Voltage converter, power supply and magnetic element

Abstract

A voltage converter, a power supply and a magnetic element are disclosed. The voltage converter includes a magnetic core, a primary side coil and a secondary side coil. The magnetic core includes a first leg. The first leg has a first main air gap and a first stepped air gap. The first main air gap breaks the first leg. The first stepped air gap is provided in a portion of the first leg. The primary side coil is disposed on the magnetic core. The secondary side coil is disposed on the magnetic core.

Description

Technical Field

[0001] This invention relates to an electronic component and electronic device, and more particularly to a voltage converter, power supply and magnetic component. Background Technology

[0002] A voltage converter is a key component within a power supply. Its primary function is to convert the input voltage into the required stable output voltage to power electronic devices. Power supplies typically include the following voltage conversion stages: AC-DC conversion, DC-DC conversion, rectification, and filtering.

[0003] In voltage converters, the output hold-up time is the duration (usually measured in milliseconds) during which the power supply can maintain a stable output when the power input (AC or DC) is suddenly interrupted. The output hold-up time determines the power supply's immunity to brief voltage interruptions, affecting the system's stability and reliability. Extending the output hold-up time can prevent abnormal device restarts and improve the reliability of industrial and servo power supplies.

[0004] In current technology, it is necessary to increase capacitance, increase voltage, and reduce power consumption to effectively extend the output sustain time. Summary of the Invention

[0005] This invention relates to a voltage converter, power supply, and magnetic element that, through a design of a main air gap and a stepped air gap, results in two inductance decays. These two inductance decays increase the maximum gain, thereby reducing the need for an energy storage capacitor. Therefore, even with a smaller energy storage capacitor, the output sustain time can still reach the expected level.

[0006] According to one aspect of the present invention, a voltage converter is provided. The voltage converter includes a magnetic core, a primary side coil, and a secondary side coil. The magnetic core includes a first core post. The first core post has a first main air gap and a first step air gap. The first main air gap is disconnected from the first core post. The first step air gap passes through a portion of the first core post. The primary side coil is disposed on the magnetic core. The secondary side coil is disposed on the magnetic core.

[0007] According to another aspect of the present invention, a power supply is provided. The power supply includes an input terminal, an output terminal, and a voltage converter. The input terminal is used to connect to a power source. The output terminal is used to connect to a load. The voltage converter is connected between the input terminal and the load terminal. The voltage converter includes a magnetic core, a primary winding, and a secondary winding. The magnetic core includes a first core post. The first core post has a first main air gap and a first step air gap. The first main air gap is disconnected from the first core post. The first step air gap passes through a portion of the first core post. The primary winding is disposed on the magnetic core. The secondary winding is disposed on the magnetic core.

[0008] According to another aspect of the present invention, a magnetic element is provided. The magnetic element includes a magnetic core, a main air gap, and a stepped air gap. The magnetic core has a plurality of core posts. One of these core posts has a winding portion. The main air gap interrupts one of these core posts. The stepped air gap passes through a portion of one of these core posts. The position of the stepped air gap differs from the position of the winding portion.

[0009] To provide a better understanding of the above and other aspects of the present invention, specific embodiments are described below in conjunction with the accompanying drawings: Attached Figure Description

[0010] Figure 1 A schematic diagram illustrating a power supply according to an embodiment of the present invention;

[0011] Figure 2A A schematic diagram of the magnetic core of a voltage converter according to an embodiment of the present invention is shown;

[0012] Figure 2B A schematic diagram illustrating the magnetic core, primary coil, and secondary coil of a voltage converter according to an embodiment of the present invention is shown.

[0013] Figure 2C A perspective view of the magnetic core of a voltage converter according to an embodiment of the present invention is shown;

[0014] Figure 3 The inductance drop of the voltage converters shown in Figures 2A to 2C is illustrated.

[0015] Figure 4 Plot the changes in the gain curves of the voltage converter in Figures 2A to 2C during the two inductance decays;

[0016] Figure 5 This example illustrates the change in the energy storage capacitor when the inductance decreases and the output duration remains constant.

[0017] Figure 6 The experimental diagram shows the energy storage capacitor using 96μF;

[0018] Figure 7This example illustrates how the output sustain time changes when the inductance decreases while the energy storage capacitor remains constant.

[0019] Figure 8 The experimental diagram shows the energy storage capacitor using 100μF.

[0020] Figure 9A A schematic diagram of the magnetic core of a voltage converter according to another embodiment of the present invention is shown;

[0021] Figure 9B A schematic diagram illustrating the magnetic core, primary coil, and secondary coil of a voltage converter according to another embodiment of the present invention is shown.

[0022] Figure 10A A schematic diagram of the magnetic core of a voltage converter according to another embodiment of the present invention is shown;

[0023] Figure 10B A schematic diagram illustrating the magnetic core, primary coil, and secondary coil of a voltage converter according to another embodiment of the present invention is shown.

[0024] Figure 10C A perspective view of the magnetic core of a voltage converter according to another embodiment of the present invention is shown;

[0025] Figure 11 The inductance drop of the voltage converters shown in Figures 10A to 10C is illustrated.

[0026] Figure 12A A perspective view of the magnetic core of a voltage converter according to another embodiment of the present invention is shown;

[0027] Figure 12B A side view of the magnetic core of a voltage converter according to another embodiment of the present invention is shown;

[0028] Figure 13A A schematic diagram of the magnetic core of a voltage converter according to another embodiment of the present invention is shown;

[0029] Figure 13B A schematic diagram illustrating the magnetic core, primary coil, and secondary coil of a voltage converter according to another embodiment of the present invention is shown.

[0030] In the attached figures, the following labels are used:

[0031] 100, 200, 300, 400, 500: Voltage converters;

[0032] 110, 210, 310, 410, 510: magnetic core;

[0033] 111,211,311,411,511: First core post;

[0034] 111W, 212W, 213W, 311W, 411W, 511W, 512W: Winding section;

[0035] 112, 212, 312, 412, 512: Second core post;

[0036] 113,213,313,413: Third core post;

[0037] 114,214,314,414,514: First flat plate;

[0038] 115, 215, 315, 415, 515: Second flat plate;

[0039] 120, 220, 320, 520: Primary side coil;

[0040] 130, 230, 330, 530: Secondary coils;

[0041] 700: Input terminal;

[0042] 800: Output terminal;

[0043] 1000: Power supply;

[0044] C bulk Energy storage capacitor

[0045] Co1: Output capacitor;

[0046] Cr: Resonant capacitor;

[0047] D: Duty cycle;

[0048] D1, D2: Diodes;

[0049] G31, G32, G33, G peak Maximum gain;

[0050] LD: Load;

[0051] Lm: Magnetizing inductance;

[0052] Lr: Resonant inductance;

[0053] MG11, MG21, MG31, MG41, MG51: First main air gap;

[0054] MG52: Second main air gap;

[0055] n: Turns ratio;

[0056] P in Input power;

[0057] PW: Power supply;

[0058] R11, R12, R21, R22, R41, R42, R51, R52: Corner;

[0059] S1, S2: Switches;

[0060] SG11, SG21, SG31, SG41, SG51: First-stage air gap;

[0061] SG12, SG22, SG32, SG42, SG52: Second-step stepped air gap;

[0062] ST11, ST31: First stage;

[0063] ST12, ST32: Second stage;

[0064] ST13, ST33: Third stage;

[0065] T hold-up Output duration;

[0066] V bus DC-Link voltage;

[0067] V in Input voltage;

[0068] V o Output voltage. Detailed Implementation

[0069] The technical terms used in this specification are based on common terminology in the field. Where this specification provides further explanation or definition of certain terms, the interpretation of those terms shall be based on the explanation or definition provided in this specification. Each embodiment of the present invention has one or more technical features. Where feasible, those skilled in the art may selectively implement some or all of the technical features in any embodiment, or selectively combine some or all of the technical features in these embodiments.

[0070] Please refer to Figure 1The diagram illustrates a power supply 1000 according to an embodiment of the present invention. The power supply 1000 is, for example, a server power supply, a charging station, or a charging device. The power supply 1000 includes an input terminal 700, an output terminal 800, and a voltage converter 100. The voltage converter 100 is, for example, a magnetic element. Besides the voltage converter 100, the technology of the present invention is also applicable to magnetic elements such as converters, transformers, and inductors. The input terminal 700 is used to connect a power supply PW. The output terminal 800 is used to connect a load LD. The voltage converter 100 is connected between the input terminal 700 and the load terminal 800. The voltage converter 100 is, for example, an LLC resonant converter. An LLC resonant converter is a high-efficiency DC-DC power conversion topology commonly used in servo power supplies, LED drivers, telecommunications power supplies, and electric vehicle chargers. LLC resonant converters utilize resonant circuits to reduce switching losses and improve efficiency. In an LLC resonant converter, the primary side circuit can be a full-bridge or half-bridge, and the secondary side circuit can be a full-bridge or a center-tapped circuit.

[0071] like Figure 1 As shown, the voltage converter 100 includes, for example, (but is not limited to) an energy storage capacitor C. bulk Two switches S1 and S2, a resonant capacitor Cr, a resonant inductor Lr, a magnetizing inductor Lm, two diodes D1 and D2, and an output capacitor Co1.

[0072] Energy storage capacitor C bulk Located on the primary side circuit of voltage converter 100, it is typically connected to the PFC circuit. Energy storage capacitor C bulk Responsible for converting the input voltage V provided by the PFC circuit in (e.g., 400V DC) voltage regulation reduces voltage fluctuations and ensures stable input voltage for voltage converter 100. Energy storage capacitor C bulk It can provide output hold-up time. During a momentary AC power outage, the energy storage capacitor C... bulk This can release energy, allowing the voltage converter 100 to run continuously for a short period, preventing the device from restarting. And the energy storage capacitor C... bulk Together with the PFC inductor, they can filter high-frequency noise, ensuring a smooth input for the voltage converter 100.

[0073] Switches S1 and S2 are, for example, MOSFETs. Switches S1 and S2 can form a full-bridge or half-bridge circuit to drive the voltage converter 100. In one embodiment, by alternating switching of switches S1 and S2 through high-frequency switching action, a high-frequency AC signal can be generated to drive the resonant circuit. Switches S1 and S2 operate under zero-voltage switching (ZVS) conditions, which can significantly reduce switching losses and improve efficiency.

[0074] The resonant capacitor Cr and the resonant inductor Lr are connected in series between the switches S1 and S2 of the voltage converter 100 and the magnetizing inductor Lm. The resonant capacitor Cr and the resonant inductor Lr generate high-frequency oscillations, enabling the voltage converter 100 to operate at zero voltage switching.

[0075] The magnetizing inductor Lm is connected in parallel to the primary circuit. The magnetizing inductor Lm and the resonant inductor Lr together affect the output voltage regulation range of the voltage converter 100. The magnetizing inductor Lm can store energy and release it during the switching of switches S1 and S2, further reducing switching losses.

[0076] Diodes D1 and D2 are located in the secondary circuit and are used to rectify the AC voltage, converting high-frequency AC to DC. Output capacitor Co1 is connected in parallel to the secondary circuit of voltage converter 100 and is responsible for smoothing the DC voltage.

[0077] Using the aforementioned components, the voltage converter 100 can convert the input voltage V in Convert to the required stable output voltage V o This is to supply power for the operation of electronic devices. In voltage converter 100, the output hold-up time is the time (usually measured in milliseconds, ms) during which the voltage converter 100 can maintain a stable output when the power input (AC or DC) is suddenly interrupted. The output hold-up time determines the voltage converter 100's ability to resist brief voltage interruptions, affecting the stability and reliability of the system. Extending the output hold-up time can prevent abnormal device restarts and improve the reliability of industrial power supplies and servo power supplies.

[0078] By increasing the energy storage capacitor C bulk While this can extend the output sustain time, it increases size and cost. In this invention, there is no need to increase the size of the energy storage capacitor C. bulk Various implementation methods are proposed to extend the output duration in the given circumstances.

[0079] Please refer to Figures 2A-2C , Figure 2A A schematic diagram illustrating the magnetic core 110 of a voltage converter 100 according to an embodiment of the present invention is shown. Figure 2BA schematic diagram illustrating the magnetic core 110, primary coil 120, and secondary coil 130 of a voltage converter 100 according to an embodiment of the present invention is shown. Figure 2C A perspective view of the magnetic core 110 of a voltage converter 100 according to an embodiment of the present invention is shown.

[0080] like Figures 2A-2C As shown, the voltage converter 100 is, for example, a magnetic element. The voltage converter 100 includes a magnetic core 110, a primary coil 120, and a secondary coil 130. The magnetic core 110 includes a first core post 111, a second core post 112, a third core post 113, a first plate 114, and a second plate 115. The first plate 114 connects the first core post 111, the second core post 112, and the third core post 113. The second plate 115 connects the first core post 111, the second core post 112, and the third core post 113. The first core post 111 is located between the second core post 112 and the third core post 113. The first core post 111 has a first main air gap MG11, a first stepped air gap SG11, and a second stepped air gap SG12. The first core post 111 has a winding portion 111W. The winding section 111W is used to set the primary side coil 120 and the secondary side coil 130.

[0081] The first main air gap MG11 is located in the middle of the first core post 111. The first main air gap MG11 is disconnected from the first core post 111. The term "disconnected" means that the first core post 111 is divided into two unconnected parts by the first main air gap MG11. The winding part 111W and the first main air gap MG11 are located on the same first core post 111.

[0082] The first stepped air gap SG11 is located near the connection between the first plate 114 and the first core post 111, and is also near the corner R11 of the magnetic core 110. The second stepped air gap SG12 is located near the connection between the second plate 115 and the first core post 111, and is also near the corner R12 of the magnetic core 110. The first stepped air gap SG11 and the second stepped air gap SG12 are disposed on the side wall of the first core post 111. The first stepped air gap SG11 passes through a portion of the first core post 111, and the second stepped air gap SG12 passes through a portion of the first core post 111. The term "passes through a portion" means that although the first core post 111 is passed through by the first stepped air gap SG11, there is still a connected portion, and although the first core post 111 is passed through by the second stepped air gap SG12, there is still a connected portion. The first-step air gap SG11 is located at a different position than the winding section 111W, and the second-step air gap SG12 is located at a different position than the winding section 111W.

[0083] For example, the winding section 111W is positioned differently in the height direction from the first-step air gap SG11, and also differently in the height direction from the second-step air gap SG12. This staggering of the winding section 111W from the first-step air gap SG11 and the second-step air gap SG12 prevents the edge effects of the first-step air gap SG11, the second-step air gap SG12, and the winding section 111W from interfering with each other. Furthermore, with the positions staggered, the winding section 111W primarily senses a uniform magnetic field region, improving output accuracy and stability.

[0084] A first-step air gap SG11 and a second-step air gap SG12 are disposed on both sides of a first main air gap MG11. In one embodiment, the area of ​​the first-step air gap SG11 is substantially equal to the area of ​​the second-step air gap SG12. The area of ​​the first-step air gap SG11 is, for example, less than 2 / 3 of the area of ​​the first main air gap MG11. The height of the first-step air gap SG11 is substantially equal to the height of the second-step air gap SG12. The height of the first-step air gap SG11 refers, for example, to the gap width along the extension direction of the first core post 111, and the height of the second-step air gap SG12 refers, for example, to the gap width along the extension direction of the first core post 111. The height of the first main air gap MG11 is substantially greater than the height of the first-step air gap SG11. The height of the first main air gap MG11 refers, for example, to the gap width along the extension direction of the first core post 111.

[0085] like Figure 2B As shown, the primary coil 120 and the secondary coil 130 are disposed on the first core post 111.

[0086] Please refer to Figure 3 The diagram illustrates the inductance drop of the voltage converter 100 shown in Figures 2A to 2C. The first main air gap MG11, the first step air gap SG11, and the second step air gap SG12 can adjust the permeability, thereby adjusting the inductance.

[0087] The first main air gap MG11, which is completely cut off, completely severs the first core post 111, so the magnetic field must completely pass through the first main air gap MG11. For the first main air gap MG11, the effective core cross-sectional area is small, resulting in a large magnetic flux density, making it easier to enter magnetic saturation.

[0088] The first-stage air gap SG11 and the second-stage air gap SG12, which are partially cut, only partially cut the first core post 111, leaving a magnetic circuit on one side, allowing the magnetic field to partially bypass the first-stage air gap SG11 and the second-stage air gap SG12. For the first-stage air gap SG11 and the second-stage air gap SG12, the effective cross-sectional area of ​​the magnetic core is larger, so the magnetic flux density is smaller and less prone to saturation.

[0089] like Figure 3 As shown, in the first stage ST11 when the current is low, the magnetic core 110 is not yet saturated, and the magnetic field mainly passes through the magnetic core 110. The influence of the first main air gap MG11, the first step air gap SG11, and the second step air gap SG12 is relatively small, the inductance change is not significant, and the magnetic permeability of the core remains high. At this time, the magnetic flux is mainly concentrated within the magnetic core 110, and the influence of the first step air gap SG11 and the second step air gap SG12 is relatively small. The inductance remains almost unchanged, and the inductance performance is close to the ideal state.

[0090] In the second stage ST12 with moderate current, the magnetic core 110 is partially saturated, and some of the magnetic field begins to pass through the first-step air gap SG11 and the second-step air gap SG12, resulting in a decrease in inductance. At this time, the regions of the first-step air gap SG11 and the second-step air gap SG12 enter magnetic saturation, and the magnetic permeability of the core decreases.

[0091] In the third stage (ST13) with higher current, the magnetic core 110 is fully saturated. The first main air gap (MG11) comes into play, and the inductance drops significantly. At this point, most of the magnetic core 110 enters saturation, and the core permeability decreases sharply.

[0092] The above process consists of two inductance attenuations formed by the first main air gap MG11, the first step air gap SG11, and the second step air gap SG12.

[0093] Please refer to Figure 4 Its illustration Figures 2A-2C The change in the gain curve of voltage converter 100 during two inductance decays. When the inductance decreases, it affects the resonant characteristics and gain curve of voltage converter 100. The equivalent gain of voltage converter 100 is related to the current distribution of the transformer; when the inductance decreases, more current flows through the resonant slot, thus increasing the gain.

[0094] like Figure 4 As shown, during the first inductance attenuation, the maximum gain G31 (approximately 1.386) increases to the maximum gain G32 (approximately 2.67); during the second inductance attenuation, the maximum gain G32 (approximately 2.67) increases to the maximum gain G33 (approximately 3.85).

[0095] When the maximum gain G31 is increased to the maximum gain G32, at a lower input voltage V in Under these conditions, a stable output voltage V can still be maintained. o This reduces the energy storage capacitor C during a sudden power outage. bulk The additional energy required, therefore the energy storage capacitor C bulk It can be reduced appropriately.

[0096] Please refer to equations (1) and (2) below. Figure 5Equation (1) explains the DC-Link voltage V. bus Maximum gain G peak Duty cycle D, turns ratio n, output voltage V o Equation (2) explains the relationship with the energy storage capacitor C. bulk PFC voltage V in DC-Link voltage V bus Input power P in Output duration T hold-up The relationship. Figure 5 Example illustrating the decrease in sensitivity and the output duration T hold-up With the energy storage capacitor C remaining unchanged, bulk The changes.

[0097] V bus ×G peak ×D=n×V o …………………………(1),

[0098]

[0099] According to equation (1), when the maximum gain G peak When increased, at a lower DC-Link voltage V bus It can still maintain the output voltage V. o This means that even if the DC-Link voltage V bus Even with a drop in voltage, the voltage converter 100 can compensate by increasing its gain, maintaining output stability. In other words, the voltage converter 100 can operate at lower DC-Link voltages VV. bus Operating below the threshold reduces the impact on the energy storage capacitor C. bulk The demand.

[0100] According to equation (2), when the maximum gain G peak When increased, the DC-Link voltage V bus The minimum operable value is reduced (because the voltage converter 100 can still maintain the output voltage). DC-Link voltage V bus Become smaller, making The value increases, therefore the energy on the left side increases. To satisfy the inequality, the energy storage capacitor C can be reduced. bulk Because the same energy can be stored in a smaller energy storage capacitor C. bulk supply.

[0101] like Figure 5 As shown, during the inductance decay process, when the inductance value drops from 630μH to μH, according to the derivation of equations (1) and (2) above, the DC-Link voltage V bus It will drop from 304V to 157V, with maximum gain G. peakIt will increase from 1.386 to 2.67, and the energy storage capacitor C bulk It will decrease from 192μF to 96μF.

[0102] Please refer to Figure 6 Its diagram shows the energy storage capacitor C. bulk The experimental results were obtained using 96 μF. (In the above...) Figure 5 Under the same conditions, the energy storage capacitor C bulk Using an experiment with 96μF, it can be found that when the power input is suddenly interrupted, the output sustain time T is [not specified]. hold-up The time reached 20.6ms, which indeed exceeded the expected 20ms.

[0103] Please refer to Figure 7 The example illustrates that when the inductance decreases and the energy storage capacitor C... bulk With the output duration T remaining unchanged hold-up Changes. For example... Figure 7 As shown, during the inductance decay process, when the inductance value drops from 630μH to μH, according to the derivation of equations (1) and (2) above, the DC-Link voltage V bus It will drop from 304V to 157V, with maximum gain G. peak The output duration T will increase from 1.386 to 2.651. hold-up It will increase from 10.36ms to 22.4ms.

[0104] Please refer to Figure 8 Its diagram shows the energy storage capacitor C. bulk Experimental results using 100 μF. (In the above...) Figure 7 Under the same conditions, the energy storage capacitor C bulk Using an experiment with 100μF, it can be found that when the power input is suddenly interrupted, the output sustaining time T is [not specified]. hold-up The time reached 23.6ms, which indeed exceeded the expected 20ms.

[0105] In conclusion, Figures 2A-2C With the design of the first main air gap MG11, the first step air gap SG11, and the second step air gap SG12, a structure like this will be formed. Figure 3 The two insensitivity decays. These two insensitivity decays can cause... Figure 4 The maximum gain G shown peak Increase, and thus such as Figure 5 The figure shows that it can reduce the impact on the energy storage capacitor C. bulk The demand. Therefore, as Figure 6 and Figure 8 As shown, in the energy storage capacitor C bulk Even with a smaller output duration T, the output duration can still be maintained. hold-up The expected level has been achieved.

[0106] Please refer to Figures 9A-9B , Figure 9A A schematic diagram illustrating the magnetic core 210 of a voltage converter 200 according to another embodiment of the present invention is shown. Figure 9B A schematic diagram illustrating the magnetic core 210, primary coil 220, and secondary coil 230 of a voltage converter 200 according to another embodiment of the present invention is shown. Figures 9A-9B As shown, the voltage converter 200 includes a magnetic core 210, a primary coil 220, and a secondary coil 230. The magnetic core 210 includes a first core post 211, a second core post 212, a third core post 213, a first plate 214, and a second plate 215. The first core post 211 is located between the second core post 212 and the third core post 213. The first core post 211 has a first main air gap MG21, a first stepped air gap SG21, and a second stepped air gap SG22. The second core post 212 has a winding portion 212W, and the third core post 213 has a winding portion 213w. The winding portion 212W is used to house the primary coil 220, and the winding portion 213w is used to house the secondary coil 230.

[0107] The first main air gap MG21 is located in the middle of the first core post 211. The first main air gap MG21 is disconnected from the first core post 211. The winding part 212W and the first main air gap MG21 are located on different second core posts 212 and first core posts 211, respectively. The winding part 213w and the first main air gap MG21 are located on different third core posts 213 and first core posts 211, respectively.

[0108] The first stepped air gap SG21 is located near the connection between the first plate 214 and the first core post 211, and is also near the corner R21 of the magnetic core 210. The second stepped air gap SG22 is located near the connection between the second plate 215 and the first core post 111, and is also near the corner R22 of the magnetic core 210. The first stepped air gap SG21 and the second stepped air gap SG22 are disposed on the side wall of the first core post 211. The first stepped air gap SG21 passes through a portion of the first core post 211, and the second stepped air gap SG22 passes through a portion of the first core post 211. The first stepped air gap SG21 is positioned differently from the winding portions 212W and 213w, and the second stepped air gap SG22 is positioned differently from the winding portions 212W and 213w.

[0109] For example, the winding sections 212W and 213w are positioned differently in the height direction from the first-step air gap SG21, and the winding sections 212W and 213w are positioned differently in the height direction from the second-step air gap SG22. This staggering of the winding sections 212W and 213w from the first-step air gap SG21 and the second-step air gap SG22 prevents the edge effects of the first-step air gap SG21, the second-step air gap SG22, and the winding sections 212W and 213w from interfering with each other. Furthermore, after the positions are staggered, the winding sections 212W and 213w primarily sense a uniform magnetic field region, which improves output accuracy and stability.

[0110] A first-step air gap SG21 and a second-step air gap SG22 are disposed on both sides of a first main air gap MG21. In one embodiment, the area of ​​the first-step air gap SG21 is substantially equal to the area of ​​the second-step air gap SG22. The area of ​​the first-step air gap SG21 is, for example, less than 2 / 3 of the area of ​​the first main air gap MG21. The height of the first-step air gap SG21 is substantially equal to the height of the second-step air gap SG22. The height of the first-step air gap SG21 refers, for example, to the gap width along the extension direction of the first core post 211, and the height of the second-step air gap SG22 refers, for example, to the gap width along the extension direction of the first core post 211. The height of the first main air gap MG21 is substantially greater than the height of the first-step air gap SG21. The height of the first main air gap MG21 refers, for example, to the gap width along the extension direction of the first core post 211.

[0111] like Figure 9B As shown, the primary coil 220 is disposed on the second core post 212, and the secondary coil 230 is disposed on the third core post 213.

[0112] Based on the above explanation, Figures 9A-9B The design of the first main air gap MG21, the first step air gap SG21, and the second step air gap SG22 will also form a structure like... Figure 3 The two insensitivity decays. These two insensitivity decays can cause... Figure 4 The maximum gain G shown peak Increase, and thus such as Figure 5 The figure shows that it can reduce the impact on the energy storage capacitor C. bulk The demand. Therefore, as Figure 6 , 8 As shown, in the energy storage capacitor C bulk Even with a smaller output duration T, the output duration can still be maintained. hold-up The expected level has been achieved.

[0113] Please refer to Figures 10A-10C , Figure 10A A schematic diagram illustrating the magnetic core 310 of a voltage converter 300 according to another embodiment of the present invention is shown. Figure 10B A schematic diagram illustrating the magnetic core 310, primary coil 320, and secondary coil 330 of a voltage converter 300 according to another embodiment of the present invention is shown. Figure 10C A perspective view of the magnetic core 310 of a voltage converter 300 according to another embodiment of the present invention is shown. Figures 10A-10B As shown, the voltage converter 300 includes a magnetic core 310, a primary coil 320, and a secondary coil 330. The magnetic core 310 includes a first core post 311, a second core post 312, a third core post 313, a first plate 314, and a second plate 315. The first core post 311 is located between the second core post 312 and the third core post 313. The first core post 311 has a first main air gap MG31, a first stepped air gap SG31, and a second stepped air gap SG32. The first core post 311 has a winding portion 311W. The winding portion 311W is used to mount the primary coil 220 and the secondary coil 330.

[0114] The first main air gap MG31 is located in the middle of the first core post 311. The first main air gap MG31 is disconnected from the first core post 311. The winding part 311W and the first main air gap MG31 are located on the same first core post 311.

[0115] The first stepped air gap SG31 is located near the connection between the first flat plate 314 and the first core post 311, and is disposed inside the first core post 311. The second stepped air gap SG32 is located near the connection between the second flat plate 315 and the first core post 311, and is disposed inside the first core post 311. The first stepped air gap SG31 and the second stepped air gap SG32 pass through a portion of the first core post 311. The first stepped air gap SG31 and the winding portion 311W are located at different positions, and the second stepped air gap SG32 and the winding portion 311W are located at different positions.

[0116] For example, the winding section 311W is positioned differently in the height direction from the first-step air gap SG31, and also differently in the height direction from the second-step air gap SG32. This staggering of the winding section 311W from the first-step air gap SG31 and the second-step air gap SG32 prevents the edge effects of the first-step air gap SG31, the second-step air gap SG32, and the winding section 311W from interfering with each other. Furthermore, with the positions staggered, the winding section 311W primarily senses a uniform magnetic field region, improving output accuracy and stability.

[0117] A first-step air gap SG31 and a second-step air gap SG32 are disposed on both sides of a first main air gap MG31. In one embodiment, the area of ​​the first-step air gap SG31 is substantially equal to the area of ​​the second-step air gap SG32. The area of ​​the first-step air gap SG31 is, for example, less than 2 / 3 of the area of ​​the first main air gap MG31. The height of the first-step air gap SG31 is substantially equal to the height of the second-step air gap SG32. The height of the first-step air gap SG31 refers, for example, to the gap width along the extension direction of the first core post 311, and the height of the second-step air gap SG32 refers, for example, to the gap width along the extension direction of the first core post 311. The height of the first main air gap MG31 is substantially greater than the height of the first-step air gap SG31. The height of the first main air gap MG31 refers, for example, to the gap width along the extension direction of the first core post 311.

[0118] like Figure 10B As shown, the primary coil 320 and the secondary coil 330 are disposed on the first core post 311.

[0119] Please refer to Figure 11 Its illustration Figures 10A-10C The inductance drop of the voltage converter 300 is described. The permeability of the first main air gap MG31, the first step air gap SG31, and the second step air gap SG32 can be adjusted, thereby adjusting the inductance.

[0120] The first main air gap MG31, which is completely cut off, completely severs the first core post 311, so the magnetic field must completely pass through the first main air gap MG31. For the first main air gap MG31, the effective core cross-sectional area is relatively small, resulting in a larger magnetic flux density and making it easier to enter magnetic saturation.

[0121] The first-step air gap SG31 and the second-step air gap SG32, which are partially cut, only partially cut the first core post 311, leaving a magnetic circuit on one side. This allows the magnetic field to partially bypass the first-step air gap SG31 and the second-step air gap SG32. For the first-step air gap SG31 and the second-step air gap SG32, the effective cross-sectional area of ​​the magnetic core is relatively large, resulting in a smaller magnetic flux density and making it less prone to saturation.

[0122] like Figure 11 As shown, in the first stage ST31 when the current is low, the magnetic core 310 is not yet saturated, and the magnetic field mainly passes through the magnetic core 310. The influence of the first main air gap MG31, the first step air gap SG31, and the second step air gap SG32 is relatively small, the inductance change is not significant, and the magnetic permeability of the core remains high. At this time, the magnetic flux is mainly concentrated in the iron core 310, and the influence of the first step air gap SG31 and the second step air gap SG32 is relatively small. The inductance is almost unchanged, and the inductance performance is close to the ideal state.

[0123] In the second stage ST32 with moderate current, the magnetic core 310 is partially saturated, and some of the magnetic field begins to pass through the first-step air gap SG31 and the second-step air gap SG32, resulting in a decrease in inductance. At this point, the regions of the first-step air gap SG31 and the second-step air gap SG32 enter magnetic saturation, and the magnetic permeability of the core decreases.

[0124] In the third stage (ST33) with higher current, the magnetic core 310 is fully saturated. The first main air gap (MG31) comes into play, and the inductance drops significantly. At this point, most of the magnetic core 310 enters saturation, and the core permeability decreases sharply.

[0125] The above process consists of two inductance attenuations formed by the first main air gap MG31, the first step air gap SG31, and the second step air gap SG32.

[0126] Based on the above explanation, Figures 10A-10C With the design of the first main air gap MG31, the first step air gap SG31, and the second step air gap SG32, a structure like this will be formed. Figure 11 The two insensitivity decays. These two insensitivity decays can cause... Figure 4 The maximum gain G shown peak Increase, and thus such as Figure 5 The figure shows that it can reduce the impact on the energy storage capacitor C. bulk The demand. Therefore, as Figure 6 and Figure 8 As shown, in the energy storage capacitor C bulk Even with a smaller output duration T, the output duration can still be maintained. hold-up The expected level has been achieved.

[0127] Please refer to Figures 12A-12B , Figure 12A A perspective view of the magnetic core 410 of a voltage converter 400 according to another embodiment of the present invention is shown. Figure 12B A side view of the magnetic core 410 of a voltage converter 400 according to another embodiment of the present invention is shown. Figures 12A-12B As shown in the figure, the voltage converter 400 includes a magnetic core 410, a primary coil (not shown), and a secondary coil (not shown). The magnetic core 410 includes a first core post 411, a second core post 412, a third core post 413, a first plate 414, and a second plate 415. The first core post 411 is located between the second core post 412 and the third core post 413. The first core post 411 has a first main air gap MG41, a first stepped air gap SG41, and a second stepped air gap SG42. The first core post 411 has a winding portion 411W. The winding portion 411W is used to mount the primary coil (not shown) and the secondary coil (not shown).

[0128] The first main air gap MG41 is located in the middle of the first core post 411. The first main air gap MG41 is disconnected from the first core post 411. The winding part 411W and the first main air gap MG41 are located on the same first core post 411.

[0129] The first stepped air gap SG41 is located near the connection between the first plate 414 and the first core post 411, and is also near the corner R41 of the magnetic core 410. The second stepped air gap SG42 is located near the connection between the second plate 415 and the first core post 411, and is also near the corner R42 of the magnetic core 410. The first stepped air gap SG41 and the second stepped air gap SG42 are disposed on the side wall of the first core post 411. The first stepped air gap SG41 passes through a portion of the first core post 411, and the second stepped air gap SG42 passes through a portion of the first core post 411. The first stepped air gap SG41 and the winding portion 411W are located at different positions, and the second stepped air gap SG42 and the winding portion 411W are also located at different positions.

[0130] For example, the winding section 411W is positioned differently in the height direction from the first-step air gap SG41, and also differently in the height direction from the second-step air gap SG42. This staggering of the winding section 411W from the first-step air gap SG41 and the second-step air gap SG42 prevents the edge effects of the first-step air gap SG41, the second-step air gap SG42, and the winding section 411W from interfering with each other. Furthermore, with the positions staggered, the winding section 411W primarily senses a uniform magnetic field region, improving output accuracy and stability.

[0131] like Figure 12A As shown, the first core post 411 is a cylinder, the first main air gap MG41 is circular, and the first step air gap SG41 is semi-circular.

[0132] A first-step air gap SG41 and a second-step air gap SG42 are disposed on both sides of a first main air gap MG41. In one embodiment, the area of ​​the first-step air gap SG41 is substantially equal to the area of ​​the second-step air gap SG42. The area of ​​the first-step air gap SG41 is, for example, less than 2 / 3 of the area of ​​the first main air gap MG41. The height of the first-step air gap SG41 is substantially equal to the height of the second-step air gap SG42. The height of the first-step air gap SG41 refers, for example, to the gap width along the extension direction of the first core post 411, and the height of the second-step air gap SG42 refers, for example, to the gap width along the extension direction of the first core post 411. The height of the first main air gap MG41 is substantially greater than the height of the first-step air gap SG41. The height of the first main air gap MG41 refers, for example, to the gap width along the extension direction of the first core post 411.

[0133] Based on the above explanation, Figures 12A-12B The design of the first main air gap MG41, the first step air gap SG41, and the second step air gap SG42 will also form a structure like... Figure 3 The two insensitivity decays. These two insensitivity decays can cause... Figure 4 The maximum gain G shown peak Increase, and thus such as Figure 5 The figure shows that it can reduce the impact on the energy storage capacitor C. bulk The demand. Therefore, as Figure 6 and Figure 8 As shown, in the energy storage capacitor C bulk Even with a smaller output duration T, the output duration can still be maintained. hold-up The expected level has been achieved.

[0134] Please refer to Figures 13A-13B , Figure 13A A schematic diagram illustrating the magnetic core 510 of a voltage converter 500 according to another embodiment of the present invention is shown. Figure 13B A schematic diagram illustrating the magnetic core 510, primary coil 520, and secondary coil 530 of a voltage converter 500 according to another embodiment of the present invention is shown. Figures 13A-13B As shown, the voltage converter 500 includes a magnetic core 510, a primary coil 520, and a secondary coil 530. The magnetic core 510 includes a first core post 511, a second core post 512, a first plate 514, and a second plate 515. The first core post 511 has a first main air gap MG51 and a first stepped air gap SG51. The second core post 512 has a second main air gap MG52 and a second stepped air gap SG52. The first core post 511 has a winding portion 511W, and the second core post 512 has a winding portion 512W. The winding portion 511W is used to mount the primary coil 520, and the winding portion 512W is used to mount the secondary coil 530.

[0135] The first main air gap MG51 is located in the middle of the first core post 511. The first main air gap MG51 is disconnected from the first core post 511. The second main air gap MG52 is located in the middle of the second core post 512. The second main air gap MG52 is disconnected from the second core post 512. The winding portion 511W and the first main air gap MG51 are located on the same first core post 511. The winding portion 512W and the second main air gap MG52 are located on the same second core post 512.

[0136] The first stepped air gap SG51 is located near the connection between the first plate 514 and the first core post 511, and is also near the corner R51 of the magnetic core 510. The second stepped air gap SG52 is located near the connection between the first plate 514 and the second core post 512, and is also near the corner R52 of the magnetic core 510. The first stepped air gap SG51 is disposed on the side wall of the first core post 511. The first stepped air gap SG51 passes through a portion of the first core post 511. The second stepped air gap SG52 is disposed on the side wall of the second core post 512. The second stepped air gap SG52 passes through a portion of the second core post 512. The first stepped air gap SG51 is located at a different position than the winding portion 511W, and the second stepped air gap SG52 is located at a different position than the winding portion 512W.

[0137] For example, the winding section 511W and the first-step air gap SG51 are positioned differently in the height direction, as are the winding section 512W and the second-step air gap SG52. This staggering of the winding sections 511W and 512W with the first-step air gap SG51 and the second-step air gap SG52 prevents the edge effects of the first-step air gap SG51 and the second-step air gap SG52 from interfering with each other. Furthermore, with the positions staggered, the winding sections 511W and 512W primarily sense a uniform magnetic field region, improving output accuracy and stability.

[0138] In one embodiment, the area of ​​the first main air gap MG51 is substantially equal to the area of ​​the second main air gap MG52. The area of ​​the first stepped air gap SG51 is substantially equal to the area of ​​the second stepped air gap SG52. The area of ​​the first stepped air gap SG51 is, for example, less than 2 / 3 of the area of ​​the first main air gap MG51. The area of ​​the second stepped air gap SG52 is, for example, less than 2 / 3 of the area of ​​the second main air gap MG52. The height of the first stepped air gap SG51 is substantially equal to the height of the second stepped air gap SG52. The height of the first stepped air gap SG51 refers, for example, to the gap width along the extension direction of the first core post 511, and the height of the second stepped air gap SG52 refers, for example, to the gap width along the extension direction of the second core post 512. The height of the first main air gap MG51 is substantially the same as the height of the second main air gap MG52. The height of the first main air gap MG51 refers, for example, to the gap width along the extension direction of the first core post 511 or the second core post 512. The height of the first main air gap MG51 is substantially greater than the height of the first step air gap SG51. The height of the second main air gap MG52 is substantially greater than the height of the second step air gap SG52.

[0139] like Figure 13BAs shown, the primary coil 520 is disposed on the first core post 511, and the secondary coil 530 is disposed on the second core post 512.

[0140] Based on the above explanation, Figures 13A-13B With the design of the first main air gap MG51, the second main air gap MG52, the first stepped air gap SG51, and the second stepped air gap SG52, a structure similar to the one formed in the design will also be created. Figure 3 The two insensitivity decays. These two insensitivity decays can cause... Figure 4 The maximum gain G shown peak Increase, and thus such as Figure 5 The figure shows that it can reduce the impact on the energy storage capacitor C. bulk The demand. Therefore, as Figure 6 , 8 As shown, in the energy storage capacitor C bulk Even with a smaller output duration T, the output duration can still be maintained. hold-up The expected level has been achieved.

[0141] The magnetic core 110, main air gap (such as the first main air gap MG11, MG21, MG31, MG41, MG51 or the second main air gap MG52), and stepped air gap (such as the first stepped air gap SG11, SG21, SG31, SG41, SG51 or the second stepped air gap SG12, SG22, SG32, SG42, SG52) of the present invention can be applied to magnetic components such as converters, transformers, and inductors.

[0142] In summary, although the present invention has been disclosed above with reference to embodiments, it is not intended to limit the invention. Those skilled in the art can make various modifications and refinements without departing from the spirit and scope of the invention. Therefore, the scope of protection of the present invention shall be determined by the appended claims.

Claims

1. A voltage converter, characterized in that, include: A magnetic core, comprising: A first core post, the first core post having a first main air gap and a first step air gap, the first main air gap disconnecting the first core post, the first step air gap passing through a part of the first core post. A primary coil is disposed on the magnetic core; and The primary and secondary coils are mounted on the magnetic core.

2. The voltage converter as described in claim 1, characterized in that, The first core post further has a second stepped air gap, which is inserted through a portion of the first core post.

3. The voltage converter as described in claim 2, characterized in that, The first step air gap and the second step air gap are located on both sides of the first main air gap.

4. The voltage converter as described in claim 2, characterized in that, The area of ​​the first-step air gap is equal to the area of ​​the second-step air gap.

5. The voltage converter as described in claim 2, characterized in that, The height of the first-step air gap is equal to the height of the second-step air gap.

6. The voltage converter as claimed in claim 1, characterized in that, The primary coil and the secondary coil are wound around the first core post.

7. The voltage converter as claimed in claim 1, characterized in that, The first main air gap is located in the middle of the first core column.

8. The voltage converter as claimed in claim 1, characterized in that, The area of ​​the first step air gap is less than 2 / 3 of the area of ​​the first main air gap.

9. The voltage converter as claimed in claim 1, characterized in that, The height of the first main air gap is the same as the height of the first step air gap.

10. The voltage converter as claimed in claim 1, characterized in that, The first-step air gap is set on the side wall of the first core post.

11. The voltage converter as claimed in claim 1, characterized in that, The magnetic core further includes: A second core post; and A third core post, wherein the first core post is located between the second core post and the third core post, the primary side coil is disposed on the second core post, and the secondary side coil is disposed on the third core post.

12. The voltage converter as claimed in claim 1, characterized in that, The first-stage air gap is located inside the first core post.

13. The voltage converter as claimed in claim 1, characterized in that, The first core column is cylindrical, the first main air gap is circular, and the first step air gap is semi-circular.

14. The voltage converter of claim 1, wherein the magnetic core further comprises: A second core column, the second core column having a second main air gap and a second stepped air gap.

15. The voltage converter as claimed in claim 14, characterized in that, The primary coil is wound around the first core post, and the secondary coil is wound around the second core post.

16. The voltage converter as claimed in claim 14, characterized in that, The area of ​​the first main air gap is equal to the area of ​​the second main air gap.

17. The voltage converter as claimed in claim 14, characterized in that, The area of ​​the first-step air gap is equal to the area of ​​the second-step air gap.

18. The voltage converter as claimed in claim 14, characterized in that, The height of the first main air gap is equal to the height of the second main air gap.

19. The voltage converter as claimed in claim 14, characterized in that, The height of the first-step air gap is equal to the height of the second-step air gap.

20. A power supply, characterized in that, include: One input terminal, used to connect to a power source; One output terminal, used to connect a load; as well as A voltage converter is connected between the input terminal and the load terminal, the voltage converter comprising: A magnetic core, comprising: A first core post, the first core post having a first main air gap and a first step air gap, the first main air gap disconnecting the first core post, the first step air gap passing through a part of the first core post. A primary coil is disposed on the magnetic core; and The primary and secondary coils are mounted on the magnetic core.

21. A magnetic element, characterized in that, include: A magnetic core having a plurality of core posts, wherein one of the plurality of core posts has a winding portion; A main air gap is used to disconnect one of the plurality of core posts; as well as A stepped air gap is inserted into a portion of one of the plurality of core posts, and the position of the stepped air gap is different from the position of the winding section.

22. The magnetic element as claimed in claim 21, characterized in that, The winding section and the stepped air gap are positioned differently in the height direction.

23. The magnetic element as claimed in claim 21, characterized in that, The stepped air gap is located near the corner of the magnetic core.

24. The magnetic element as claimed in claim 23, characterized in that, The magnetic core also includes a plate, which connects the plurality of core posts, and the stepped air gap is located near the connection between the plate and the core posts.

25. The magnetic element as claimed in claim 23, characterized in that, The winding section is further provided with a primary side coil and a secondary side coil.

26. The magnetic element as claimed in claim 23, characterized in that, The winding section and the main air gap are located on the same core post of the plurality of core posts.

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