve key functions such as energy transmission, electrical isolation, and current filtering.

[0003] Currently, common magnetic integrated inductors are usually composed of a coupling transformer and an independent filter inductor. Both the coupling transformer and the filter inductor are composed of a magnetic yoke, winding posts and windings. The coupling transformer is responsible for energy transfer and phase coupling, while the filter inductor is used to smooth the output current and suppress ripple.

[0004] However, this method of separating or simply integrating the coupling transformer and the filter inductor often results in a large overall size of the magnetically integrated inductor and complex wiring between the windings. Summary of the Invention

[0005] In view of this, the present invention provides a magnetically integrated inductor and a magnetically integrated circuit using the magnetically integrated inductor, in order to reduce the size of the magnetically integrated inductor and simplify the wiring between the windings. The specific solution is as follows:

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] A magnetically integrated inductor includes: a first magnetic core and a second magnetic core. The first magnetic core includes: a first magnetic yoke, N first winding posts, N first windings, and M first center posts. The second magnetic core includes: a second magnetic yoke, N second winding posts, N second windings, and M second center posts, where N is an integer greater than or equal to two, and M is an integer greater than or equal to one.

[0008] The first magnetic core and the second magnetic core are arranged in parallel opposite directions;

[0009] The N first winding posts, the M first middle posts, the N second winding posts, and the M second middle posts are all vertically connected between the first magnetic yoke and the second magnetic yoke;

[0010] The axial lengths of the N first winding posts are all greater than the axial lengths of the M first middle posts, and the axial lengths of the N second winding posts are all greater than the axial lengths of the M second middle posts, so that an air gap is formed between the M first middle posts and the M second middle posts.

[0011] The N first windings are wound one-to-one on the N first winding posts, and the N second windings are wound one-to-one on the N second winding posts.

[0012] In one possible implementation, when N is two and M is one...

[0013] The two first winding posts are respectively vertically arranged on both sides of the symmetrical arrangement between the first magnetic yoke and the second magnetic yoke, and the first middle post is vertically arranged in the middle position between the first magnetic yoke and the second magnetic yoke;

[0014] or,

[0015] The two first winding posts are respectively vertically arranged at two symmetrical corners on one side between the first magnetic yoke and the second magnetic yoke, and the first middle post is vertically arranged on the other side between the first magnetic yoke and the second magnetic yoke.

[0016] In one possible implementation, when N is four and M is one,

[0017] The four first winding posts are respectively vertically arranged at the four corners between the first magnetic yoke and the second magnetic yoke, and the first middle post is vertically arranged in the middle position between the first magnetic yoke and the second magnetic yoke. The first middle post is a single middle post or a cross-shaped middle post.

[0018] In one possible implementation, when N is two and M is two,

[0019] The two first central pillars are respectively vertically arranged on both sides of the symmetrical arrangement between the first magnetic yoke and the second magnetic yoke, and the two first winding pillars are respectively vertically arranged on both sides of the symmetrical arrangement in the middle between the first magnetic yoke and the second magnetic yoke.

[0020] In one possible implementation, the first magnetic yoke, the N first winding posts, the M first central posts, the second magnetic yoke, the N second winding posts, and the M second central posts are all made of soft magnetic material.

[0021] In one possible implementation, both the N first windings and the N second windings are printed circuit board coils or Litz coils.

[0022] In one possible implementation, a first non-magnetic spacer is provided between each of the M first central pillars and the first magnetic yoke, and a second non-magnetic spacer is provided between each of the M second central pillars and the second magnetic yoke.

[0023] In one possible implementation, the first magnetic core and the second magnetic core are fixed together by bonding, snapping or screwing to form a closed magnetic circuit.

[0024] A second aspect of this application provides a magnetic integrated circuit using a magnetic integrated inductor, comprising: an input voltage device, a first switch, a second switch, a first capacitor, a second capacitor, and a magnetic integrated inductor;

[0025] The magnetic integrated inductor includes: a first magnetic core and a second magnetic core. The first magnetic core includes: a first yoke, N first winding posts, N first windings, and M first center posts. The second magnetic core includes: a second yoke, N second winding posts, N second windings, and M second center posts. N is an integer greater than or equal to two, and M is an integer greater than or equal to one. The first magnetic core and the second magnetic core are arranged in parallel opposite directions. The N first winding posts, the M first center posts, the N second winding posts, and the M second center posts... Each of the second central posts is perpendicularly connected between the first magnetic yoke and the second magnetic yoke; the axial length of each of the N first winding posts is greater than the axial length of the M first central posts, and the axial length of each of the N second winding posts is greater than the axial length of the M second central posts, so that an air gap is formed between the M first central posts and the M second central posts; the N first windings are wound one-to-one on the N first winding posts, and the N second windings are wound one-to-one on the N second winding posts;

[0026] The input voltage device is connected to one end of the first capacitor via the first switch, and the other end of the first capacitor is connected to the opposite end of the first target winding post in the magnetic integrated inductor.

[0027] The input voltage device is connected to one end of the second capacitor via the first switch, and the other end of the second capacitor is connected to the same end of the second target winding post in the magnetic integrated inductor.

[0028] The same-name end of the first target winding post and the opposite-name end of the second target winding post are both connected to the M first central posts and the M second central posts in the magnetic integrated inductor.

[0029] In one possible implementation, when the duty cycle of the magnetic integrated inductor is 50%, the magnetomotive force generated by the current in the magnetic integrated inductor on the N first winding posts and the N second winding posts cancels each other out.

[0030] When the duty cycle of the magnetic integrated inductor is not 50%, the magnetomotive force generated by the current in the N first winding posts and the N second winding posts of the magnetic integrated inductor does not cancel each other out, and the magnetic flux corresponding to the non-cancelled magnetomotive force flows through the M first middle posts and the M second middle posts, so that the M first middle posts and the M second middle posts serve as integrated filter inductors.

[0031] The above-described embodiments of the present invention disclose a magnetically integrated inductor and a magnetically integrated circuit using the magnetically integrated inductor. This magnetically integrated inductor integrates N winding posts and M center posts between a shared first and second magnetic yoke, allowing the entire structure to simultaneously perform energy coupling and filtering / energy storage functions. The multi-phase windings wound on the winding posts achieve efficient energy transfer and interphase coupling through a closed magnetic circuit, while the shorter-axial-length center posts naturally form an air gap inside the magnetic cores when the two cores are joined, constituting a stable filtering inductor path. Because the filtering function is not... Instead of relying on external independent inductors, the windings are embedded in the central column area of ​​the main magnetic core, eliminating the need for additional magnetic cores, frames, and packaging space, thus significantly reducing the overall size. At the same time, all windings are physically adjacent to the central column, and specific leads of the windings can be directly connected to the common electrical nodes corresponding to the central column, eliminating the need for cross-regional wiring or flying wires. This makes the high-frequency current loop highly localized, and the wiring path is greatly shortened and concentrated on the same end face of the magnetic core. This effectively solves the problems of large overall size and complex wiring between windings caused by traditional discrete or simple spliced ​​structures containing two independent magnetic components. Attached Figure Description

[0032] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0033] Figure 1 This is a three-dimensional structural schematic diagram of a magnetically integrated inductor disclosed in Embodiment 1 of the present invention;

[0034] Figure 2 This is a planar structural diagram of a magnetically integrated inductor disclosed in Embodiment 1 of the present invention;

[0035] Figure 3 This is a side view of the planar structure of a magnetically integrated inductor disclosed in Embodiment 1 of the present invention;

[0036] Figure 4 This is a three-dimensional structural diagram of a magnetic core disclosed in Embodiment 1 of the present invention;

[0037] Figure 5 This is a planar structural diagram of a magnetic core disclosed in Embodiment 1 of the present invention;

[0038] Figure 6 This is a top view of the planar structure of a magnetic core disclosed in Embodiment 1 of the present invention;

[0039] Figure 7This is a three-dimensional structural diagram of another magnetic core disclosed in Embodiment 1 of the present invention;

[0040] Figure 8 This is a planar view of another magnetic core structure disclosed in Embodiment 1 of the present invention;

[0041] Figure 9 This is a top view of the planar structure of another magnetic core disclosed in Embodiment 1 of the present invention;

[0042] Figure 10 This is a three-dimensional structural diagram of a magnetic core disclosed in Embodiment 2 of the present invention;

[0043] Figure 11 This is a side view of the planar structure of a magnetic core disclosed in Embodiment 2 of the present invention;

[0044] Figure 12 This is a top view of the planar structure of a magnetic core disclosed in Embodiment 2 of the present invention;

[0045] Figure 13 This is a three-dimensional structural diagram of another magnetic core disclosed in Embodiment 2 of the present invention;

[0046] Figure 14 This is a side view of the planar structure of another magnetic core disclosed in Embodiment 2 of the present invention;

[0047] Figure 15 This is a top view of the planar structure of another magnetic core disclosed in Embodiment 2 of the present invention;

[0048] Figure 16 This is a three-dimensional structural diagram of a magnetic core disclosed in Embodiment 3 of the present invention;

[0049] Figure 17 This is a planar structural diagram of a magnetic core disclosed in Embodiment 3 of the present invention;

[0050] Figure 18 This is a top view of the planar structure of a magnetic core disclosed in Embodiment 3 of the present invention;

[0051] Figure 19 This is a schematic diagram of a magnetic integrated circuit disclosed in Embodiment 4 of the present invention;

[0052] Figure 20 This is a schematic diagram of another magnetic integrated circuit disclosed in Embodiment 4 of the present invention.

[0053] Figure label:

[0054] 1-First magnetic yoke; 2-First winding post; 3-First middle post; 4-Second magnetic yoke; 5-Second winding post; 6-Second middle post. Detailed Implementation

[0055] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0056] Example 1

[0057] Please refer to Figure 1 , Figure 1 This is a three-dimensional structural diagram of a magnetically integrated inductor disclosed in Embodiment 1 of the present invention.

[0058] The integrated magnetic inductor includes a first magnetic core and a second magnetic core. The first magnetic core includes a first magnetic yoke 1, N first winding posts 2, N first windings, and M first center posts 3. The second magnetic core includes a second magnetic yoke 4, N second winding posts 5, N second windings, and M second center posts 6, where N is an integer greater than or equal to two, and M is an integer greater than or equal to one. The first and second magnetic cores are arranged in parallel and opposite to each other.

[0059] It should be noted that this magnetically integrated inductor consists of two independent magnetic core units (i.e., the first and second magnetic cores) placed in parallel in a mirror-symmetrical manner to form an integrated magnetic circuit system. This integration is not a simple stacking, but rather achieves the coexistence and coordinated operation of multiple inductor windings within a single magnetic component through a shared magnetic circuit and air gap design. Its core design concept lies in: balancing magnetic flux through a symmetrical structure, centrally controlling reluctance using a central column, and independently adjusting inductor parameters and energy storage capacity through precise air gap design. It is particularly suitable for modern high-density power modules that require multiple high-performance inductors (such as multiphase converters and interleaved topologies).

[0060] Each magnetic core is a fully functional subunit: The yoke serves as the horizontal path of the magnetic circuit, connecting all vertical columns and providing a low-resistance return path for the magnetic flux. The winding posts are the functional core of the inductor. Each winding post has a separate winding (the first winding), forming an independent inductor path. A quantity N≥2 means that the device integrates at least two (or more) inductors, which can be used for multi-phase parallel connection to distribute current, reduce ripple, or handle different circuit signals. The center post is the common adjustment point for the magnetic circuit. A quantity M≥1, it has no winding; the magnetic flux generated by all winding posts ultimately forms a loop or couples through this shared path of the center post.

[0061] N first winding posts 2, M first middle posts 3, N second winding posts 5 and M second middle posts 6 are all vertically connected between the first magnetic yoke 1 and the second magnetic yoke 4.

[0062] It should be noted that all winding posts and center posts are vertically connected between the top first yoke 1 and the bottom second yoke 4, thus creating multiple parallel and defined magnetic circuit channels between the two yokes. This vertically connected layout ensures that magnetic lines of force can flow between the upper and lower yokes along the shortest and most direct path, greatly reducing useless force and leakage flux in the magnetic circuit. More importantly, it provides a stable and predictable three-dimensional magnetic circuit framework for the entire core, allowing subsequent air gap design and winding layout to be based on this precise geometry.

[0063] The axial lengths of the N first winding posts 2 are all greater than the axial lengths of the M first middle posts 3, and the axial lengths of the N second winding posts 5 are all greater than the axial lengths of the M second middle posts 6, so that an air gap is formed between the M first middle posts 3 and the M second middle posts 6.

[0064] It should be noted that an axial length difference is created between the winding posts and the center posts. When the first and second magnetic cores are assembled, the winding posts on both sides, being longer, will contact and fit tightly first, providing the main mechanical support. The center posts, being shorter, cannot contact each other, naturally forming a physical gap, or air gap, at the mating surface of the two cores. This air gap is an artificially introduced high magnetic reluctance region; its presence completely alters the characteristics of the magnetic circuit. It makes the inductance value primarily determined by the size of the air gap, thus becoming stable and precisely controllable. Simultaneously, it can store most of the magnetic energy and effectively prevent the magnetic core from saturating under DC bias, which is crucial for achieving high power density and reliability. This design simplifies the complex air gap control to a centralized location (the center post surface).

[0065] N first windings are wound one-to-one on N first winding posts 2, and N second windings are wound one-to-one on N second winding posts 5.

[0066] It should be noted that each winding post has a corresponding winding coil tightly wound around it. When current flows through these windings, it excites magnetic flux in the winding post where they are located, thus converting electrical energy into magnetic energy for storage. This one-to-one winding method means that each winding and its winding post together form an independent inductance channel with a specific inductance. The N windings on the first magnetic core and the N windings on the second magnetic core can be connected to circuits to achieve functions such as multi-phase power supply, filtering, or energy transfer. The magnetic flux generated by these windings will eventually converge on the common central post path with an air gap, forming a complete magnetic loop, thus achieving the design goal of integrated magnetic circuit and independent circuit.

[0067] As one possible implementation, when N is two and M is one, the two first winding posts 2 are respectively vertically arranged on both sides of the symmetrical arrangement between the first magnetic yoke 1 and the second magnetic yoke 4, and the first middle post 3 is vertically arranged in the middle position between the first magnetic yoke 1 and the second magnetic yoke 4.

[0068] It should be noted that when N is two and M is one, the first and second magnetic cores of the magnetically integrated inductor each contain two winding posts and one center post. Specifically, the two first winding posts 2 are symmetrically and vertically arranged on the left and right sides between the first yoke 1 and the second yoke 4, while the first center post 3 is located in the middle between them; the structure of the second magnetic core corresponds exactly to this, with its two second winding posts 5 also symmetrically arranged on both sides, and the second center post 6 centrally located. This symmetrical layout not only ensures the balance of the magnetic circuit, which is beneficial for achieving natural current sharing among multiphase currents, but also ensures that the air gap is precisely located at the geometric center of the magnetic core, ensuring the stability and consistency of the filter inductor. The winding posts on both sides are the main carriers of the windings and current, responsible for generating the magnetic field. Each winding post is wound with one or more windings, which generate magnetomotive force by being energized, thus forming a closed magnetic circuit. Since the winding posts are distributed on both sides of the magnetic core and arranged symmetrically, they can effectively guide the magnetic field generated by the current to the yoke, and then conduct it to the winding post on the other side through the yoke, thereby forming an efficient energy transfer path. This design ensures uniform magnetic flux distribution, which helps improve the overall efficiency of the magnetic circuit and reduces the risk of local saturation.

[0069] Specifically, the first yoke 1 and the second yoke 4, serving as a shared frame, not only provide mechanical support but also constitute a low-resistivity main flux path. In this configuration, the flux originates from one winding post, passes through the yoke, and is transmitted to the other winding post, forming a closed loop. This not only achieves efficient energy coupling and transfer but also, due to the symmetrical arrangement of the winding posts, ensures that the two-phase currents cancel out unbalanced flux during operation, further enhancing the system's stability and reliability. Furthermore, the first and second central posts 3 and 6, located in the center, function as filtering and energy storage units. Due to the short axial length of the central posts, a concentrated air gap is formed between the first and second magnetic cores when they are connected. This air gap, surrounded by the winding posts, constitutes a high-resistivity path, capable of carrying net flux even in the presence of DC bias or volt-second imbalance, thus effectively functioning as an embedded filtering inductor. This design allows the magnetically integrated inductor to achieve smooth output current and ripple suppression without the need for additional independent filtering components.

[0070] For easier understanding, please refer to Figure 1 , Figure 2 and Figure 3 . Figure 1This is a three-dimensional structural diagram of a magnetically integrated inductor disclosed in Embodiment 1 of the present invention. The lower plate-shaped structure is the first magnetic yoke 1, and the upper plate-shaped structure is the second magnetic yoke 4. The two are connected by six vertical pillars: two symmetrical first winding pillars 2 and two symmetrical second winding pillars 5 on the left and right, used for subsequent winding; and a first central pillar 3 and a second central pillar 6 in the middle, which are not wound or only serve as structural supports. All pillars extend vertically from the surface of the magnetic yoke, forming a regular array. This three-dimensional diagram visually presents the overall outline of the magnetically integrated inductor and the spatial relative positions of its components. Figure 2 This is a planar structural diagram of a magnetically integrated inductor disclosed in Embodiment 1 of the present invention. Figure 3 This is a side view of the planar structure of a magnetically integrated inductor disclosed in Embodiment 1 of the present invention.

[0071] Furthermore, you can refer to Figure 4 , Figure 5 and Figure 6 . Figure 4 This is a three-dimensional structural diagram of a magnetic core disclosed in Embodiment 1 of the present invention. The lower flat structure in the diagram is the first magnetic yoke 1, on which three vertical pillars are arranged: two symmetrical first winding pillars 2 on the left and right, used for subsequent winding; and a first central pillar 3 in the middle, which is not wound or only serves as structural support. All pillars extend vertically from the surface of the first magnetic yoke 1, forming a regular array. This three-dimensional diagram intuitively presents the overall outline of the magnetic core and the spatial relative positions of each component. Figure 5 This is a planar structural diagram of a magnetic core disclosed in Embodiment 1 of the present invention. Figure 6 This is a top view of the planar structure of a magnetic core disclosed in Embodiment 1 of the present invention.

[0072] As another possible implementation, when N is two and M is one, the two first winding posts 2 are respectively vertically arranged at two symmetrical corners on one side between the first magnetic yoke 1 and the second magnetic yoke 4, and the first middle post 3 is vertically arranged on the other side between the first magnetic yoke 1 and the second magnetic yoke 4.

[0073] It should be noted that when N is two and M is one, the magnetic integrated inductor can adopt a non-centrally symmetrical but functionally equivalent structural layout: the two first winding posts 2 on the first yoke 1 are concentrated at two symmetrical corner positions on one side (e.g., the left side), that is, one is located at the left front corner and the other at the left rear corner (or the upper left corner and the lower left corner), and the two are mirror symmetrical on this side edge; at the same time, the first middle post 3 is vertically set at the middle position on the opposite side (e.g., the right side) or at a corresponding position that matches the layout of the winding posts. The structure of the second magnetic core is mirror symmetrical to the first magnetic core. When the first magnetic core and the second magnetic core are parallel and connected, all the end faces of the winding posts are in contact with each other, forming a closed main magnetic flux path, while the middle post, due to its shorter axial length, naturally forms an air gap between the connecting surfaces, constituting the high magnetic reluctance branch required for filtering. From the perspective of magnetic circuit principle, although the winding post and the center post are located on both sides of the magnetic core in the plane and are no longer collinear or common center, since the first magnetic yoke 1 and the second magnetic yoke 4 are continuous magnetic conductors that run through the entire structure, the magnetic flux can still start from the winding post on one side, be transversely conducted through the magnetic yoke to the center post area on the opposite side, and complete the loop through the air gap, thereby maintaining the complete magnetic coupling and filtering function.

[0074] Specifically, the two-phase windings are wound on two winding posts on the same side. The alternating magnetic flux generated by them, after being superimposed in the yoke, can still be effectively coupled and achieve phase-to-phase energy sharing. The net magnetic flux generated by DC bias or volt-second imbalance preferentially flows through the air gap path of the middle post with high magnetic reluctance, avoiding saturation of the main magnetic core and ensuring the stability of the filter inductance. Therefore, although this layout breaks the geometric center symmetry, it does not sacrifice the integrity of the magnetic circuit or functional performance. This arrangement of "winding posts concentrated in one corner and the middle post biased on the opposite side" allows all winding leads to be uniformly led out from the side where the winding posts are located at the PCB routing level. This facilitates short-distance, low-parasitic connections with power switches, driver ICs, or input / output capacitors arranged on the same side, greatly simplifying the routing topology, reducing the high-frequency loop area, thereby reducing EMI and improving efficiency.

[0075] For easier understanding, please refer to Figure 7 , Figure 8 and Figure 9 . Figure 7 This is a three-dimensional structural diagram of another magnetic core disclosed in Embodiment 1 of the present invention; the lower flat structure in the figure is the first magnetic yoke 1, on which three vertical pillars are arranged: two symmetrical first winding pillars 2 on one side, used for subsequent winding; and a first central pillar 3 on the other side, which is not wound or only serves as structural support. All pillars extend vertically from the surface of the first magnetic yoke 1, forming a regular array. This three-dimensional diagram intuitively presents the overall outline of the magnetic core and the spatial relative positions of each component. Figure 8 This is a planar view of another magnetic core structure disclosed in Embodiment 1 of the present invention. Figure 9 This is a top view of the planar structure of another magnetic core disclosed in Embodiment 1 of the present invention.

[0076] The first yoke 1, N first winding posts 2, M first center posts 3, the second yoke 4, N second winding posts 5, and M second center posts 6 are all made of soft magnetic material. The N first windings and N second windings are all printed circuit board coils or Litz coils.

[0077] It should be noted that, to ensure the high efficiency of the magnetically integrated inductor, the first yoke 1, N first winding posts 2, M first center posts 3, second yoke 4, N second winding posts 5, and M second center posts 6 are all made of soft magnetic materials. These materials possess high permeability and low coercivity, enabling them to efficiently conduct magnetic flux under alternating magnetic fields and reduce energy loss. Furthermore, the selection of soft magnetic materials also considers their good temperature stability and anti-saturation capability, ensuring that the magnetic circuit remains stable under high current or high-frequency operating conditions, avoiding system failures caused by localized overheating or core saturation.

[0078] To optimize electrical performance and improve integration, the N first windings and N second windings utilize either printed circuit board (PCB) coils or Litz coils. PCB coils, implemented using multi-layer printed circuit boards, not only reduce size but also allow direct integration with power management chips or other electronic components on the same PCB, greatly simplifying wiring complexity. Litz coils, on the other hand, are braided from multiple strands of fine copper wire, effectively reducing the increased AC resistance caused by skin and proximity effects, making them particularly suitable for high-frequency applications. The choice of these two winding types significantly improves inductor efficiency and helps reduce parasitic parameters, further enhancing the overall performance of the device.

[0079] A first non-magnetic spacer is provided between each of the M first central pillars 3 and the first magnetic yoke 1, and a second non-magnetic spacer is provided between each of the M second central pillars 6 and the second magnetic yoke 4. The first magnetic core and the second magnetic core are fixed together by adhesive, snap-fit, or screws to form a closed magnetic circuit.

[0080] It should be noted that, in order to precisely control the air gap size and prevent direct contact between the central pillars and the yoke from causing a magnetic short circuit, a first non-magnetic spacer is provided between the M first central pillars 3 and the first yoke 1. Similarly, a second non-magnetic spacer is provided between the M second central pillars 6 and the second yoke 4. These spacers are typically made of ceramic, plastic, or other non-magnetic materials, ensuring structural strength without interfering with the magnetic flux. In this way, the air gap size can be precisely adjusted to obtain the required filter inductance value, and it can be ensured that the net magnetic flux can smoothly close through the air gap path under DC bias or volt-second imbalance conditions, thereby maintaining stable magnetic circuit performance.

[0081] To ensure the mechanical stability and magnetic circuit integrity of the entire integrated magnetic inductor, the first and second magnetic cores need to be firmly bonded together. This can be achieved in several ways, such as bonding, using snap-fit ​​connections, or installing screws. Adhesives provide strong adhesion without adding extra thickness; snap-fit ​​designs facilitate quick assembly and disassembly for maintenance; while screw connections offer higher mechanical strength, especially suitable for applications requiring high mechanical stress. Regardless of the fixing method used, the ultimate goal is to ensure that the two magnetic cores fit tightly together, forming a complete closed magnetic circuit to maximize magnetic flux transmission efficiency and reduce magnetic leakage.

[0082] The leads of N first windings and N second windings are all led out from the first magnetic yoke 1, or the leads of N first windings and N second windings are all led out from the second magnetic yoke 4.

[0083] It should be noted that, to simplify electrical connections and optimize PCB layout, the leads of the N first windings and N second windings can be uniformly led out from either the first yoke 1 or the second yoke 4. This centralized lead-out method helps shorten lead lengths, reduce parasitic inductance and resistance, and also facilitates a more compact modular design. The specific side chosen as the lead-out point depends on the wiring requirements of the actual application scenario and its spatial relationship with other components. Regardless of whether the lead-out point is from the first yoke 1 or the second yoke 4, the key is to ensure that all leads are located on the same side for centralized management and connection, as well as for subsequent testing and maintenance.

[0084] Example 2

[0085] Please refer to Figure 10 and Figure 13 . Figure 10 This is a three-dimensional structural diagram of a magnetic core disclosed in Embodiment 2 of the present invention; Figure 13 This is a three-dimensional structural diagram of another magnetic core disclosed in Embodiment 2 of the present invention.

[0086] As one possible implementation, when N is four and M is one, the four first winding posts 2 are respectively vertically arranged at the four corners between the first magnetic yoke 1 and the second magnetic yoke 4, and the first middle post 3 is vertically arranged at the middle position between the first magnetic yoke 1 and the second magnetic yoke 4. The first middle post 3 is a single middle post.

[0087] It should be noted that when N is four and M is one, the first magnetic core adopts a highly symmetrical four-phase layout structure: the four first winding posts 2 are respectively vertically arranged at the four corners of the first yoke 1 (i.e., front left, front right, rear left, and rear right), forming a rectangular or square array; the first center post 3 serves as a single center post, vertically arranged at the geometric center of the first yoke 1. The second magnetic core has the same structure. When the first and second magnetic cores are parallelly connected, all the winding post end faces are in contact with each other, forming four parallel low reluctance main magnetic circuits used to carry the energy transmission of the four-phase coupled windings; while the central first center post 3 and second center post 6, due to their shorter axial length, form a concentrated air gap between their mating surfaces. This air gap is surrounded by the surrounding winding posts, forming a high reluctance filter branch. This "four corner winding posts + central single center post" layout achieves a highly symmetrical magnetic circuit design, allowing the magnetic flux generated by the four-phase windings to cancel each other out the common-mode components in the central region, effectively reducing EMI and improving current sharing capability. Meanwhile, due to its shorter length, the central column forms a concentrated air gap with the opposite central column after assembly, constituting a high magnetoresistive filtering path and realizing the embedded inductor function.

[0088] For easier understanding, please refer to Figure 10 , Figure 11 and Figure 12 . Figure 10 This is a three-dimensional structural diagram of a magnetic core disclosed in Embodiment 2 of the present invention. The lower flat structure in the diagram is the first magnetic yoke 1, on which five vertical pillars are arranged: four symmetrical first winding pillars 2 at the four corners, used for subsequent winding; and a single single first central pillar 3 in the middle, which is not wound or only serves as structural support. All pillars extend vertically from the surface of the first magnetic yoke 1, forming a regular array. This three-dimensional diagram intuitively presents the overall outline of the magnetic core and the spatial relative positions of each component. Figure 11 This is a side view of the planar structure of a magnetic core disclosed in Embodiment 2 of the present invention. Figure 12 This is a top view of the planar structure of a magnetic core disclosed in Embodiment 2 of the present invention;

[0089] As another possible implementation, when N is four and M is one, the four first winding posts 2 are respectively vertically arranged at the four corners between the first magnetic yoke 1 and the second magnetic yoke 4, and the first central post 3 is vertically arranged at the middle position between the first magnetic yoke 1 and the second magnetic yoke 4. The first central post 3 is a single cross-shaped central post.

[0090] It should be noted that when N is four and M is one, the first magnetic core adopts a highly symmetrical four-phase layout structure: the four first winding posts 2 are respectively vertically arranged at the four corners of the first yoke 1 (i.e., front left, front right, rear left, and rear right), forming a rectangular or square array; the first central post 3 serves as a cross-shaped central post, vertically arranged at the geometric center of the first yoke 1, its shape resembling a "+", dividing the first magnetic core into four quadrants. The cross-shaped design not only increases mechanical strength but also provides a larger surface area to disperse heat, which is helpful for thermal management. The second magnetic core has the same design. When the first and second magnetic cores are parallelly connected, all the winding post end faces are in contact with each other, forming four parallel low magnetic reluctance main magnetic circuits used to carry the energy transmission of the four-phase coupled windings; while the central first central post 3 and the second central post 6, due to their shorter axial length, form a concentrated air gap between their mating surfaces. This air gap is surrounded by the surrounding winding posts, forming a high magnetic reluctance filter branch. This "four-corner winding post + central single-unit post" layout achieves a highly symmetrical magnetic circuit design, allowing the magnetic flux generated by the four-phase windings to cancel each other out common-mode components in the central region, effectively reducing EMI and improving current sharing capability. At the same time, due to its shorter length, the central post forms a concentrated air gap with the opposite post after assembly, constituting a high magnetoresistance filtering path and realizing the embedded inductor function.

[0091] For easier understanding, please refer to Figure 13 , Figure 14 and Figure 15 . Figure 13 This is a three-dimensional structural diagram of another magnetic core disclosed in Embodiment 2 of the present invention; the lower flat structure in the figure is the first magnetic yoke 1, on which five vertical pillars are arranged: four symmetrical first winding pillars 2 at the four corners, used for subsequent winding; and a cross-shaped first central pillar 3 in the middle, which is not wound or only serves as structural support. All pillars extend vertically from the surface of the first magnetic yoke 1, forming a regular array. This three-dimensional diagram intuitively presents the overall outline of the magnetic core and the spatial relative positions of each component. Figure 14 This is a side view of the planar structure of another magnetic core disclosed in Embodiment 2 of the present invention. Figure 15 This is a top view of the planar structure of another magnetic core disclosed in Embodiment 2 of the present invention.

[0092] Example 3

[0093] Please refer to Figure 16 . Figure 16 This is a three-dimensional structural diagram of a magnetic core disclosed in Embodiment 3 of the present invention.

[0094] As one possible implementation, when N is two and M is two, the two first central pillars 3 are respectively vertically arranged on both symmetrical sides between the first magnetic yoke 1 and the second magnetic yoke 4, and the two first winding pillars 2 are respectively vertically arranged on both symmetrical sides in the middle between the first magnetic yoke 1 and the second magnetic yoke 4.

[0095] It should be noted that when N is two and M is two, the first magnetic core adopts an interleaved symmetrical two-phase dual-filter layout structure: the two first central pillars 3 are respectively vertically arranged on the symmetrical sides (i.e., the left and right sides) of the first magnetic yoke 1 to construct two independent filter magnetic circuits; the two first winding pillars 2 are respectively vertically arranged on the symmetrical sides (such as the front and rear sides, or the left and right inner sides near the center line) of the middle area of ​​the first magnetic yoke 1 to form the main magnetic flux path for energy coupling transmission. The second magnetic core has the same structure. When the first magnetic core and the second magnetic core are parallelly connected, all the end faces of the winding pillars are in contact with each other to form two parallel low magnetic reluctance main magnetic circuits, which respectively carry the energy transmission and interphase coupling of the two-phase coupled windings; while the four central pillars (the first central pillar 3 and the second central pillar 6 are paired) are all shorter than the winding pillars in axial length, forming two concentrated air gaps at the docking surface, located on the left and right sides of the magnetic core respectively. This "outer double-column + inner double-winding-column" layout achieves functional zoning and magnetic circuit decoupling: the two-phase windings are concentrated in the central region of the core, which helps to shorten the interphase coupling path and improve current sharing performance; while the air gaps of the two columns are independent of each other, which can respectively address the filtering requirements of each phase, or work together to enhance the overall filtering capability. Because the columns and winding-columns are staggered in the plane, the magnetic flux paths are clearly separated, effectively suppressing mutual interference between the main magnetic circuit and the filtering branches. At the same time, the structure maintains overall left-right symmetry, ensuring magnetomotive force balance, avoiding bias saturation, and reserving central channels or edge heat dissipation space for PCB routing, balancing electrical performance and thermo-mechanical reliability. By integrating the functions of a two-phase transformer and a dual-channel filtering inductor within a single core assembly, power density and system integration are significantly improved.

[0096] For easier understanding, please refer to Figure 16 , Figure 17 and Figure 18 . Figure 16 This is a three-dimensional structural diagram of a magnetic core disclosed in Embodiment 3 of the present invention. The lower flat structure in the diagram is the first magnetic yoke 1, on which four vertical pillars are arranged: two symmetrical first winding pillars 2 on the left and right sides, used for subsequent winding; and two symmetrical first central pillars 3 on the front and rear sides in the middle, which are not wound or only serve as structural supports. All pillars extend vertically from the surface of the first magnetic yoke 1, forming a regular array. This three-dimensional diagram intuitively presents the overall outline of the magnetic core and the spatial relative positions of each component. Figure 17 This is a planar structural diagram of a magnetic core disclosed in Embodiment 3 of the present invention. Figure 18 This is a top view of the planar structure of a magnetic core disclosed in Embodiment 3 of the present invention.

[0097] Example 4

[0098] Please refer to Figure 19 and Figure 20 . Figure 19This is a schematic diagram of a magnetic integrated circuit disclosed in Embodiment 4 of the present invention; Figure 20 This is a schematic diagram of another magnetic integrated circuit disclosed in Embodiment 4 of the present invention.

[0099] A magnetic integrated circuit using a magnetic integrated inductor includes: an input voltage device, a first switch, a second switch, a first capacitor, a second capacitor, and a magnetic integrated inductor;

[0100] The magnetic integrated inductor includes: a first magnetic core and a second magnetic core. The first magnetic core includes: a first yoke 1, N first winding posts 2, N first windings, and M first center posts 3. The second magnetic core includes: a second yoke 4, N second winding posts 5, N second windings, and M second center posts 6. N is an integer greater than or equal to two, and M is an integer greater than or equal to one. The first and second magnetic cores are arranged in parallel and opposite directions. Each of the second central posts 6 is perpendicularly connected between the first magnetic yoke 1 and the second magnetic yoke 4; the axial length of each of the N first winding posts 2 is greater than the axial length of each of the M first central posts 3, and the axial length of each of the N second winding posts 5 is greater than the axial length of each of the M second central posts 6, so that an air gap is formed between the M first central posts 3 and the M second central posts 6; the N first windings are wound one-to-one on the N first winding posts 2, and the N second windings are wound one-to-one on the N second winding posts 5;

[0101] The input voltage device is connected to one end of the first capacitor via a first switch, and the other end of the first capacitor is connected to the opposite end of the first target winding post in the magnetic integrated inductor.

[0102] The input voltage device is connected to one end of the second capacitor via the first switch, and the other end of the second capacitor is connected to the same-name end of the second target winding post in the magnetic integrated inductor.

[0103] The same-named end of the first target winding post and the opposite-named end of the second target winding post are both connected to the M first middle posts 3 and the M second middle posts 6 in the magnetic integrated inductor.

[0104] It should be noted that when magnetically integrated inductors are applied to power electronic systems with a two-phase interleaved topology, their electrical connections and operating modes exhibit high symmetry and functional coupling. Specifically, the input voltage device V... IN The first capacitor C is connected to one end of the first switch. AB The other end is connected to the opposite end of the first target winding post in the magnetic integrated inductor; simultaneously, the input voltage device is also connected to the second capacitor C via the second switch. BAOne end of the second capacitor is connected to the other end of the second target winding post in the magnetic integrated inductor. This cross-connection method constitutes a typical X-type or bridge input structure, so that the current paths of the two phases form a mutually coupled magnetomotive force inside the magnetic core.

[0105] Furthermore, the same-named ends of the first target winding column and the opposite-named ends of the second target winding column are both connected to the M first central columns 3 and M second central columns 6 in the magnetically integrated inductor. That is, the common endpoints of these two windings are connected to the central column region, thus using the central column as a common-mode filtering path. This design achieves a deep integration of main power transmission and filtering energy storage: during normal operation, the currents of the two phase windings conduct alternately, and the magnetomotive forces they generate are superimposed or canceled in the magnetic core. The part that is not completely canceled is borne by the air gap of the central column, avoiding saturation of the main magnetic core.

[0106] For easier understanding, please refer to Figure 19 and Figure 20 . Figure 19 This is a schematic diagram of a magnetic integrated circuit disclosed in Embodiment 4 of the present invention; the figure shows the equivalent circuit connection and magnetic flux path under ideal operating conditions where the duty cycle of the magnetic integrated inductor is 50%. In this state, the first switch and the second switch are alternately turned on and the on-time is equal, so that the current I flowing through the winding A on the N first winding posts is... A The current I flowing through the winding B on the N second winding posts B The amplitudes are equal and the directions are opposite. Since the two windings are wound in the same direction (or connected in opposite directions according to the definition of the same terminal), the magnetomotive forces they generate in the main magnetic circuit of the core are equal in magnitude and opposite in polarity, thus completely canceling each other out, and the net magnetic flux is zero. At this time, there is no DC bias in the main magnetic circuit, and all alternating magnetic flux is effectively constrained within a closed low magnetic reluctance path; while the M central columns, due to the lack of net ampere-turn excitation, basically do not participate in magnetic flux conduction and exist only as structural supports.

[0107] Figure 20This is a schematic diagram of another magnetic integrated circuit disclosed in Embodiment 4 of the present invention. The diagram shows the operating states of the magnetic integrated inductor when the duty cycle D>50% and D<50%, respectively. The magnetomotive force generated by the current in the N first winding posts and the N second winding posts of the connecting tube of the magnetic integrated inductor does not cancel each other out, and the magnetic flux corresponding to the non-cancelled magnetomotive force flows through the M first middle posts and the M second middle posts, so that the M first middle posts and the M second middle posts act as integrated filter inductors. Specifically, when D>50%, the conduction time of bridge arm A is longer, the current in winding A is larger, and a positive magnetomotive force is generated; the conduction time of bridge arm B is shorter, the current in winding B is smaller, and a smaller reverse magnetomotive force is generated, resulting in an overall magnetomotive force imbalance and the appearance of net magnetic flux. This net magnetic flux cannot close in the main magnetic circuit and can only flow back through the air gap path of the middle post, so that the middle post acts as an integrated filter inductor L, absorbing excess energy and suppressing output ripple. At this time, the current I of the integrated filter inductor L is... L The trend is upward. Similarly, when D < 50%, bridge arm B dominates, and winding B generates a large reverse magnetomotive force, which will also establish a reverse net magnetic flux in the middle column, still borne by the air gap of the middle column. At this time, the current I of the integrated filter inductor L is... L The ripple will decrease accordingly, thus continuously achieving the ripple suppression function.

[0108] In summary, the present invention discloses a magnetically integrated inductor and a magnetically integrated circuit using the magnetically integrated inductor. This magnetically integrated inductor integrates N winding posts and M center posts between a shared first and second magnetic core, with the first and second magnetic cores arranged parallel to each other. This allows the entire structure to simultaneously perform energy coupling and filtering / energy storage functions. The multi-phase windings wound on the winding posts achieve efficient energy transfer and interphase coupling through a closed magnetic circuit. The shorter axial length of the center posts naturally forms an air gap inside the magnetic cores when the two cores are joined, constituting a stable filtering inductor path. Due to the filtering function... Instead of relying on an external independent inductor, it is embedded in the central column area of ​​the main magnetic core, eliminating the need for additional magnetic cores, frames, and packaging space, thus significantly reducing the overall size. At the same time, all windings are physically adjacent to the central column, and specific leads of the windings can be directly connected to the common electrical nodes corresponding to the central column, without the need for cross-regional wiring or flying wires. This makes the high-frequency current loop highly localized, and the wiring path is greatly shortened and concentrated on the same end face of the magnetic core. This effectively solves the problems of large overall size and complex wiring between windings caused by traditional discrete or simple spliced ​​structures containing two independent magnetic components.

[0109] It should be noted that in this specification, relational terms such as first and second are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations.

[0110] Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0111] Those skilled in the art will further recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. To clearly illustrate the interchangeability of hardware and software, the components and steps of the various examples have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementations should not be considered beyond the scope of this invention.

[0112] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention.

[0113] Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A magnetically integrated inductor, characterized in that, include: A first magnetic core and a second magnetic core, wherein the first magnetic core comprises: a first magnetic yoke, N first winding posts, N first windings and M first center posts, and the second magnetic core comprises: a second magnetic yoke, N second winding posts, N second windings and M second center posts, wherein N is an integer greater than or equal to two and M is an integer greater than or equal to one; The first magnetic core and the second magnetic core are arranged in parallel opposite directions; The N first winding posts, the M first middle posts, the N second winding posts, and the M second middle posts are all vertically connected between the first magnetic yoke and the second magnetic yoke; The axial lengths of the N first winding posts are all greater than the axial lengths of the M first middle posts, and the axial lengths of the N second winding posts are all greater than the axial lengths of the M second middle posts, so that an air gap is formed between the M first middle posts and the M second middle posts. The N first windings are wound one-to-one on the N first winding posts, and the N second windings are wound one-to-one on the N second winding posts.

2. The magnetic integrated inductor according to claim 1, characterized in that, When N is two and M is one. The two first winding posts are respectively vertically arranged on both sides of the symmetrical arrangement between the first magnetic yoke and the second magnetic yoke, and the first middle post is vertically arranged in the middle position between the first magnetic yoke and the second magnetic yoke; or, The two first winding posts are respectively vertically arranged at two symmetrical corners on one side between the first magnetic yoke and the second magnetic yoke, and the first middle post is vertically arranged on the other side between the first magnetic yoke and the second magnetic yoke.

3. The magnetic integrated inductor according to claim 1, characterized in that, When N is four and M is one. The four first winding posts are respectively vertically arranged at the four corners between the first magnetic yoke and the second magnetic yoke, and the first middle post is vertically arranged in the middle position between the first magnetic yoke and the second magnetic yoke. The first middle post is a single middle post or a cross-shaped middle post.

4. The magnetic integrated inductor according to claim 1, characterized in that, When N is two and M is two The two first central pillars are respectively vertically arranged on both sides of the symmetrical arrangement between the first magnetic yoke and the second magnetic yoke, and the two first winding pillars are respectively vertically arranged on both sides of the symmetrical arrangement in the middle between the first magnetic yoke and the second magnetic yoke.

5. The magnetic integrated inductor according to claim 1, characterized in that, The first magnetic yoke, the N first winding posts, the M first central posts, the second magnetic yoke, the N second winding posts, and the M second central posts are all made of soft magnetic material.

6. The magnetic integrated inductor according to claim 1, characterized in that, Both the N first windings and the N second windings are printed circuit board coils or Litz coils.

7. The magnetic integrated inductor according to claim 1, characterized in that, A first non-magnetic spacer is provided between each of the M first central pillars and the first magnetic yoke, and a second non-magnetic spacer is provided between each of the M second central pillars and the second magnetic yoke.

8. The magnetic integrated inductor according to claim 1, characterized in that, The first magnetic core and the second magnetic core are fixed together by adhesive, snap-fit ​​or screw to form a closed magnetic circuit.

9. A magnetic integrated circuit using a magnetic integrated inductor, characterized in that, include: Input voltage device, first switch, second switch, first capacitor, second capacitor, and magnetic integrated inductor; The magnetic integrated inductor includes: a first magnetic core and a second magnetic core. The first magnetic core includes: a first yoke, N first winding posts, N first windings, and M first center posts. The second magnetic core includes: a second yoke, N second winding posts, N second windings, and M second center posts. N is an integer greater than or equal to two, and M is an integer greater than or equal to one. The first magnetic core and the second magnetic core are arranged in parallel opposite directions. The N first winding posts, the M first center posts, the N second winding posts, and the M second center posts... Each of the second central posts is perpendicularly connected between the first magnetic yoke and the second magnetic yoke; the axial length of each of the N first winding posts is greater than the axial length of the M first central posts, and the axial length of each of the N second winding posts is greater than the axial length of the M second central posts, so that an air gap is formed between the M first central posts and the M second central posts; the N first windings are wound one-to-one on the N first winding posts, and the N second windings are wound one-to-one on the N second winding posts; The input voltage device is connected to one end of the first capacitor via the first switch, and the other end of the first capacitor is connected to the opposite end of the first target winding post in the magnetic integrated inductor. The input voltage device is connected to one end of the second capacitor via the first switch, and the other end of the second capacitor is connected to the same end of the second target winding post in the magnetic integrated inductor. The same-name end of the first target winding post and the opposite-name end of the second target winding post are both connected to the M first central posts and the M second central posts in the magnetic integrated inductor.

10. The magnetic integrated circuit using a magnetic integrated inductor according to claim 9, characterized in that, When the duty cycle of the magnetic integrated inductor is 50%, the magnetomotive force generated by the current in the N first winding posts and the N second winding posts of the magnetic integrated inductor cancels each other out. When the duty cycle of the magnetic integrated inductor is not 50%, the magnetomotive force generated by the current in the N first winding posts and the N second winding posts of the magnetic integrated inductor does not cancel each other out, and the magnetic flux corresponding to the non-cancelled magnetomotive force flows through the M first middle posts and the M second middle posts, so that the M first middle posts and the M second middle posts serve as integrated filter inductors.

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