Multi-module dc-dc converter, integrated magnetic assembly and method of manufacturing an integrated magnetic assembly

Abstract

The present application provides an integrated magnetic assembly and a manufacturing method thereof for a multi-module DC-DC converter. The integrated magnetic assembly includes N primary windings, N secondary windings and N magnetic cores, and N is an integer greater than 1. The N magnetic cores are sequentially arranged, and each magnetic core includes a plate, a first common magnetic core column, a second common magnetic core column, an inductor magnetic core column and a transformer magnetic core column. The first common magnetic core column and the second common magnetic core column are arranged on the first side and the second side of the plate respectively. The inductor magnetic core column is configured to be wound with corresponding primary windings or corresponding secondary windings, and the transformer magnetic core column is configured to be wound with corresponding primary and secondary windings which are interleaved with each other.

Description

Technical Field

[0001] This case relates to a DC-DC converter, a magnetic component, and a method of manufacturing the magnetic component, particularly a multi-module DC-DC converter, an integrated magnetic component, and a method of manufacturing the integrated magnetic component. Background Technology

[0002] In multi-module converters, effective current distribution methods (such as maximum current distribution or droop control) are crucial for ensuring balanced operation when multiple modules are connected in parallel. For example, in resonant converters, frequency modulation is typically used for regulation, which complicates the control strategy. Conversely, in pulse width modulation (PWM) converters, voltage gain is adjusted through duty cycle control or phase shift control, which directly affects the current distribution among parallel modules. Similarly, when multiple modules are connected in series, an effective voltage distribution method is required.

[0003] The need for more complex control strategies (such as frequency modulation and phase shift control) leads to the use of more expensive microcontroller units (MCUs) or digital signal processors (DSPs), and consumes more control resources. Summary of the Invention

[0004] This invention provides a multi-module DC-DC converter, an integrated magnetic component, and a method for manufacturing the integrated magnetic component, thereby overcoming the shortcomings of the prior art.

[0005] According to the concept of this invention, an integrated magnetic component is provided for a multi-module DC-DC converter. The integrated magnetic component includes N primary windings, N secondary windings, and N magnetic cores, where N is an integer greater than 1. The N magnetic cores are arranged sequentially. Each magnetic core includes a plate, a first common core post, a second common core post, an inductor core post, and a transformer core post. The first common core post and the second common core post are respectively disposed on a first side and a second side of the plate. The inductor core and the transformer core are disposed on the plate. The inductor core post is configured to be wound with corresponding primary windings from the N primary windings, or with corresponding secondary windings from the N secondary windings, and the transformer core post is configured to be wound with corresponding primary windings and corresponding secondary windings interleaved.

[0006] According to another concept of this case, a method for manufacturing an integrated magnetic component is provided. The integrated magnetic component is used in a multi-module DC-DC converter. The manufacturing method includes providing N primary windings and N secondary windings, where N is an integer greater than 1; providing N magnetic cores arranged sequentially, wherein each magnetic core includes a plate, a first common magnetic core post, a second common magnetic core post, an inductor magnetic core post, and a transformer magnetic core post, wherein in each magnetic core, the first common magnetic core post and the second common magnetic core post are respectively disposed on a first side and a second side of the plate, and the inductor magnetic core post and the transformer magnetic core post are disposed on the plate; and in each magnetic core, the inductor magnetic core post is configured to be wound with a corresponding primary winding of the N primary windings or with a corresponding secondary winding of the N secondary windings, and the transformer magnetic core post is configured to be wound with corresponding primary windings and corresponding secondary windings interleaved.

[0007] According to another concept in this case, a multi-module DC-DC converter is provided. The multi-module DC-DC converter comprises N conversion modules, configured to connect between a power source and a load, where N is an integer greater than 1. Each of the N conversion modules comprises a DC-AC unit, a transformer and inductor unit, and an AC-DC unit. The N transformer and inductor units of the N conversion modules are formed by integrated magnetic components. The integrated magnetic components comprise N primary windings, N secondary windings, and N magnetic cores, which are arranged sequentially. Each of the N magnetic cores comprises a plate, a first common core post, a second common core post, an inductor core post, and a transformer core post. The first common core post and the second common core post are respectively disposed on a first side and a second side of the plate. The inductor core post and the transformer core post are disposed on the plate. An inductor core is structured with corresponding primary windings from N primary windings or corresponding secondary windings from N secondary windings, while a transformer core is structured with corresponding primary windings and corresponding secondary windings interleaved. Attached Figure Description

[0008] Figure 1 This is a circuit diagram showing a multi-module DC-DC converter according to an embodiment of the present invention.

[0009] Figure 2 This is a schematic diagram of a circuit topology, showing... Figure 1 The structure of the conversion module is shown.

[0010] Figure 3A This is a schematic diagram showing... Figure 2 The diagram shows various possible implementations of the DC-AC unit in the conversion module.

[0011] Figure 3B This is a schematic diagram showing... Figure 2 The diagram shows various possible implementations of the transformer and inductor units in the conversion module.

[0012] Figure 3C This is a schematic diagram showing... Figure 2 Various possible implementations of the AC-DC unit in the conversion module are shown.

[0013] Figure 4 This is a circuit diagram showing... Figure 1 The first embodiment of the multi-module DC-DC converter is shown.

[0014] Figure 5A This is a three-dimensional structural diagram showing the magnetic core structure of the integrated magnetic component in the first embodiment of this case.

[0015] Figure 5B , Figure 5C and Figure 5D This is a schematic diagram of a three-dimensional structure, showing that it is based on Figure 5A The magnetic core shown is formed Figure 4 Various embodiments of the integrated magnetic assembly of the transformer and inductor units in the conversion module shown.

[0016] Figure 6A and Figure 6B This is a schematic diagram of the three-dimensional structure, showing... Figure 5B The diagram shows a variation of the integrated magnetic component and its corresponding winding configuration.

[0017] Figure 6C and Figure 6D This is a schematic diagram of the three-dimensional structure, showing... Figure 5C The diagram shows a variation of the integrated magnetic component and its corresponding winding configuration.

[0018] Figure 6E and Figure 6F This is a schematic diagram of the three-dimensional structure, showing... Figure 5D The diagram shows a variation of the integrated magnetic component and its corresponding winding configuration.

[0019] Figure 7A This is a three-dimensional structural diagram showing the magnetic core structure of the integrated magnetic component in the second embodiment of this case.

[0020] Figure 7B , Figure 7C and Figure 7D This is a schematic diagram of a three-dimensional structure, showing that it is based on Figure 7A The magnetic core shown is formed in Figure 4 Various embodiments of the integrated magnetic assembly of the transformer and inductor units in the conversion module shown.

[0021] Figure 8 This is a circuit diagram showing... Figure 1 The second embodiment of the multi-module DC-DC converter is shown.

[0022] Figure 9AThis is a three-dimensional structural diagram showing the magnetic core structure of the integrated magnetic component in the third embodiment of this case.

[0023] Figure 9B This is a schematic diagram of a three-dimensional structure, showing that it is based on Figure 9A The magnetic core shown is formed in Figure 8 The transformer and inductor unit are integrated into a magnetic component in the conversion module shown.

[0024] Figure 10A and Figure 10B This is a schematic diagram of the three-dimensional structure, showing... Figure 9B The diagram shows a variation of the integrated magnetic component and its corresponding winding configuration.

[0025] Figure 11A This is a three-dimensional structural diagram showing the magnetic core structure of the integrated magnetic component in the fourth embodiment of this case.

[0026] Figure 11B This is a schematic diagram of a three-dimensional structure, showing that it is based on Figure 11A The magnetic core shown is formed in Figure 8 The transformer and inductor unit are integrated into a magnetic component in the conversion module shown.

[0027] Figure 12A and Figure 12B This is a schematic diagram of the three-dimensional structure, showing... Figure 11B The diagram shows a variation of the integrated magnetic component and its corresponding winding configuration.

[0028] Figure 13A This is a schematic diagram of a three-dimensional structure, showing that it is based on Figure 5A The magnetic core shown is an integrated magnetic assembly consisting of four conversion modules, transformers, and inductors.

[0029] Figure 13B This is a schematic diagram of a three-dimensional structure, showing... Figure 13A The example shown is a variation of the integrated magnetic component.

[0030] Figure 14 This is a schematic diagram of a three-dimensional structure, showing... Figure 5B The example shown is a variation of the integrated magnetic component.

[0031] Figure 15A This is a circuit diagram showing a three-phase conversion module.

[0032] Figure 15B This is a schematic diagram of a three-dimensional structure, showing... Figure 15A The three magnetic cores corresponding to the three-phase conversion module shown are based on Figure 5A The magnetic core structure is shown.

[0033] Figure 15C This is a schematic diagram of a three-dimensional structure, showing... Figure 15BThe integrated structure of the three magnetic cores is shown.

[0034] Figure 16 This is a schematic diagram of a three-dimensional structure, showing that it is based on Figure 15C The integrated magnetic component consists of a transformer and an inductor unit forming two three-phase conversion modules based on the magnetic core structure shown.

[0035] List of reference numerals

[0036] 1, 1a, 1b: Multi-module DC-DC converter

[0037] 101, 401: DC-AC Unit

[0038] 102, 402: Transformer and Inductor Units

[0039] 103, 403: AC-DC unit

[0040] 11, 12, 1N: Conversion Modules

[0041] 20: Parts

[0042] 2a, 2b, 2c, 2d, 21, 22, 23, 24, 3a, 3b, 3c, 3d, 3e, 40, 40a, 40b, 41, 42, 43: Magnetic core

[0043] 201: First side

[0044] 202: Second side

[0045] 4: Three-phase conversion module

[0046] ACL: Auxiliary core post

[0047] CCL: Common Core Pillar

[0048] Cin: Input capacitance

[0049] Co: Output capacitor

[0050] Lm1, Lm2: Magnetizing inductors

[0051] Lp1, Lp2: Primary inductors

[0052] Ls1, Ls2: Secondary inductors

[0053] PICL, PICL1, PICL2, PICL3, PICLM: Primary inductor core posts

[0054] RL: Load

[0055] SCL1: First side core post

[0056] SCL2: Second side magnetic core post

[0057] SICL, SICL1, SICL2, SICL3, SICLM: Secondary inductor core pillars

[0058] TCL, TCL1, TCL2, TCL3, TCLM: Transformer core column

[0059] TR1, TR2: Transformers

[0060] Vin: Power supply

[0061] Wp1, Wp11, Wp12, Wp13, Wp2, Wp21, Wp22, Wp23, Wp3, Wp4: Primary winding

[0062] Ws1, Ws11, Ws12, Ws13, Ws2, Ws21, Ws22, Ws23, Ws3, Ws4: Secondary windings Detailed Implementation

[0063] Some typical embodiments that embody the features and advantages of this invention will be described in detail in the following description. It should be understood that this invention can have various variations in different forms, all of which do not depart from the scope of this invention, and the descriptions and drawings therein are for illustrative purposes only and not for limiting this invention.

[0064] This invention provides a general solution for simplifying the magnetic components used in parallel or series modules of a multi-module converter by integrating the inductors, main transformers, and balancing circuits of multiple modules into a single integrated magnetic component. This integrated design reduces the complexity of the magnetic components, minimizes losses, and improves overall performance. Furthermore, the provided integrated magnetic component can be extended to three-phase converters, ensuring effective current distribution among parallel modules and phase balance within each module.

[0065] Figure 1 This is a circuit diagram illustrating a multi-module DC-DC converter according to an embodiment of this invention. Figure 1As shown, the multi-module DC-DC converter 1 includes N conversion modules 11, 12, ..., 1N and is configured to provide power conversion between a power supply Vin and a load RL, where N is an integer greater than 1. In one embodiment, the multi-module DC-DC converter 1 may include an input capacitor Cin connected in parallel with the power supply Vin and / or an output capacitor Co connected in parallel with the load RL. In this embodiment, the multiple conversion modules 11-1N are configured in an input parallel output parallel (IPOP) configuration. In other words, the input terminals of the conversion modules 11-1N are connected in parallel and the output terminals of the conversion modules 11-1N are connected in parallel. However, this is not a limitation. For example, the multiple conversion modules 11-1N may be configured in an input series output series (ISOS) configuration, an input series output parallel (ISOP) configuration, or an input parallel output series (IPOS) configuration.

[0066] Figure 2 This is a schematic diagram of a circuit topology, showing... Figure 1 The structure of the conversion module is shown below. Figure 2 As shown, each conversion module 11-1N includes a DC-AC unit 101, a transformer and inductor unit 102, and an AC-DC unit 103 electrically connected between a power supply Vin and a load RL. The DC-AC unit 101 is configured to convert DC signals to AC signals (e.g., high-frequency AC signals), the transformer and inductor unit 102 is configured to perform energy processing, and the AC-DC unit 103 is configured to convert AC signals to DC signals. In one embodiment, the conversion module may include a capacitor connected between the DC-AC unit 101 and the transformer and inductor unit 102, and / or a capacitor connected between the transformer and inductor unit 102 and the AC-DC unit 103. These capacitors may be resonant capacitors or DC blocking capacitors used in resonant converters, but are not limited thereto.

[0067] Each DC-AC unit 101, transformer and inductor unit 102, and AC-DC unit 103 can be implemented with any suitable circuit topology. For example, the DC-AC unit 101 can adopt, for instance, a suitable circuit topology. Figure 3A The circuit shown includes, but is not limited to, full-bridge circuits, half-bridge circuits with or without capacitor arms, stacked half-bridge circuits, or flying capacitor three-level circuits. The transformer and inductor unit 102 can be adopted as follows: Figure 3BThe primary resonant inductor and transformer, secondary inductor and transformer, or a combination of primary and secondary inductors and transformers shown are examples, but not limited to these. The AC-DC unit 103 may employ, as shown in the example... Figure 3C The circuits shown include full-bridge circuits, half-bridge circuits with or without capacitor arms, stacked half-bridge circuits, or flying capacitor three-level circuits, but are not limited thereto.

[0068] Figure 4 This is a circuit diagram showing... Figure 1 The first embodiment of the multi-module DC-DC converter is shown. In one embodiment, as... Figure 4 As shown, N is 2, and each conversion module 11, 12, DC-AC unit 101, and AC-DC unit 103 of the multi-module DC-DC converter 1a includes a full-bridge circuit, and the transformer and inductor unit 102 includes a combination of primary and secondary inductors and transformers. Specifically, the transformer and inductor unit 102 of conversion module 11 includes a transformer TR1, a primary inductor Lp1, a secondary inductor Ls1, and a magnetizing inductor Lm1, and the transformer and inductor unit 102 of conversion module 12 includes a transformer TR2, a primary inductor Lp2, a secondary inductor Ls2, and a magnetizing inductor Lm2. The integrated magnetic components used to form the transformer and inductor units of the conversion modules will be described below.

[0069] Figure 5A This is a three-dimensional structural diagram showing the magnetic core structure of the integrated magnetic component in the first embodiment of this invention. Figure 5AAs shown, the magnetic core 2a includes a plate 20 and a primary inductor core post PICL, a transformer core post TCL, a secondary inductor core post SICL, at least one first-side core post SCL1, and at least one second-side core post SCL2 disposed on the plate 20. The magnetic core 2a is assembled with another similar magnetic core or another core plate to form a complete structure; this part is not shown in the figure for clarity. The primary inductor core post PICL is configured with a primary winding, and the secondary inductor core post SICL is configured with a secondary winding. The transformer core post TCL is configured with both a primary and secondary winding, wherein the primary and secondary windings wound on the transformer core post TCL can be stacked to achieve interleaving. The primary inductor core post PICL, the transformer core post TCL, and the secondary inductor core post SICL may be located between at least one first-side core post SCL1 and at least one second-side core post SCL2, but are not limited thereto. It should be noted that the positions and relative positions of the primary inductor core post PICL, the transformer core post TCL, the secondary inductor core post SICL, at least one first-side core post SCL1, and at least one second-side core post SCL2 are not limited to those shown in the figures and are not limited in this application. The first-side core post SCL1 and the second-side core post SCL2 are respectively disposed on opposite first sides 201 and second sides 202 on the plate 20 of the core 2a. Each core post may contain a single air gap or multiple air gaps formed by multiple smaller air gaps. Furthermore, the cross-sectional shape of each core post is not limited to a square; it may also be circular, elliptical, polygonal, or other various shapes.

[0070] Figure 5B This is a schematic diagram of a three-dimensional structure, showing that it is based on Figure 5A The magnetic core shown is formed Figure 4 The conversion module shown integrates a transformer and an inductor unit with a magnetic component. In this embodiment, as... Figure 5B As shown, the integrated magnetic assembly includes magnetic cores 21 and 22, primary windings Wp1 and Wp2, and secondary windings Ws1 and Ws2. Each magnetic core 21 and 22 includes three first-side magnetic core posts disposed on the first side 201 of the plate 20 and three second-side magnetic core posts disposed on the second side 202 of the plate 20. Among these first-side and second-side magnetic core posts, one second-side magnetic core post of the magnetic core 21 and one first magnetic core post of the adjacent magnetic core 22 form a common magnetic core post CCL, while another first-side and second-side magnetic core post forms an auxiliary magnetic core post ACL. This is to form the transformer and inductor unit 102 of the conversion module 11 (e.g., Figure 4As shown), the primary winding Wp1 is wound around the primary inductor core post PICL and the transformer core post TCL wound on the magnetic core 21, as well as the two common core posts CCL of magnetic cores 21 and 22. The secondary winding Ws1 is wound around the secondary inductor core post SICL and the transformer core post TCL wound on the magnetic core 21. This is to form the transformer and inductor unit 102 of the conversion module 12 (as shown). Figure 4 As shown, the primary winding Wp2 winds around the primary inductor core post PICL and the transformer core post TCL wound on core 22, as well as the two common core posts CCL of cores 21 and 22. The secondary winding Ws2 winds around the secondary inductor core post SICL and the transformer core post TCL wound on core 22. The primary windings Wp1 and Wp2 have the same number of turns and are both wound on the common core post CCL. The currents flowing through the primary windings Wp1 and Wp2 are in opposite directions, thereby ensuring that the magnetic flux generated by the current flowing through the primary windings Wp1 and Wp2 cancels each other out. This causes the magnetomotive force generated by the current flowing through the primary windings Wp1 and Wp2 to cancel each other out on the common core post CCL. Furthermore, since the currents flowing through the primary inductors Lp1 and Lp2 are equal, the currents flowing through the secondary inductors Ls1 and Ls2 are also equal, thereby achieving current balance between the conversion modules.

[0071] At Figure 5B In the illustrated embodiment, an adjacent pair of first-side core posts and second-side core posts are configured as a common core post CCL and wound with primary windings Wp1 and Wp2. In another embodiment, as shown... Figure 5C As shown, besides the common core post CCL being wound with primary windings Wp1 and Wp2, other pairs of adjacent first-side and second-side core posts can also serve as the common core post CCL and be wound with secondary windings Ws1 and Ws2. In another embodiment, as... Figure 5D As shown, alternatively, only one pair of adjacent first-side core posts and second-side core posts can serve as a common core post (CCL) and be wound with secondary windings Ws1 and Ws2. Therefore, it should be noted that in two adjacent cores, at least one pair of adjacent first-side core posts and second-side core posts must serve as a common core post (CCL) and be wound with either a primary winding or a secondary winding. This achieves the effects of flux cancellation and current balance.

[0072] In one embodiment, multiple adjacent boards 20 can be integrated into a single board, multiple common core pillars (CCLs) can be integrated into a single common core pillar, and multiple adjacent auxiliary core pillars (ACLs) can be integrated into a single auxiliary core pillar. In other words, adjacent cores can share boards, common core pillars, and auxiliary core pillars. For example, Figure 6A and Figure 6B This is a schematic diagram of the three-dimensional structure, showing... Figure 5BThe diagram shows a variation of the integrated magnetic assembly and its corresponding winding configuration. Please refer to [link / reference]. Figure 6A Matching Figure 5B . Figure 5B The magnetic cores 21 and 22 are integrated into a single magnetic core 3a as shown in Figure 6A. Specifically, based on... Figure 5B The magnetic cores 21 and 22 are integrated into a single plate 20. The three auxiliary core posts ACL on the first side 201 of plate 20 of core 21 are integrated into a single auxiliary core post ACL, and the three auxiliary core posts ACL on the second side 202 of plate 20 of core 22 are integrated into a single auxiliary core post ACL. Furthermore, on the second side 202 of plate 20 of core 21 and the first side 201 of plate 20 of core 22, the two common core posts CCL wound with primary windings Wp1 and Wp2 are integrated into a single common core post CCL, and the four auxiliary core posts ACL are integrated into a single auxiliary core post. The corresponding winding distribution is shown in... Figure 6B .

[0073] Figure 6C and Figure 6D This is a schematic diagram of the three-dimensional structure, showing... Figure 5C The diagram shows a variation of the integrated magnetic assembly and its corresponding winding configuration. Please refer to [link / reference]. Figure 6C Matching Figure 5C . Figure 5C The magnetic cores 21 and 22 shown are integrated as Figure 6C The single magnetic core 3b is shown. Figure 5C The magnetic cores 21 and 22 are integrated into a single magnetic core 3b as shown in Figure 6C. Specifically, based on... Figure 5C The magnetic cores 21 and 22 are integrated into a single plate 20. The three auxiliary core posts ACL on the first side 201 of plate 20 of core 21 are integrated into a single auxiliary core post ACL, and the three auxiliary core posts ACL on the second side 202 of plate 20 of core 22 are integrated into a single auxiliary core post ACL. Furthermore, on the second side 202 of plate 20 of core 21 and the first side 201 of plate 20 of core 22, two common core posts CCL wound with primary windings Wp1 and Wp2 are integrated into a single common core post CCL, and two common core posts CCL wound with secondary windings Ws1 and Ws2 are integrated into another common core post CCL. The two auxiliary core posts ACL are also integrated into a single auxiliary core post. The corresponding winding distribution is shown in... Figure 6D .

[0074] Figure 6E and Figure 6F This is a schematic diagram of the three-dimensional structure, showing... Figure 5D The diagram shows a variation of the integrated magnetic assembly and its corresponding winding configuration. Please refer to [link / reference]. Figure 6E Matching Figure 5D . Figure 5D The magnetic cores 21 and 22 are integrated into a single magnetic core 3c as shown in Figure 6E. Specifically, based on... Figure 5D The magnetic cores 21 and 22 are integrated into a single plate 20. The three auxiliary core posts ACL on the first side 201 of plate 20 of core 21 are integrated into a single auxiliary core post ACL, and the three auxiliary core posts ACL on the second side 202 of plate 20 of core 22 are integrated into a single auxiliary core post ACL. Furthermore, on the second side 202 of plate 20 of core 21 and the first side 201 of plate 20 of core 22, the two common core posts CCL wound with secondary windings Ws1 and Ws2 are integrated into a single common core post CCL, and the four auxiliary core posts ACL are integrated into a single auxiliary core post. The corresponding winding distribution is shown in... Figure 6F .

[0075] Figure 7A This is a three-dimensional structural diagram showing the core structure of the integrated magnetic component in the second embodiment of this invention. Figure 7A In, with Figure 5A The corresponding components and elements all use the same numerical designation, and the details will not be elaborated here. In this case, the number of primary and secondary inductor core columns and transformer core columns is not limited. For example, such as Figure 7A As shown, magnetic core 2b contains M primary inductor core pillars PICL1-PICLM, M transformer core pillars TCL1-TCLM, and M secondary inductor core pillars SICL1-SICLM, where M is an integer greater than 1.

[0076] Taking M as an example of 2. Figure 7B This is a schematic diagram of a three-dimensional structure, showing that it is based on Figure 7A The magnetic core shown is formed in Figure 4 The conversion module shown integrates a transformer and an inductor unit with a magnetic component. In this embodiment, as... Figure 7B As shown, the integrated magnetic assembly includes magnetic cores 21 and 22, primary windings Wp1 and Wp2, and secondary windings Ws1 and Ws2. A second-side core post of magnetic core 21 and a first core post of adjacent magnetic core 22 form a common core post CCL, while another first-side core post and a second-side core post form an auxiliary core post ACL. This is to form the transformer and inductor unit 102 of the conversion module 11 (e.g., ...). Figure 4As shown), the primary winding Wp1 is wound around the primary inductor core pillars PICL1 and PICL2 and the transformer core pillars TCL1 and TCL2 wound on the magnetic core 21, as well as the two common core pillars CCL of magnetic cores 21 and 22. The secondary winding Ws1 is wound around the secondary inductor core pillars SICL1 and SICL2 and the transformer core pillars TCL1 and TCL2 wound on the magnetic core 21. This is to form the transformer and inductor unit 102 of the conversion module 12 (as shown). Figure 4 As shown, the primary winding Wp2 winds around the primary inductor core pillars PICL1 and PICL2, the transformer core pillars TCL1 and TCL2, and the two common core pillars CCL of cores 21 and 22, which are wound on magnetic core 22. The secondary winding Ws2 winds around the secondary inductor core pillars SICL1 and SICL2, and the transformer core pillars TCL1 and TCL2, which are wound on magnetic core 22. It should be noted that each winding is wound in a figure-eight pattern. The primary windings Wp1 and Wp2 have the same number of turns and are both wound on the common core pillar CCL. The currents flowing through the primary windings Wp1 and Wp2 are in opposite directions, thereby ensuring that the magnetic flux generated by the current flowing through the primary windings Wp1 and Wp2 cancels each other out. This causes the magnetomotive force generated by the current flowing through the primary windings Wp1 and Wp2 to cancel each other out on the common core pillar CCL. Furthermore, since the currents flowing through the primary inductors Lp1 and Lp2 are equal, the currents flowing through the secondary inductors Ls1 and Ls2 are also equal, thereby achieving current balance between the conversion modules. Additionally, adjacent first-side or second-side core posts (without windings) can be integrated into a single core post. For example, in core 21, three first-side core posts can be integrated into a single auxiliary core post ACL, and two second-side core posts without windings can be integrated into another auxiliary core post ACL. Similarly, in core 22, two first-side core posts without windings can be integrated into a single auxiliary core post ACL, and three second-side core posts can be integrated into another auxiliary core post ACL.

[0077] At Figure 7B In the illustrated embodiment, an adjacent pair of first-side core posts and second-side core posts are configured as a common core post CCL and wound with primary windings Wp1 and Wp2. In another embodiment, as shown... Figure 7C As shown, besides the common core post CCL being wound with primary windings Wp1 and Wp2, other pairs of adjacent first-side and second-side core posts can also serve as the common core post CCL and be wound with secondary windings Ws1 and Ws2. In another embodiment, as... Figure 7DAs shown, alternatively, only one pair of adjacent first-side core posts and second-side core posts can serve as a common core post (CCL) and be wound with secondary windings Ws1 and Ws2. Therefore, it should be noted that in two adjacent cores, at least one pair of adjacent first-side core posts and second-side core posts must serve as a common core post (CCL) and be wound with either a primary winding or a secondary winding. This achieves the effects of flux cancellation and current balance.

[0078] Figure 8 This is a circuit diagram showing... Figure 1 The second embodiment of the multi-module DC-DC converter is shown. Figure 8 In, with Figure 4 The corresponding parts and components all use the same numerical designation; details will not be elaborated here. Figure 4 Compared to the multi-module DC-DC converter 1a shown, in Figure 8 In the multi-module DC-DC converter 1b, the secondary inductor and capacitor on the secondary side of the transformer are omitted.

[0079] Figure 9A This is a three-dimensional structural diagram showing the magnetic core structure of the integrated magnetic component in the third embodiment of this invention. Figure 9A In, with Figure 5A The corresponding parts and components all use the same numerical designation; details will not be elaborated here. Figure 5A Compared to the magnetic core 2a shown, in Figure 9A In the magnetic core 2c, the secondary inductor core column is omitted.

[0080] Figure 9B This is a schematic diagram of a three-dimensional structure, showing that it is based on Figure 9A The magnetic core shown is formed in Figure 8 The conversion module shown integrates a transformer and an inductor unit with a magnetic component. In this embodiment, as... Figure 9B As shown, the integrated magnetic assembly includes magnetic cores 21 and 22, primary windings Wp1 and Wp2, and secondary windings Ws1 and Ws2. Each magnetic core 21 and 22 includes two first-side magnetic core posts disposed on a first side 201 of the plate 20 and two second-side magnetic core posts disposed on a second side 202 of the plate 20. Among these first-side and second-side magnetic core posts, one second-side magnetic core post of the magnetic core 21 and one first magnetic core post of the adjacent magnetic core 22 form a common magnetic core post CCL, while the other first-side and second-side magnetic core posts form an auxiliary magnetic core post ACL. To form the transformer and inductor unit 102 of the conversion module 11 (e.g., Figure 8As shown), the primary winding Wp1 is wound around the primary inductor core post PICL and the transformer core post TCL wound on the magnetic core 21, as well as the two common core posts CCL of magnetic cores 21 and 22, and the secondary winding Ws1 is wound around the transformer core post TCL wound on the magnetic core 21. This is to form the transformer and inductor unit 102 of the conversion module 12 (as shown). Figure 8 As shown, the primary winding Wp2 winds around the primary inductor core post PICL and the transformer core post TCL wound on the magnetic core 22, as well as the two common core posts CCL of magnetic cores 21 and 22. The secondary winding Ws2 winds around the transformer core post TCL wound on the magnetic core 22. The primary windings Wp1 and Wp2 have the same number of turns and are both wound on the common core post CCL. The currents flowing through the primary windings Wp1 and Wp2 are in opposite directions, thereby ensuring that the magnetic flux generated by the current flowing through the primary windings Wp1 and Wp2 cancels each other out. This causes the magnetomotive force generated by the current flowing through the primary windings Wp1 and Wp2 to cancel each other out on the common core post CCL. Furthermore, the currents flowing through the primary inductors Lp1 and Lp2 are equal, thereby achieving current balance between the switching modules.

[0081] In one embodiment, adjacent magnetic cores may share a common plate, a common core post, and an auxiliary core post. For example, Figure 10A and Figure 10B This is a schematic diagram of the three-dimensional structure, showing... Figure 9B The diagram shows a variation of the integrated magnetic assembly and its corresponding winding configuration. Please refer to [link / reference]. Figure 10A Matching Figure 9B . Figure 9B The magnetic cores 21 and 22 are integrated into Figure 10A The single magnetic core 3D shown. Specifically, based on... Figure 9B The magnetic cores 21 and 22 are integrated into a single plate 20. The two auxiliary core posts ACL of the first side 201 of the plate 20 of core 21 are integrated into a single auxiliary core post ACL, and the two auxiliary core posts ACL of the second side 202 of the plate 20 of core 22 are integrated into a single auxiliary core post ACL. Furthermore, on the second side 202 of the plate 20 of core 21 and the first side 201 of the plate 20 of core 22, the two common core posts CCL wound with primary windings Wp1 and Wp2 are integrated into a single common core post CCL, and the two auxiliary core posts ACL are integrated into a single auxiliary core post. The corresponding winding distribution is shown in... Figure 10B .

[0082] Figure 11A This is a three-dimensional structural diagram showing the core structure of the integrated magnetic component in the fourth embodiment of this invention. Figure 11A In, with Figure 9AThe corresponding components and elements all use the same numerical designation, and the details will not be elaborated here. In this case, the number of primary and secondary inductor core columns and transformer core columns is not limited. For example, such as Figure 11A As shown, magnetic core 2d includes M primary inductor core pillars PICL1-PICLM and M transformer core pillars TCL1-TCLM.

[0083] Taking M as an example of 2. Figure 11B This is a schematic diagram of a three-dimensional structure, showing that it is based on Figure 11A The magnetic core shown is formed in Figure 8 The conversion module shown integrates a transformer and an inductor unit with a magnetic component. In this embodiment, as... Figure 11B As shown, the integrated magnetic assembly includes magnetic cores 21 and 22, primary windings Wp1 and Wp2, and secondary windings Ws1 and Ws2. A second-side core post of magnetic core 21 and a first core post of adjacent magnetic core 22 form a common core post CCL, while another first-side core post and a second-side core post form an auxiliary core post ACL. This is to form the transformer and inductor unit 102 of the conversion module 11 (e.g., ...). Figure 8 As shown), the primary winding Wp1 is wound around the primary inductor core posts PICL1 and PICL2 and the transformer core posts TCL1 and TCL2 wound on the magnetic core 21, as well as the two common core posts CCL of magnetic cores 21 and 22. The secondary winding Ws1 is wound around the transformer core posts TCL1 and TCL2 wound on the magnetic core 21. This is to form the transformer and inductor unit 102 of the conversion module 12 (as shown). Figure 8 As shown, the primary winding Wp2 winds around the primary inductor core pillars PICL1 and PICL2, the transformer core pillars TCL1 and TCL2, and the two common core pillars CCL of cores 21 and 22, which are wound on magnetic core 22. The secondary winding Ws2 winds around the transformer core pillars TCL1 and TCL2, which are wound on magnetic core 22. It should be noted that each winding is wound in a figure-eight pattern. The primary windings Wp1 and Wp2 have the same number of turns and are both wound on the common core pillar CCL. The currents flowing through the primary windings Wp1 and Wp2 are in opposite directions, thereby ensuring that the magnetic flux generated by the current flowing through the primary windings Wp1 and Wp2 cancels each other out. This causes the magnetomotive force generated by the current flowing through the primary windings Wp1 and Wp2 to cancel each other out on the common core pillar CCL. Furthermore, the currents flowing through the primary inductors Lp1 and Lp2 are equal, thereby achieving current balance between the switching modules. Furthermore, adjacent first-side core posts or second-side core posts (without windings) of the core can be integrated into a single core post. For example, in core 21, two first-side core posts can be integrated into a single auxiliary core post ACL, and in core 22, two second-side core posts can be integrated into a single auxiliary core post ACL.

[0084] In one embodiment, adjacent magnetic cores may share a common plate, a common core post, and an auxiliary core post. For example, Figure 12A and Figure 12B This is a schematic diagram of the three-dimensional structure, showing... Figure 11B The diagram shows a variation of the integrated magnetic assembly and its corresponding winding configuration. Please refer to [link / reference]. Figure 12A Matching Figure 11B . Figure 11B The magnetic cores 21 and 22 are integrated into Figure 12A The single magnetic core 3e is shown. Specifically, based on... Figure 11B The magnetic cores 21 and 22, and the two plates 20 of magnetic cores 21 and 22 are integrated into a single plate 20. Furthermore, on the second side 202 of plate 20 of magnetic core 21 and the first side 201 of plate 20 of magnetic core 22, two common core pillars CCL wound with primary windings Wp1 and Wp2 are integrated into a single common core pillar CCL, and two auxiliary core pillars ACL are integrated into a single auxiliary core pillar. The corresponding winding distribution is shown in... Figure 12B .

[0085] At Figures 8 to 12B In the illustrated embodiment, the transformer and inductor unit of each conversion module includes a primary inductor but does not include a secondary inductor. In another embodiment, the transformer and inductor unit of each conversion module may include a secondary inductor but not a primary inductor. The corresponding integrated magnetic component can be replaced by a secondary inductor core column. Figures 9A to 12B The primary inductor core is implemented in the transformer. Furthermore, the primary winding is wound around the transformer core, and the secondary winding is wound around the secondary inductor core and the common core.

[0086] Furthermore, the various integrated magnetic components in the above embodiments are only used as examples when the multi-module DC-DC converter contains two conversion modules (i.e., N is 2). When N is greater than 2, any two adjacent conversion modules, primary or secondary windings are wound around a common magnetic core.

[0087] As an example, Figure 13A This is a schematic diagram of a three-dimensional structure, showing that it is based on Figure 5A The magnetic core shown represents an integrated magnetic assembly comprised of the transformers and inductors of the four conversion modules. In this embodiment, N equals 4, meaning the multi-module DC-DC converter contains four conversion modules, and each conversion module's transformer and inductor unit includes a primary inductor and a secondary inductor. Figure 13AAs shown, the integrated magnetic assembly includes magnetic cores 21, 22, 23, and 24, primary windings Wp1, Wp2, Wp3, and Wp4, and secondary windings Ws1, Ws2, Ws3, and Ws4. A pair of adjacent first-side core posts and second-side core posts of any two adjacent magnetic cores form a common core post CCL, and another pair of first-side core posts and second-side core posts form an auxiliary core post ACL. To form the transformer and inductor unit of the first conversion module, the primary winding Wp1 surrounds the primary inductor core post PICL and the transformer core post TCL wound on magnetic core 21, as well as the two common core posts CCL of magnetic cores 21 and 22. The secondary winding Ws1 surrounds the secondary inductor core post SICL and the transformer core post TCL wound on magnetic core 21. To form the transformer and inductor unit of the second conversion module, the primary winding Wp2 is wound around the primary inductor core post PICL and the transformer core post TCL wound on the magnetic core 22, as well as the four common core posts CCL of the magnetic cores 21, 22, and 23. The secondary winding Ws2 is wound around the secondary inductor core post SICL and the transformer core post TCL wound on the magnetic core 22. To form the transformer and inductor unit of the third conversion module, the primary winding Wp3 is wound around the primary inductor core post PICL and the transformer core post TCL wound on the magnetic core 23, as well as the four common core posts CCL of the magnetic cores 22, 23, and 24. The secondary winding Ws3 is wound around the secondary inductor core post SICL and the transformer core post TCL wound on the magnetic core 23. To form the transformer and inductor unit of the fourth conversion module, the primary winding Wp4 surrounds the primary inductor core post PICL and the transformer core post TCL wound on core 24, as well as the two common core posts CCL of cores 23 and 24. The secondary winding Ws4 surrounds the secondary inductor core post SICL and the transformer core post TCL wound on core 24. The primary windings Wp1, Wp2, Wp3, and Wp4 all have the same number of turns and are wound on the common core post CCL. Therefore, flux cancellation and current balance can be achieved.

[0088] Furthermore, the common core column (CCL) is not limited to being entirely wound with either primary or secondary windings. Specifically, some adjacent common core columns (CCLs) can be wound with primary windings, and some adjacent common core columns (CCLs) can be wound with secondary windings. As an example, Figure 13B This is a schematic diagram of a three-dimensional structure, showing... Figure 13A The illustration shows a variation of the integrated magnetic component. Figure 13B In the illustrated embodiment, the adjacent common core posts CCL of magnetic cores 21 and 22 are wound with secondary windings Ws1 and Ws2. The adjacent common core posts CCL of magnetic cores 22 and 23 are wound with primary windings Wp2 and Wp3, and the adjacent common core posts CCL of magnetic cores 23 and 24 are wound with secondary windings Ws3 and Ws4. Furthermore, in Figure 13A and 13BIn the multiple integrated magnetic components shown, adjacent plates are integrable, and adjacent common core posts or auxiliary core posts are integrable to improve performance.

[0089] In one embodiment, to further increase the coupling between the primary and secondary windings, some primary windings may span across the secondary inductor core posts, and some secondary windings may span across the primary inductor core posts. As an example, Figure 14 This is a schematic diagram of a three-dimensional structure, showing... Figure 5B The illustration shows a variation of the integrated magnetic component. Figure 14 In the illustrated embodiment, the primary winding Wp1 is the winding that surrounds the primary inductor core post PICL, the transformer core post TCL, and the secondary inductor core post SICL wound on the magnetic core 21, as well as the common core post CCL of the magnetic cores 21 and 22. The secondary winding Ws1 is the winding that surrounds the primary inductor core post PICL, the transformer core post TCL, and the secondary inductor core post SICL wound on the magnetic core 21. The primary winding Wp2 is the winding that surrounds the primary inductor core post PICL, the transformer core post TCL, and the secondary inductor core post SICL wound on the magnetic core 22, as well as the common core post CCL of the magnetic cores 21 and 22. The secondary winding Ws2 is the winding that surrounds the primary inductor core post PICL, the transformer core post TCL, and the secondary inductor core post SICL wound on the magnetic core 22. To achieve built-in leakage inductance, the turns ratio of the primary inductor core post PICL, the transformer core post TCL, and the secondary inductor core post SICL cannot be the same.

[0090] In the above embodiments, the conversion module is exemplified by a unidirectional converter. However, this invention is not limited to this. In one embodiment, the conversion module may be a multi-phase converter. For example, Figure 15A This is a circuit diagram showing a three-phase conversion module. Figure 15A As shown, the three-phase conversion module 4 includes a DC-AC unit 401, a transformer and inductor unit 402, and an AC-DC unit 403. The transformer and inductor unit 402 includes three phases. The three phases have a phase offset of 120 degrees relative to each other, and each phase includes its own transformer, primary inductor, and secondary inductor. Figure 15B This is a schematic diagram of a three-dimensional structure, showing... Figure 15A The three magnetic cores corresponding to the three-phase conversion module shown are based on Figure 5A The magnetic core structure is shown. (As shown in the image.) Figure 15BAs shown, core 41 corresponding to the first phase includes a primary inductor core pillar PICL1, a transformer core pillar TCL1, and a secondary inductor core pillar SICL1. Core 41 corresponding to the second phase includes a primary inductor core pillar PICL2, a transformer core pillar TCL2, and a secondary inductor core pillar SICL2. Core 43 corresponding to the third phase includes a primary inductor core pillar PICL3, a transformer core pillar TCL3, and a secondary inductor core pillar SICL3. Furthermore, cores 41, 42, and 43 can be integrated together. Figure 15C As shown, magnetic cores 41, 42, and 43 are integrated into magnetic core 40. It should be noted that the positions of the primary inductor core pillars PICL1, PICL2, and PICL3, the transformer core pillars TCL1, TCL2, and TCL3, and the secondary inductor core pillars SICL1, SICL2, and SICL3 are not limited to those shown in the figure.

[0091] Figure 16 This is a schematic diagram of a three-dimensional structure, showing that it is based on Figure 15C The magnetic core structure shown represents an integrated magnetic assembly comprised of transformer and inductor units forming two three-phase conversion modules. In the two adjacent magnetic cores corresponding to the two multi-phase conversion modules, a common core column is wound with a primary or secondary winding of the same phase. For example... Figure 16 As shown, in the integrated magnetic assembly, magnetic cores 40a and 40b correspond to the first conversion module and the second conversion module, respectively. The primary winding Wp11 and secondary winding Ws11 correspond to the first phase of the first conversion module, the primary winding Wp12 and secondary winding Ws12 correspond to the second phase of the first conversion module, and the primary winding Wp13 and secondary winding Ws13 correspond to the third phase of the first conversion module. Similarly, the primary winding Wp21 and secondary winding Ws21 correspond to the first phase of the second conversion module, the primary winding Wp22 and secondary winding Ws22 correspond to the second phase of the second conversion module, and the primary winding Wp23 and secondary winding Ws23 correspond to the third phase of the second conversion module. Each primary winding is wound around the primary inductor core post and transformer core post of the corresponding phase, and each secondary winding is wound around the secondary inductor core post and transformer core post of the corresponding phase. Furthermore, the primary windings Wp13 and Wp23 are wound around the common core post CCL of the magnetic cores 40a and 40b. In one embodiment, adjacent boards are integrateable, and adjacent common core posts and / or auxiliary core posts are integrateable to improve performance.

[0092] In the above embodiments, the conversion modules of the multi-module DC-DC converter are configured using IPOP. However, this invention is not limited to this. It should be noted that the above-described integrated magnetic component and winding configuration can also be applied to conversion modules using ISOS, ISOP, or IPOP configurations. When the conversion modules are electrically connected in series, the integrated magnetic component and winding arrangement can achieve voltage balance between the conversion modules.

[0093] Broadly speaking, according to the concept of this invention, an integrated magnetic component is provided for a multi-module DC-DC converter. The integrated magnetic component includes N primary windings, N secondary windings, and N magnetic cores, where N is an integer greater than 1. The N magnetic cores are arranged sequentially. Each magnetic core includes a plate, a first common core post, a second common core post, an inductor core post, and a transformer core post. The first common core post and the second common core post are respectively disposed on a first side and a second side of the plate. The inductor core and the transformer core are disposed on the plate. The inductor core post is configured to be wound with corresponding primary windings from the N primary windings, or with corresponding secondary windings from the N secondary windings, and the transformer core post is configured to be wound with corresponding primary windings and corresponding secondary windings interleaved.

[0094] In one embodiment, the second side of the plate of the nth magnetic core out of the N magnetic cores is configured to be adjacent to the first side of the plate of the (n+1)th magnetic core out of the N magnetic cores, where n is a positive integer less than N. The second common core post of the nth magnetic core and the first common core post of the (n+1)th magnetic core are configured to be wound with the nth primary winding and the (n+1)th primary winding out of the N primary windings, or with the nth secondary winding and the (n+1)th secondary winding out of the N secondary windings.

[0095] In one embodiment, the plates of the nth magnetic core and the (n+1)th magnetic core are integrated into a single plate, and the second common core post of the nth magnetic core and the first common core post of the (n+1)th magnetic core, which are adjacent to each other, are integrated into a single common core post.

[0096] In one embodiment, each magnetic core includes two first common core posts and two second common core posts; wherein one of the two second common core posts of the nth magnetic core and one of the two first common core posts of the (n+1)th magnetic core are configured to be wound with an nth primary winding and an (n+1)th primary winding, and / or the other of the two second common core posts of the nth magnetic core and the other of the two first common core posts of the (n+1)th magnetic core are configured to be wound with an nth secondary winding and an (n+1)th secondary winding.

[0097] In one embodiment, in each magnetic core, the inductor core post includes a primary inductor core post and a secondary inductor core post, the primary inductor core post being configured to be wound with a corresponding primary winding, and the secondary inductor core post being configured to be wound with a corresponding secondary winding.

[0098] In one embodiment, each magnetic core includes multiple primary inductor core pillars, multiple secondary inductor core pillars, and multiple transformer core pillars. In each of the N magnetic cores, the corresponding primary winding is structured in a figure-eight pattern and wound around the multiple primary inductor core pillars and multiple transformer core pillars, and the corresponding secondary winding is structured in a figure-eight pattern and wound around the multiple secondary inductor core pillars and multiple transformer core pillars.

[0099] In one embodiment, each of the N magnetic cores includes multiple inductor core posts and multiple transformer core posts; wherein in each of the N magnetic cores, one of the primary winding and the corresponding secondary winding is configured to be wound in a figure-eight pattern around the multiple inductor core posts and the multiple transformer core posts, and the other of the primary winding and the corresponding secondary winding is configured to be wound in a figure-eight pattern around the multiple transformer core posts.

[0100] In one embodiment, each of the N primary windings includes X primary winding components, each corresponding to one of the X phases; each of the N secondary windings includes X secondary winding components, each corresponding to one of the X phases, where X is an integer greater than 1; each of the N magnetic cores includes X inductor core posts and X transformer core posts. The X inductor core posts are configured to be wound with either the X primary winding components corresponding to the primary winding or the X secondary winding components corresponding to the secondary winding, and the X transformer core posts are... The structure is configured with X primary winding components corresponding to the primary winding and X secondary winding components corresponding to the secondary winding; wherein the second common core post of the nth core and the first common core post of the (n+1)th core are configured with one of the X primary winding components of the nth primary winding and one of the X primary winding components of the (n+1)th primary winding corresponding to the same phase, or with one of the X secondary winding components of the nth secondary winding and one of the X secondary winding components of the (n+1)th secondary winding corresponding to the same phase.

[0101] In one embodiment, according to another concept of this invention, a method for manufacturing an integrated magnetic component is provided. The integrated magnetic component is used in a multi-module DC-DC converter. The manufacturing method includes providing N primary windings and N secondary windings, where N is an integer greater than 1; providing N magnetic cores arranged sequentially, wherein each magnetic core includes a plate, a first common magnetic core post, a second common magnetic core post, an inductor magnetic core post, and a transformer magnetic core post, wherein in each magnetic core, the first common magnetic core post and the second common magnetic core post are respectively disposed on a first side and a second side of the plate, and the inductor magnetic core post and the transformer magnetic core post are disposed on the plate; and in each magnetic core, the inductor magnetic core post is configured to be wound with corresponding primary windings of the N primary windings or corresponding secondary windings of the N secondary windings, and the transformer magnetic core post is configured to be wound with corresponding primary windings and corresponding secondary windings that are interleaved.

[0102] In one embodiment, the manufacturing method further includes arranging the second side of the plate of the nth magnetic core among the N magnetic cores adjacent to the first side of the plate of the (n+1)th magnetic core among the N magnetic cores, where n is a positive integer less than N; and arranging the second common core post of the nth magnetic core and the first common core post of the (n+1)th magnetic core as wound with the nth primary winding and the (n+1)th primary winding of the N primary windings, or wound with the nth secondary winding and the (n+1)th secondary winding of the N secondary windings.

[0103] In one embodiment, the manufacturing method further includes: integrating the plate of the nth magnetic core and the plate of the (n+1)th magnetic core into a single plate, and integrating the second common magnetic core post of the nth magnetic core and the first common magnetic core post of the (n+1)th magnetic core that are adjacent to each other into a single common magnetic core post.

[0104] In one embodiment, each of the N magnetic cores includes two first common core posts and two second common core posts, and the manufacturing method further includes: configuring one of the two second common core posts of the nth magnetic core and one of the two first common core posts of the (n+1)th magnetic core as wound with an nth primary winding and an (n+1)th primary winding, and / or configuring the other of the two second common core posts of the nth magnetic core and the other of the two first common core posts of the (n+1)th magnetic core as wound with an nth secondary winding and an (n+1)th secondary winding.

[0105] In one embodiment, in each of the N magnetic cores, the inductor core post includes a primary inductor core post and a secondary inductor core post, and the manufacturing method further includes: configuring the primary inductor core post to be wound with a corresponding primary winding, and configuring the secondary inductor core post to be wound with a corresponding secondary winding.

[0106] In one embodiment, each of the N magnetic cores includes a plurality of primary inductor core pillars, a plurality of secondary inductor core pillars, and a plurality of transformer core pillars, and the manufacturing method further includes: in each of the N magnetic cores, a corresponding primary winding is wound in a figure-eight pattern around the plurality of primary inductor core pillars and the plurality of transformer core pillars, and a corresponding secondary winding is wound in a figure-eight pattern around the plurality of secondary inductor core pillars and the plurality of transformer core pillars.

[0107] In one embodiment, each of the N magnetic cores includes multiple inductor core posts and multiple transformer core posts, and the manufacturing method further includes: in each of the N magnetic cores, one of the corresponding primary winding and the corresponding secondary winding is wound around the multiple inductor core posts and the multiple transformer core posts in a figure-eight pattern, and the other of the corresponding primary winding and the corresponding secondary winding is wound around the multiple transformer core posts in a figure-eight pattern.

[0108] In one embodiment, each of the N primary windings includes X primary winding components, each of which corresponds to X phases; each of the N secondary windings includes X secondary winding components, each of which corresponds to X phases, and X is an integer greater than 1; wherein each of the N magnetic cores includes X inductor core posts and X transformer core posts, and the manufacturing method further includes: in each of the N magnetic cores, configuring the X inductor core posts to be wound with X primary winding components corresponding to the primary windings, or wound with X secondary winding components corresponding to the secondary windings. Furthermore, the X transformer core pillars are configured such that they are wound with X primary winding components corresponding to the primary windings, and respectively wound with X secondary winding components corresponding to the secondary windings; and the second common core pillar of the nth core and the first common core pillar of the (n+1)th core are configured such that they are wound with one of the X primary winding components corresponding to the nth primary winding and one of the X primary winding components corresponding to the (n+1)th primary winding, or wound with one of the X secondary winding components corresponding to the nth secondary winding and one of the X secondary winding components corresponding to the (n+1)th secondary winding.

[0109] According to another concept in this case, a multi-module DC-DC converter is provided. The multi-module DC-DC converter comprises N conversion modules, configured to connect between a power source and a load, where N is an integer greater than 1. Each of the N conversion modules comprises a DC-AC unit, a transformer and inductor unit, and an AC-DC unit. The N transformer and inductor units of the N conversion modules are formed by integrated magnetic components. The integrated magnetic components comprise N primary windings, N secondary windings, and N magnetic cores, which are arranged sequentially. Each of the N magnetic cores comprises a plate, a first common core post, a second common core post, an inductor core post, and a transformer core post. The first common core post and the second common core post are respectively disposed on a first side and a second side of the plate. The inductor core post and the transformer core post are disposed on the plate. An inductor core is structured with corresponding primary windings from N primary windings or corresponding secondary windings from N secondary windings, while a transformer core is structured with corresponding primary windings and corresponding secondary windings interleaved.

[0110] In one embodiment, the second side of the plate of the nth magnetic core out of the N magnetic cores is configured to be adjacent to the first side of the plate of the (n+1)th magnetic core out of the N magnetic cores, where n is a positive integer less than N. The second common core post of the nth magnetic core and the first common core post of the (n+1)th magnetic core are configured to be wound with the nth primary winding and the (n+1)th primary winding out of the N primary windings, or with the nth secondary winding and the (n+1)th secondary winding out of the N secondary windings.

[0111] In one embodiment, the N conversion modules are configured to be connected in parallel input / parallel output configuration, serial input / serial output configuration, serial input / parallel output configuration, or parallel input / serial output configuration.

[0112] In one embodiment, the transformer and inductor unit of each of the N conversion modules includes a transformer and includes a primary inductor and / or a secondary inductor.

[0113] This case can be modified in various ways by those who are familiar with this technology, but all of them are still subject to the protection sought by the attached patent application.

Claims

1. An integrated magnetic component for a multi-module DC-DC converter, comprising: There are N primary windings and N secondary windings, where N is an integer greater than 1; and N magnetic cores are arranged sequentially, wherein each of the N magnetic cores comprises: One piece; A first common magnetic core post and a second common magnetic core post are respectively disposed on a first side and a second side of the plate; and An inductor core and a transformer core are disposed on the plate, wherein the inductor core is wound with a corresponding primary winding among the N primary windings or with a corresponding secondary winding among the N secondary windings, and the transformer core is wound with the corresponding primary windings and the corresponding secondary windings interleaved.

2. The integrated magnetic component as claimed in claim 1, wherein the second side of the plate of the nth magnetic core among the N magnetic cores is configured to be adjacent to the first side of the plate of the (n+1)th magnetic core among the N magnetic cores, and n is a positive integer less than N; The second common core post of the nth core and the first common core post of the (n+1)th core are configured to be wound with the nth primary winding and the (n+1)th primary winding among the N primary windings, or with the nth secondary winding and the (n+1)th secondary winding among the N secondary windings.

3. The integrated magnetic assembly as claimed in claim 2, wherein the plate of the nth magnetic core and the plate of the (n+1)th magnetic core are integrated into a single plate, and the second common core post of the nth magnetic core and the first common core post of the (n+1)th magnetic core that are adjacent to each other are integrated into a single common core post.

4. The integrated magnetic component as claimed in claim 1, wherein each of the N magnetic cores comprises two first common core posts and two second common core posts; wherein one of the two second common core posts of the nth magnetic core and one of the two first common core posts of the (n+1)th magnetic core are configured to be wound with the nth primary winding and the (n+1)th primary winding of the N primary windings, and / or the other of the two second common core posts of the nth magnetic core and the other of the two first common core posts of the (n+1)th magnetic core are configured to be wound with the nth secondary winding and the (n+1)th secondary winding of the N primary windings; wherein n is a positive integer less than N.

5. The integrated magnetic component as claimed in claim 1, wherein in each of the N magnetic cores, the inductor core post comprises a primary inductor core post and a secondary inductor core post, the primary inductor core post being configured to be wound with the corresponding primary winding, and the secondary inductor core post being configured to be wound with the corresponding secondary winding.

6. The integrated magnetic component as claimed in claim 5, wherein each of the N magnetic cores comprises a plurality of primary inductor core pillars, a plurality of secondary inductor core pillars, and a plurality of transformer core pillars, wherein in each of the N magnetic cores, the corresponding primary winding is configured to be wound in a figure-eight pattern around the plurality of primary inductor core pillars and the plurality of transformer core pillars, and the corresponding secondary winding is configured to be wound in a figure-eight pattern around the plurality of secondary inductor core pillars and the plurality of transformer core pillars.

7. The integrated magnetic component as claimed in claim 1, wherein each of the N magnetic cores comprises a plurality of inductor core posts and a plurality of transformer core posts; wherein in each of the N magnetic cores, one of the corresponding primary winding and the corresponding secondary winding is configured to be wound in a figure-eight pattern around the plurality of inductor core posts and the plurality of transformer core posts, and the other of the corresponding primary winding and the corresponding secondary winding is configured to be wound in a figure-eight pattern around the plurality of transformer core posts.

8. The integrated magnetic component as claimed in claim 1, wherein each of the N primary windings comprises X primary winding components, the X primary winding components corresponding to X phases respectively; each of the N secondary windings comprises X secondary winding components, the X secondary winding components corresponding to the X phases respectively, and X is an integer greater than 1; wherein each of the N magnetic cores comprises X inductor core posts and X transformer core posts, the X inductor core posts being configured to be wound with the X primary winding components of the corresponding primary winding, or with the X secondary winding components of the corresponding secondary winding respectively; the X transformer core posts being configured to be wound with the X primary winding components of the corresponding primary winding respectively. Let X be the secondary winding components of the corresponding secondary windings, respectively; wherein the second common core post of the nth magnetic core and the first common core post of the (n+1)th magnetic core of the N magnetic cores are configured to be wound with one of the X primary winding components of the nth primary winding of the N primary windings corresponding to the same phase and one of the X primary winding components of the (n+1)th primary winding of the N primary windings, or wound with one of the X secondary winding components of the nth secondary winding of the N secondary windings corresponding to the same phase and one of the X secondary winding components of the (n+1)th secondary winding of the N secondary windings; wherein n is a positive integer less than N.

9. A method for manufacturing an integrated magnetic component for use in a multi-module DC-DC converter, the method comprising: Provide N primary windings and N secondary windings, where N is an integer greater than 1; Provides N magnetic cores arranged in sequence, wherein each of the N magnetic cores includes a plate, a first common magnetic core post, a second common magnetic core post, an inductor magnetic core post, and a transformer magnetic core post. In each of the N magnetic cores, the first common magnetic core post and the second common magnetic core post are respectively disposed on a first side and a second side of the plate, and the inductor magnetic core post and the transformer magnetic core post are disposed on the plate. In each of the N magnetic cores, the inductor core is wound with the corresponding primary winding of the N primary windings or with the corresponding secondary winding of the N secondary windings, and the transformer core is wound with the corresponding primary windings and the corresponding secondary windings interleaved.

10. The manufacturing method of claim 9, further comprising: The second side of the plate of the nth magnetic core out of the N magnetic cores is configured to be adjacent to the first side of the plate of the (n+1)th magnetic core out of the N magnetic cores, where n is a positive integer less than N; and The second common core post of the nth core and the first common core post of the (n+1)th core are configured to be wound with the nth primary winding and the (n+1)th primary winding among the N primary windings, or with the nth secondary winding and the (n+1)th secondary winding among the N secondary windings.

11. The manufacturing method of claim 10, further comprising: The plate of the nth magnetic core and the plate of the (n+1)th magnetic core are integrated into a single plate, and the second common magnetic core pillar of the nth magnetic core and the first common magnetic core pillar of the (n+1)th magnetic core, which are adjacent to each other, are integrated into a single common magnetic core pillar.

12. The manufacturing method of claim 9, wherein each of the N magnetic cores comprises two of the first common core posts and two of the second common core posts, and the manufacturing method further comprises: One of the two second common core pillars of the nth magnetic core in the N magnetic cores and one of the two first common core pillars of the (n+1)th magnetic core in the N magnetic cores are configured to be wound with the nth primary winding and the (n+1)th primary winding in the N primary windings, and / or the other of the two second common core pillars of the nth magnetic core and the other of the two first common core pillars of the (n+1)th magnetic core are configured to be wound with the nth secondary winding and the (n+1)th secondary winding in the N primary windings; where n is a positive integer less than N.

13. The manufacturing method of claim 9, wherein in each of the N magnetic cores, the inductor core post comprises a primary inductor core post and a secondary inductor core post, and the manufacturing method further comprises: The primary inductor core is configured to be wound with the corresponding primary winding, and the secondary inductor core is configured to be wound with the corresponding secondary winding.

14. The manufacturing method of claim 13, wherein each of the N magnetic cores comprises a plurality of primary inductor core pillars, a plurality of secondary inductor core pillars, and a plurality of transformer core pillars, and the manufacturing method further comprises: In each of the N magnetic cores, the corresponding primary winding is wound in a figure-eight pattern around the plurality of primary inductor core pillars and the plurality of transformer core pillars, and the corresponding secondary winding is wound in a figure-eight pattern around the plurality of secondary inductor core pillars and the plurality of transformer core pillars.

15. The manufacturing method of claim 9, wherein each of the N magnetic cores comprises a plurality of the inductor core pillars and a plurality of the transformer core pillars, and the manufacturing method further comprises: In each of the N magnetic cores, one of the corresponding primary winding and the corresponding secondary winding is wound around the plurality of inductor core posts and the plurality of transformer core posts in a figure-eight pattern, and the other of the corresponding primary winding and the corresponding secondary winding is wound around the plurality of transformer core posts in a figure-eight pattern.

16. The manufacturing method of claim 9, wherein each of the N primary windings comprises X primary winding components, the X primary winding components corresponding to X phases respectively; each of the N secondary windings comprises X secondary winding components, the X secondary winding components corresponding to the X phases respectively, and X is an integer greater than 1; wherein each of the N magnetic cores comprises X inductor core pillars and X transformer core pillars, and the manufacturing method further comprises: In each of the N magnetic cores, the X inductor core pillars are configured to be wound with the X primary winding components of the corresponding primary winding, or with the X secondary winding components of the corresponding secondary winding; and the X transformer core pillars are configured to be wound with the X primary winding components of the corresponding primary winding, and with the X secondary winding components of the corresponding secondary winding; and The second common core post of the nth magnetic core and the first common core post of the (n+1)th magnetic core of the N magnetic cores are configured to be wound with one of the X primary winding components of the nth primary winding and one of the X primary winding components of the (n+1)th primary winding of the N primary windings corresponding to the same phase, or wound with one of the X secondary winding components of the nth secondary winding and one of the X secondary winding components of the (n+1)th secondary winding of the N secondary windings corresponding to the same phase; where n is a positive integer less than N.

17. A multi-module DC-DC converter, comprising: There are N conversion modules connected between a power source and a load, where N is an integer greater than 1, and each of the N conversion modules includes a DC-AC unit, a transformer and inductor unit, and an AC-DC unit. The N transformer and inductor units of the N conversion modules are formed by an integrated magnetic assembly, which includes N primary windings, N secondary windings, and N magnetic cores. The N magnetic cores are arranged sequentially, and each of the N magnetic cores includes: One piece; A first common magnetic core post and a second common magnetic core post are respectively disposed on a first side and a second side of the plate; and An inductor core and a transformer core are disposed on the plate. The inductor core is configured to be wound with corresponding primary windings of N primary windings or corresponding secondary windings of N secondary windings, and the transformer core is configured to be wound with corresponding primary windings and corresponding secondary windings interleaved with each other.

18. The multi-module DC-DC converter as described in claim 17, wherein, The second side of the plate of the nth magnetic core among the N magnetic cores is configured to be adjacent to the first side of the plate of the (n+1)th magnetic core among the N magnetic cores, and n is a positive integer less than N; The second common core post of the nth core and the first common core post of the (n+1)th core are configured to be wound with the nth primary winding and the (n+1)th primary winding among the N primary windings, or with the nth secondary winding and the (n+1)th secondary winding among the N secondary windings.

19. The multi-module DC-DC converter of claim 17, wherein the N conversion modules are configured to be connected in a parallel-input parallel-output configuration, a series-input series-output series configuration, a series-input series-output parallel configuration, or a parallel-input series-output series configuration.

20. The multi-module DC-DC converter of claim 17, wherein the transformer and inductor unit of each of the N conversion modules includes a transformer and includes a primary inductor and / or a secondary inductor.

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