A dual-inductor and transformer secondary magnetic coupling DCDC magnetic component and power supply device

Abstract

This invention relates to a DC-DC converter and power supply device with dual inductors and a transformer secondary magnetic coupling, comprising a first magnetic core, a second magnetic core, a transformer winding, and at least two inductor windings. The first and second magnetic cores are each provided with a magnetic base. The first and second magnetic cores are each provided with a shared magnetic wall. Magnetic posts corresponding to the transformer winding and inductor winding are respectively provided on the first and second magnetic cores. When the shared magnetic wall is in seamless contact, a combined shared magnetic wall is formed, and the magnetic posts are respectively formed as combined magnetic posts and combined magnetic posts with gaps, the gap width being used to adjust the inductance value. This invention integrates an isolated transformer and two magnetically coupled output inductors onto the same magnetic core through secondary magnetic coupling, achieving shared core materials and deep coupling of the magnetic materials. This allows the magnetic fields of the transformer and the dual inductors to cancel each other out twice, reducing product size, decreasing the total amount of core material used, effectively reducing core losses and production costs, and improving conversion efficiency and power density.

Description

Technical Field

[0001] This invention relates to the field of power electronics technology, and more specifically, to a DC-DC magnetic component and power supply device with dual inductors and transformer secondary magnetic coupling. Background Technology

[0002] With the advancement of the global energy revolution, the energy structure is shifting from fossil fuels to electrical energy. Energy efficiency, power density, and cost of power switching power supply products have become core performance indicators for the industry. Taking automotive power supplies as an example, the isolated phase-shifted full-bridge DC-DC converter is a core component, primarily used to convert the high-voltage DC power from the power battery into safe DC power compatible with the low-voltage battery, supplying power to low-voltage equipment in the vehicle. As the computing power of autonomous driving technology continues to improve, the demand for automotive power is growing accordingly, and the scale of low-voltage loads is expanding. Vehicle engineers have placed higher demands on the conversion efficiency, power density, and cost control of isolated DC-DC converters: higher conversion efficiency enables energy saving and consumption reduction, higher power density enables product lightweighting, helping to improve the vehicle's driving range, and lower cost promotes product adoption, meeting the travel needs of the general public.

[0003] In current mainstream isolated phase-shifted full-bridge DC-DC power converters, the core magnetic components are the isolation transformer and the output inductor. Both are designed independently, meaning the transformer and inductor use different magnetic cores, and the magnetic flux loops are not coupled together. This technical solution has significant drawbacks: the consumption of magnetic core material is relatively large, resulting in a larger overall product size; at the same time, the magnetic core itself has high losses, further limiting the improvement of conversion efficiency and power density. Summary of the Invention

[0004] The technical problem to be solved by the present invention is that the existing isolation transformer and output inductor use different magnetic cores and the magnetic flux circuit is not coupled, which leads to large consumption of magnetic core materials and product size, high magnetic core loss, and limited conversion efficiency and power density. In view of the above-mentioned defects of the prior art, a DC-DC magnetic component and power supply device with dual inductors and transformer secondary magnetic coupling is provided.

[0005] The technical solution adopted by this invention to solve its technical problem is: The isolation transformer and the dual inductor are integrated by secondary magnetic coupling.

[0006] A DC-DC magnetic component with dual inductors and transformer secondary magnetic coupling is constructed, comprising a first magnetic core, a second magnetic core, a transformer winding, and at least two inductor windings. The first and second magnetic cores are arranged opposite to each other. Each of the first and second magnetic cores has a magnetic base, with the transformer winding and the inductor winding located between the magnetic bases of the first and second magnetic cores. Each of the first and second magnetic cores has a shared magnetic wall, also arranged opposite to each other. Each of the first and second magnetic cores has a magnetic post corresponding to the transformer winding and the inductor winding, respectively, with the magnetic posts of the transformer winding and the inductor winding located on opposite sides of the shared magnetic wall. The magnetic posts and the shared magnetic wall are both located on the same side of the magnetic base, forming a magnetic flux loop. When the shared magnetic wall is in seamless contact, a combined shared magnetic wall is formed. The magnetic posts form both combined magnetic posts and combined magnetic posts with gaps, with the gap width of the combined magnetic posts with gaps used to adjust the inductance value.

[0007] Furthermore, the magnetic column includes a first inductor magnetic column, a second inductor magnetic column, and a transformer magnetic column; the first inductor magnetic column, the second inductor magnetic column, and the transformer magnetic column are fixedly disposed on the magnetic chassis; the first inductor magnetic column, the second inductor magnetic column, and the transformer magnetic column of the first magnetic core and the second magnetic core are respectively arranged opposite to each other.

[0008] Furthermore, in the vertical direction of the magnetic pillars of the first magnetic core or the second magnetic core, the height of the first inductor magnetic pillar and the second inductor magnetic pillar is lower than the height of the common magnetic wall or the transformer magnetic pillar; the height of the common magnetic wall of the first magnetic core and the second magnetic core is the same; the height of the transformer magnetic pillar of the first magnetic core and the second magnetic core is the same; when the first magnetic core and the second magnetic core are in relative contact, the transformer magnetic pillar and the common magnetic wall are in seamless contact and respectively form a combined transformer magnetic pillar and the combined common magnetic wall; the first inductor magnetic pillar and the second inductor magnetic pillar respectively form a combined first inductor magnetic pillar and a combined second inductor magnetic pillar.

[0009] Furthermore, the inductor winding includes a first inductor winding and a second inductor winding; the transformer winding includes a primary winding and a secondary winding; the first inductor winding and the second inductor winding are respectively wound around the periphery of the combined first inductor magnetic post and the combined second inductor magnetic post; the primary winding and the secondary winding are respectively wound around the periphery of the combined transformer magnetic post, and the first inductor winding, the second inductor winding, the primary winding and the secondary winding all avoid the common magnetic wall.

[0010] Furthermore, the combined first inductor post and the combined second inductor post are respectively provided with gaps, and the inductance value of the inductor is adjusted by adjusting the width of the gaps; wherein, the gaps include one or more of the following: air gaps, insulating pads, and non-magnetic conductive materials.

[0011] Furthermore, the first inductor winding and the second inductor winding avoid the gap portion to prevent the leakage magnetic field generated at the gap from cutting the wires of the first inductor winding and the second inductor winding, thus preventing eddy current effects.

[0012] Furthermore, the first inductor winding, the combined first inductor column, the partial magnetic base of the first and second magnetic cores, and the combined shared magnetic wall constitute a first inductor; the second inductor winding, the combined second inductor column, the partial magnetic base of the first and second magnetic cores, and the combined shared magnetic wall constitute a second inductor; the transformer primary winding, the transformer secondary winding, the combined transformer column, the partial magnetic base of the first and second magnetic cores, and the combined shared magnetic wall constitute an isolation transformer; the first inductor and the second inductor are magnetically coupled, and are also magnetically coupled secondary to the isolation transformer.

[0013] Furthermore, the magnetic fields generated by the common-mode currents of the first inductor winding and the second inductor winding cancel each other out in the joint shared magnetic wall.

[0014] Furthermore, the magnetic field generated by the differential mode current of the first inductor winding and the second inductor winding cancels out the magnetic field generated by the primary winding of the transformer in the joint shared magnetic wall.

[0015] A power supply device is constructed, comprising a DC-DC magnetic component with dual inductors and a transformer secondary magnetic coupling.

[0016] The beneficial effects of this invention are as follows: This application integrates the isolation transformer and two pre-coupled output inductors in a phase-shifted full-bridge topology onto the same magnetic core through secondary magnetic coupling. This enables the sharing of magnetic core materials and deep coupling of magnetic materials, allowing the magnetic fields of the transformer and the two inductors to cancel each other out twice. This reduces product size, the total amount of magnetic core material used, effectively reduces core losses, and significantly lowers costs. It can be applied to power supply devices in various fields, improving the conversion efficiency and power density of DC-DC converters to save energy and achieve product lightweighting. When applied to automotive power supplies, it can increase the vehicle's driving range. Attached Figure Description

[0017] Figure 1 This is an exploded schematic diagram of a DC-DC magnetic component with dual inductors and transformer secondary magnetic coupling in one embodiment of the present invention. Figure 2 This is a three-dimensional schematic diagram of the first and second magnetic cores assembled in one embodiment of the present invention; Figure 3 This is an exploded schematic diagram of the first magnetic core and the second magnetic core in one embodiment of the present invention; Figure 4 This is a three-dimensional schematic diagram of a DC-DC magnetic component with dual inductors and transformer secondary magnetic coupling in one embodiment of the present invention; Figure 5 This is a front view schematic diagram of the second magnetic core in one embodiment of the present invention; Figure 6 This is a front view schematic diagram of the first magnetic core and the second magnetic core assembled in one embodiment of the present invention; Figure 7 This is a front view schematic diagram of a DC-DC magnetic component with dual inductors and transformer secondary magnetic coupling in one embodiment of the present invention; Figure 8 This is a schematic diagram of the equivalent principle of a DC-DC magnetic component with dual inductors and transformer secondary magnetic coupling in one embodiment of the present invention. Figure 9 This is a simulation diagram of the magnetic field lines of the first and second inductors of this invention; Figure 10 This is a simulation diagram of the magnetic field lines of the first inductor, the second inductor, and the isolation transformer of the present invention; Figure 11 This is a simulation diagram of the magnetic field strength of a DC-DC magnetic component with dual inductors and transformer secondary magnetic coupling according to the present invention. Figure 12 This is a simulation diagram of the magnetic field strength of the second magnetic core of the present invention; Figure 13 This is a perspective view of a power supply device according to an embodiment of the present invention; Figure 14 This is a top view schematic diagram of a power supply device according to an embodiment of the present invention; Figure 15 This is the present invention. Figure 14 Sectional view at point AA; Figure 16 This is a circuit topology diagram corresponding to a power supply device in one embodiment of the present invention.

[0018] Labeling Explanation: First magnetic core 1, Second magnetic core 2, Transformer winding 3, Inductor winding 4, Common magnetic wall 5, Magnetic column 6, Magnetic base 7, Combined common magnetic wall 8, Combined magnetic column 9, Combined magnetic column with gap 10, First inductor magnetic column 601, Second inductor magnetic column 602, Transformer magnetic column 603, First inductor winding 401, Second inductor winding 402, Transformer primary winding 301, Transformer secondary winding 302, Combined transformer magnetic column 901, Combined first inductor magnetic column 902, Combined second inductor magnetic column 903, Gap 904. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0020] In current isolated phase-shifted full-bridge DC-DC power converters, the isolation transformer and output inductor are independently configured, and the transformer and inductor use different magnetic cores, with no coupling relationship in the magnetic flux circuit. This results in a large consumption of magnetic core material and a larger overall product size, as well as high core losses, which limits conversion efficiency and power density.

[0021] Please refer to Figure 1 This invention proposes a DC-DC magnetic component with dual inductors and transformer secondary magnetic coupling, comprising a first magnetic core 1, a second magnetic core 2, a transformer winding 3, and at least two inductor windings 4, wherein the first magnetic core 1 and the second magnetic core 2 are arranged opposite to each other. Each of the first and second magnetic cores 1 and 2 is provided with a magnetic base 7, with the transformer winding 3 and inductor windings 4 located between the magnetic base 7 of the first and second magnetic cores 1 and 2. Each of the first and second magnetic cores 1 and 2 is provided with a common magnetic wall 5, and they are arranged opposite to each other. Each of the first and second magnetic cores 1 and 2 is provided with magnetic posts 6 corresponding to the transformer winding 3 and the inductor winding 4, respectively, with the magnetic posts 6 of the transformer winding 3 and the inductor winding 4 located on opposite sides of the common magnetic wall 5. The magnetic posts 6 and the common magnetic wall 5 are both located on the same side of the magnetic base 7, and the magnetic base 7, magnetic posts 6, and common magnetic wall 5 form a magnetic flux loop. Specifically, the magnetic flux loop provides a closed, low-resistance path for the magnetic flux, thereby efficiently constraining and guiding the magnetic field, enabling deep integration of the transformer and inductor, and precise control of the inductance. When the shared magnetic wall 5 is in seamless contact, a joint shared magnetic wall 8 is formed, and the magnetic pillars 6 form a joint magnetic pillar 9 and a joint magnetic pillar with a gap 10, respectively. The gap width of the joint magnetic pillar with a gap 10 is used to adjust the inductance value.

[0022] In this embodiment, such as Figure 1As shown, the first magnetic core 1 and the second magnetic core 2 are completely symmetrical, and during assembly, the first magnetic core 1 and the second magnetic core 2 are arranged opposite each other. This splicing method of the two magnetic cores facilitates replacement. The first magnetic core 1 and the second magnetic core 2 are each provided with a magnetic base 7, while the transformer winding 3 and multiple inductor windings 4 are respectively located between the magnetic base 7 of the first magnetic core 1 and the magnetic base 7 of the second magnetic core 2. That is, all windings, magnetic pillars 6, and common magnetic walls 5 are located in the middle of the two magnetic bases 7. Furthermore, the first magnetic core 1 and the second magnetic core 2 are each provided with a common magnetic wall 5 arranged opposite each other. Magnetic pillars 6, corresponding to the transformer winding 3 and the inductor winding 4, are respectively provided on the first magnetic core 1 and the second magnetic core 2, and are respectively located on both sides of the common magnetic wall 5. The magnetic pillars 6 and the common magnetic wall 5 are both located on the same side of the magnetic base 7, and the magnetic base 7, magnetic pillars 6, and common magnetic wall 5 form a magnetic flux loop. The magnetic base 7, common magnetic wall 5, magnetic pillars 6, and windings cooperate to form a transformer and multiple inductors.

[0023] For further details, please refer to... Figure 2 The transformer winding 3 is positioned around the combined transformer magnetic column 901, and the inductor winding 4 is wound around the combined gap magnetic column 10. When the common magnetic wall 5 of the first magnetic core 1 and the second magnetic core 2 comes into contact, a combined common magnetic wall 8, a combined magnetic column 9, and a combined gap magnetic column 10 are formed. The inductance values ​​among the multiple inductors are adjusted by adjusting the gap width between the combined gap magnetic columns 10.

[0024] Furthermore, the first magnetic core 1 and the second magnetic core 2 can also be a single-piece structure, including a transformer magnetic pillar 603, an inductor magnetic pillar 6, and a common magnetic wall 5. Similarly, the transformer magnetic pillar 603 and the inductor magnetic pillar are respectively located on both sides of the common magnetic wall 5, forming an H-shaped structure, with gaps between the inductor magnetic pillars. Using a single-piece structure reduces assembly errors, provides a more stable magnetic coupling coefficient, and reduces reluctance interface losses.

[0025] In one embodiment, the magnetic pillar 6 includes a first inductor magnetic pillar 601, a second inductor magnetic pillar 602, and a transformer magnetic pillar 603. The first inductor magnetic pillar 601, the second inductor magnetic pillar 602, and the transformer magnetic pillar 603 are fixedly mounted on the magnetic chassis 7. The first inductor magnetic pillar 601, the second inductor magnetic pillar 602, and the transformer magnetic pillar 603 of the first magnetic core 1 and the second magnetic core 2 are respectively arranged opposite to each other.

[0026] Specifically, such as Figure 3As shown, the magnetic pillar 6 includes a first inductor magnetic pillar 601, a second inductor magnetic pillar 602, and a transformer magnetic pillar 603, which are fixedly mounted on the magnetic base 7. The first inductor magnetic pillar 601, the second inductor magnetic pillar 602, and the transformer magnetic pillar 603 of the first magnetic core 1 and the second magnetic core 2 are respectively arranged opposite to each other. The first inductor magnetic pillar 601 and the second inductor magnetic pillar 602 are arranged parallel and aligned. Besides forming a magnetic flux loop with the magnetic pillar 6 and the shared magnetic wall 5, the magnetic base 7 can also fix the first inductor magnetic pillar 601, the second inductor magnetic pillar 602, the transformer magnetic pillar 603, and the shared magnetic wall 5.

[0027] Furthermore, the fixing method may include magnetic fixing, or integral fixing through a magnetic core mold design, or setting a groove in the magnetic base 7 that corresponds to the shape and size of the magnetic post 6 and embedding the magnetic post 6 therein. Even further, the inner wall of the groove may also have multiple arc-shaped protrusions distributed thereon to better fix the magnetic post 6 to the magnetic base 7.

[0028] Please refer to Figure 5 In the vertical direction of the magnetic pillars 6 of the first magnetic core 1 or the second magnetic core 2, the height of the first inductor magnetic pillar 601 and the second inductor magnetic pillar 602 is lower than the height of the common magnetic wall 5 and the transformer magnetic pillar 603. The height of the common magnetic wall 5 of the first magnetic core 1 and the second magnetic core 2 is the same. The height of the transformer magnetic pillar 603 of the first magnetic core 1 and the second magnetic core 2 is the same.

[0029] For further details, please refer to... Figure 2 and Figure 6 When the first magnetic core 1 and the second magnetic core 2 are in relative contact, the transformer magnetic column 603 and the common magnetic wall 5 are in seamless contact, forming a combined transformer magnetic column 901 and a combined common magnetic wall 8, respectively. The first inductor magnetic column 601 and the second inductor magnetic column 602 form a combined first inductor magnetic column 902 and a combined second inductor magnetic column 903, respectively.

[0030] In one embodiment, such as Figure 4As shown, a first inductor winding 401 is provided around the periphery of the first inductor post 601, and a second inductor winding 402 is provided around the periphery of the second inductor post 602. That is, the windings are arranged around the post 6. In one specific embodiment, the transformer primary winding 301 and the transformer secondary winding 302 are respectively wound around the periphery of the transformer post 603 of the second magnetic core 2 and the first magnetic core 1. In another embodiment, the transformer primary winding 301 and the transformer secondary winding 302 may also be respectively located around the periphery of the first magnetic core 1 and the second magnetic core 2. Preferably, the transformer primary winding 301 and the transformer secondary winding 302 are wound in a sandwich manner around the periphery of the combined transformer post 901. Furthermore, the first inductor winding 401, the second inductor winding 402, the transformer primary winding 301, and the transformer secondary winding 302 all avoid the common magnetic wall 5; that is, the winding range of the windings only surrounds the post 6 and does not extend to the common magnetic wall 5.

[0031] Furthermore, the first inductor post 902 and the second inductor post 903 are respectively provided with gaps 904, and the inductance value of the inductor is adjusted by adjusting the width of the gaps 904; wherein, the gaps 904 include one or more of the following: air gap, insulating pad, and non-magnetic conductive material.

[0032] Preferably, the gap 904 is an air gap. The inductance values ​​of the two inductors are adjusted by adjusting the width of the air gap. The width of the gap 904 is determined by the height difference between the first inductor magnetic post 601 and the second inductor magnetic post 602 and the common magnetic wall 5. The height difference can be determined by adjusting the height of the first inductor magnetic post 601 and the second inductor magnetic post 602.

[0033] Furthermore, the gap 904 can also be an insulating gasket or a ceramic sheet, or it can be an air gap, a combination of an insulating gasket and other non-magnetic conductive materials. Insulating gaskets, such as polyester film (Mylar), polyimide film (Kapton), fiberglass board, and insulating paper, possess stable physical properties and precisely controllable thickness, facilitating the acquisition of consistent inductance values ​​during mass production. In one specific embodiment, the non-magnetic conductive material can be a ceramic sheet, which features high temperature resistance, high temperature resistance, dimensional stability, and non-conductivity, making it suitable for applications requiring high thermal stability and mechanical strength.

[0034] Please refer to Figure 7 The first inductor winding 401 and the second inductor winding 402 are positioned away from the gap 904 to prevent the leakage magnetic field generated at the gap 904 from cutting the wires of the first inductor winding 401 and the second inductor winding 402 and causing eddy current effects, thereby avoiding unnecessary local eddy current losses and improving conversion efficiency.

[0035] In one embodiment, Figure 8This is a schematic diagram illustrating the equivalent principle of a DC-DC magnetic component with dual inductors and transformer secondary magnetic coupling in one embodiment of the present invention. Please refer to it. Figure 8 The equivalent schematic diagram of the dual inductors shows that the first inductor is composed of a first inductor winding 401, a first inductor magnetic column 902, a portion of the magnetic base 7 of the first magnetic core 1 and the second magnetic core 2, and a shared magnetic wall 8. The second inductor is composed of a second inductor winding 402, a second inductor magnetic column 903, a portion of the magnetic base 7 of the first magnetic core 1 and the second magnetic core 2, and a shared magnetic wall 8.

[0036] Please refer to Figure 8 The equivalent schematic diagram of the transformer shows that the primary winding 301, secondary winding 302, combined transformer magnetic column 901, the first magnetic core 1, a portion of the magnetic base 7 of the second magnetic core 2, and a shared magnetic wall 8 constitute an isolation transformer. It should be noted that in actual installations, to ensure full coupling between the primary winding 301 and secondary winding 302, the leakage inductance between them needs to be minimized. Therefore, the primary winding 301 and secondary winding 302 are often configured using a sandwich winding method or a parallel winding method. Specifically, for example... Figure 7 As shown, the secondary winding 302 of the transformer is respectively located on the upper, middle, and lower layers of the primary winding 301, segmenting the primary winding 301 and sandwiching it in the middle, creating the effect of segmented sandwich winding between the primary winding 301 and the secondary winding 302. However, for a more intuitive explanation, Figure 8 The primary winding 301 and secondary winding 302 of the transformer are separately arranged, and their positions can be interchanged. Furthermore, the positions of the first inductor winding 401 and the second inductor winding 402 can also be interchanged. Figure 8 The equivalent schematic diagram in the diagram is only used to illustrate the secondary integration principle of the dual inductor and transformer. The positions of the magnetic column and the winding may not correspond exactly to the actual integrated magnetic components.

[0037] like Figure 8 As shown, firstly, the first inductor and the second inductor are pre-magnetically coupled to the same magnetic core, forming the first magnetic coupling between the first and second inductors. Then, the pre-coupled first and second inductors are further deeply magnetically integrated with the isolation transformer, forming the DC-DC magnetic component of this application with dual inductors and secondary magnetic coupling with the transformer. Specifically, this application first magnetically couples the first and second inductors, and then integrates the pre-coupled dual inductors with the isolation transformer in a secondary magnetic coupling manner onto the same magnetic core. This enables the sharing of magnetic core materials, achieving the effect of secondary deep magnetic integration and effectively reducing magnetic core losses. Simultaneously, it can reduce product size, decrease the total amount of magnetic core material used, and lower production costs.

[0038] In one embodiment, such as Figure 9As shown, the first inductor winding 401 and the second inductor winding 402 are disposed in the same magnetic core, and the magnetic fields of the common-mode currents generated therefrom cancel each other out in the joint shared magnetic wall 8. It should be noted that the first inductor winding 401 and the second inductor winding 402 can be configured in parallel or in series in a specific application circuit. In this case, the first inductor winding 401 and the second inductor winding 402 are configured in parallel inside the power supply device. Furthermore, as... Figure 16 As shown, in specific application circuits, whether the magnetic fields generated by the two magnetically coupled inductor windings 4 can cancel each other out or partially cancel each other out also depends on whether the current directions in the first inductor winding 401 and the second inductor winding 402 are consistent (i.e., if the starting directions of the two windings are the same, they are either clockwise or counterclockwise). In this case, the first inductor winding 401 and the second inductor winding 402 are connected in parallel, and the current flows in the same direction. Meanwhile, in specific applications, to ensure more complete magnetic field cancellation, the currents on the parallel first inductor winding 401 and the second inductor winding 402 are also subject to phase-interleaved control.

[0039] Specifically, when current flows through the first inductor winding 401 and the second inductor winding 402, the resulting common-mode magnetic fields are opposite in direction and cancel each other out in the joint shared magnetic wall 8. Through this mutual cancellation, the peak magnetic flux density in the magnetic core can be effectively reduced, core losses can be reduced, local overheating can be suppressed, and the size of the magnetic components can be reduced.

[0040] In one embodiment, such as Figure 10 As shown, the magnetic field generated by the differential-mode current of the first inductor winding 401 and the second inductor winding 402 is opposite in direction to and cancels out the magnetic field generated by the primary winding 301 of the transformer within the shared magnetic wall 8. More specifically, the magnetic field generated by the differential-mode current of the first inductor winding 401 and the second inductor winding 402 is opposite in direction to and cancels out the magnetic field generated by the excitation current of the primary winding 301 of the transformer within the shared magnetic wall 8. Through the mutual cancellation of magnetic fields within the shared magnetic wall 8, the peak magnetic flux density inside the core can be significantly reduced, effectively reducing core losses and shrinking the overall size of the magnetic components.

[0041] For further details, please refer to... Figure 11 and Figure 12 Simulation results show that, due to the mutual cancellation between magnetic field lines, the average magnetic field strength generated inside the magnetic core is low, resulting in less loss and a smaller area of ​​heat generation. Under the mutual cancellation effect, the magnetic flux density (B) in most areas of the magnetic core is distributed at a low level, which helps to improve the overall efficiency and power density of the DC-DC converter.

[0042] This application also constructs a power supply device, such as Figure 13The image shown is a perspective view of a power supply device according to an embodiment of this application. It should be noted that... Figure 13 The power supply device shown in the figure is only an example; other structures are possible besides the shape and construction shown in the figure.

[0043] Furthermore, such as Figure 14 and Figure 15 As shown, the power supply device includes the DC-DC magnetic components of the present application, which are magnetically coupled by a dual inductor and a transformer secondary winding. The first magnetic core 1, the second magnetic core 2, the transformer winding 3, the inductor winding 4, and the common magnetic wall 5 are all disposed within the power supply device.

[0044] Specifically, the dual-inductor and transformer secondary magnetic coupling DC-DC magnetic component of this application can be applied to DC-DC (DC-to-DC converter) power supplies in multiple fields, such as automotive power supplies, AIDC (Artificial Intelligence Data Center) power supplies, and energy storage power supplies. It can improve the conversion efficiency and power density of DC-DC converters, thereby saving energy and achieving product lightweighting. When applied to automotive power supplies, it can increase the overall vehicle range. It should be noted that the above power supply device is only an example, and the magnetic component of this application can also be applied to other power supplies.

[0045] In summary, this application provides a DC-DC magnetic component and power supply device with secondary magnetic coupling of a dual inductor and a transformer. By integrating the isolation transformer and the dual inductors onto the same magnetic core through secondary magnetic coupling, core losses can be effectively reduced, product size can be minimized, the total amount of core material used can be reduced, and costs can be significantly lowered. When applied to power supply devices, it can improve conversion efficiency and power density, save energy consumption, and achieve product lightweighting.

[0046] It should be noted that the above embodiments are merely preferred embodiments of the present invention and are not intended to limit the scope of protection thereof. In actual production, the material of the magnetic core (such as ferrite, amorphous alloy), the number of turns of the winding, and the filler material of the gaps (such as insulating pads, ceramic sheets), etc., can all be adjusted according to specific electrical parameters. All equivalent substitutions or structural modifications made under the premise of the concept of the present invention fall within the protection scope of the present invention.

Claims

1. A DCDC magnetic component with dual inductance and transformer secondary magnetic coupling, characterized in that, It includes a first magnetic core, a second magnetic core, a transformer winding, and at least two inductor windings, wherein the first magnetic core and the second magnetic core are arranged opposite to each other; The first magnetic core and the second magnetic core are respectively provided with magnetic bases, and the transformer winding and the inductor winding are located between the magnetic bases of the first magnetic core and the magnetic bases of the second magnetic core. The first magnetic core and the second magnetic core are each provided with a common magnetic wall and are arranged opposite to each other; The first magnetic core and the second magnetic core are respectively provided with magnetic posts corresponding to the transformer winding and the inductor winding, and the magnetic posts of the transformer winding and the inductor winding are respectively located on both sides of the common magnetic wall; The magnetic column and the shared magnetic wall are both located on the same side of the magnetic chassis, and the magnetic chassis, the magnetic column, and the shared magnetic wall form a magnetic flux loop; When the shared magnetic walls are in seamless contact, a joint shared magnetic wall is formed. The magnetic pillars are respectively formed as joint magnetic pillars and joint magnetic pillars with gaps. The gap width of the joint magnetic pillars with gaps is used to adjust the inductance value.

2. The dual inductance and transformer secondary magnetic coupling DCDC magnetic of claim 1, wherein, The magnetic column includes a first inductor magnetic column, a second inductor magnetic column, and a transformer magnetic column; The first inductor magnetic column, the second inductor magnetic column, and the transformer magnetic column are fixedly mounted on the magnetic chassis; The first inductor post, the second inductor post, and the transformer post of the first magnetic core and the second magnetic core are respectively arranged opposite to each other.

3. The DC-DC magnetic component with dual inductors and transformer secondary magnetic coupling according to claim 2, characterized in that, In the vertical direction of the magnetic pillars of the first magnetic core or the second magnetic core, the height of the first inductor magnetic pillar and the second inductor magnetic pillar is lower than the height of the common magnetic wall or the transformer magnetic pillar. The common magnetic wall of the first magnetic core and the second magnetic core has the same height; The transformer magnetic columns of the first magnetic core and the second magnetic core have the same height; When the first magnetic core and the second magnetic core are in relative contact, the transformer magnetic column and the common magnetic wall are in seamless contact and form a combined transformer magnetic column and the combined common magnetic wall respectively; the first inductor magnetic column and the second inductor magnetic column respectively form a combined first inductor magnetic column and a combined second inductor magnetic column.

4. The DC-DC magnetic component with dual inductors and transformer secondary magnetic coupling according to claim 3, characterized in that, The inductor winding includes a first inductor winding and a second inductor winding; The transformer windings include the primary winding and the secondary winding. The first inductor winding and the second inductor winding are respectively wound around the periphery of the combined first inductor magnetic post and the combined second inductor magnetic post; The primary winding and the secondary winding of the transformer are respectively wound around the periphery of the magnetic column of the combined transformer, and the first inductor winding, the second inductor winding, the primary winding and the secondary winding of the transformer all avoid the common magnetic wall.

5. The DC-DC magnetic component with dual inductors and transformer secondary magnetic coupling according to claim 4, characterized in that, The first and second combined inductor posts are respectively provided with gaps, and the inductance value of the inductor is adjusted by adjusting the width of the gaps; wherein, the gaps include one or more of the following: air gaps, insulating pads, and non-magnetic conductive materials.

6. The DC-DC magnetic component with dual inductors and transformer secondary magnetic coupling according to claim 5, characterized in that, The first inductor winding and the second inductor winding are positioned away from the gap to prevent the leakage magnetic field generated at the gap from cutting the wires of the first inductor winding and the second inductor winding, thus preventing eddy current effects.

7. The DC-DC magnetic component with dual inductors and transformer secondary magnetic coupling according to claim 4, characterized in that, The first inductor winding, the combined first inductor column, the first magnetic core and a portion of the magnetic base of the second magnetic core, and the combined shared magnetic wall constitute the first inductor; The second inductor winding, the combined second inductor column, the first magnetic core and a portion of the magnetic base of the second magnetic core, and the combined shared magnetic wall constitute the second inductor; The primary winding of the transformer, the secondary winding of the transformer, the combined transformer magnetic column, the magnetic base of the first magnetic core and the second magnetic core, and the combined shared magnetic wall constitute an isolation transformer; The first inductor and the second inductor are magnetically coupled, and are also magnetically coupled to the secondary winding of the isolation transformer.

8. The DC-DC magnetic component with dual inductors and transformer secondary magnetic coupling according to claim 4, characterized in that, The magnetic fields generated by the common-mode currents of the first inductor winding and the second inductor winding cancel each other out in the joint shared magnetic wall.

9. The DC-DC magnetic component with dual inductors and transformer secondary magnetic coupling according to claim 4, characterized in that, The magnetic field generated by the differential mode current of the first inductor winding and the second inductor winding cancels out the magnetic field generated by the primary winding of the transformer in the joint shared magnetic wall.

10. A power supply device, characterized in that, Includes the DC-DC magnetic component with dual inductors and transformer secondary magnetic coupling as described in any one of claims 1-9.

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