Magnetic element with magnetic flux compensation structure and method of manufacturing the same

Abstract

The present application provides a magnetic element with a magnetic flux compensation structure and a manufacturing method thereof. The manufacturing method comprises the following steps: providing a core of a magnetic element, wherein the core comprises a plurality of columns and a frame, each of the columns is arranged adjacent to the frame in a receiving space of the frame; and winding a coil on each of the columns, so that when each of the coils receives a current, each of the columns and the frame forms a magnetic flux path, and a corresponding magnetic flux is generated in each of the magnetic flux paths; wherein the structure of the core is arranged such that the magnetic flux paths formed by each of the columns and the frame pass through at least a part of the frame together, and the cross-sectional area of the frame is arranged such that the magnetic fluxes passing through the cross-sectional area of the at least part of the frame cancel each other out to make the maximum magnetic flux on the frame smaller than the maximum magnetic flux of each of the columns.

Description

Technical Field

[0001] This invention relates to a magnetic element and a method for manufacturing the same, and more particularly to a magnetic element with a flux compensation structure and a method for manufacturing the same. Background Technology

[0002] As the power demands of data centers and artificial intelligence (AI) servers continue to increase, the power conversion efficiency of AC / DC power converters within AI server racks becomes increasingly important. Because power converters incur power losses and generate heat during rectification, the potential for system failures and reduced lifespan due to this additional heat must be considered during system installation.

[0003] As mentioned above, in addition to the circuit architecture and component selection, the design of magnetic components is also related to the aforementioned issues of heat dissipation, system failure, and reduced lifespan in power converter design. Furthermore, when iron losses occur in magnetic components, additional heat dissipation is generated, and the occurrence of iron losses is due to the inability to effectively compensate for and control the magnetic flux within the magnetic components.

[0004] Therefore, how to provide a magnetic element with a flux compensation structure and its manufacturing method to improve the above problems has become an urgent research topic. Summary of the Invention

[0005] In view of the above problems, the present invention provides a method for manufacturing a magnetic element with a magnetic flux compensation structure, comprising providing an iron core of a magnetic element, the iron core including a plurality of central pillars and a frame, the central pillars being disposed adjacently in the accommodating space of the frame; and winding a coil on each of the central pillars, such that when the magnetic element receives current in each coil, each central pillar and the frame respectively form a magnetic flux path, and a corresponding magnetic flux is generated on each magnetic flux path, wherein the structure of the iron core is configured such that the magnetic flux paths formed by each central pillar and the frame pass through at least a portion of the frame, and the cross-sectional area of ​​the frame is configured such that the magnetic flux passing through at least a portion cancels each other out, such that the maximum magnetic flux on the frame is less than the maximum magnetic flux of each central pillar.

[0006] The present invention also provides a magnetic element with a flux compensation structure, comprising an iron core and a plurality of coils. The iron core includes a plurality of central posts and a frame, with each central post arranged adjacent to each other in an accommodating space of the frame. The plurality of coils are respectively wound around the central posts, such that when each coil receives a current, each central post and the frame respectively form a magnetic flux path, and a corresponding magnetic flux is generated on each magnetic flux path. The structure of the iron core is such that the magnetic flux paths formed by each central post and the frame pass through at least a portion of the frame, and the cross-sectional area of ​​the frame causes the magnetic flux passing through at least a portion to cancel each other out, so that the maximum magnetic flux on the frame is less than the maximum magnetic flux of each central post.

[0007] In summary, the magnetic element with a flux compensation structure and its manufacturing method of the present invention, by arranging multiple sets of coils in the internal structure of the same iron core, can make the magnetic flux induced by each coil in the iron core mutually cancel and compensate each other, thereby reducing iron core loss and iron core saturation, further reducing the heat generated by the power converter, and further improving the power conversion efficiency of the power converter. At the same time, it can also reduce the size of the transformer and inductor installed in the power converter. Attached Figure Description

[0008] Figure 1A and Figure 1B A perspective view and a cross-sectional view of an embodiment of a transformer;

[0009] Figure 2A A perspective view of another embodiment of a transformer;

[0010] Figure 2B for Figure 2A Waveform of magnetic flux on the transformer's center column;

[0011] Figure 2C for Figure 2A Waveform diagram of the total magnetic flux on the top cover and bottom frame of the transformer;

[0012] Figure 3A and Figure 3B The figures show a perspective view and a cross-sectional view of a transformer with a magnetic flux compensation structure according to an embodiment of the present invention.

[0013] Figures 4A to 4C For the present invention Figure 3A and Figure 3B A schematic diagram of the transient change of magnetic flux in a transformer embodiment with a magnetic flux compensation structure;

[0014] Figure 5A and Figure 5B This is a perspective view and a cross-sectional view of another embodiment of the transformer with a flux compensation structure according to the present invention; and

[0015] Figure 6A and Figure 6B The figures show a perspective view and a cross-sectional view of an inductor with a flux compensation structure. Detailed Implementation

[0016] To make the features and advantages of this application more apparent and understandable, specific embodiments of the invention are described in detail below with reference to the accompanying drawings. The following description contains specific information relating to exemplary embodiments in this application. The drawings and accompanying detailed description in this application are merely exemplary embodiments. However, this application is not limited to these exemplary embodiments. Other variations and embodiments of this application will occur to those skilled in the art. Unless otherwise stated, the same or corresponding elements in the drawings may be indicated by the same or corresponding reference numerals. Furthermore, the drawings and illustrations in this application are generally not drawn to scale and are not intended to correspond to actual relative dimensions.

[0017] For the purposes of consistency and ease of understanding, the same features are indicated by reference numerals in the exemplary drawings (although not in some examples). However, features in different embodiments may differ in other respects, and therefore should not be narrowly limited to the features shown in the drawings.

[0018] The terms "first," "second," and "third," etc., in the specification and accompanying drawings of this application are used to distinguish different objects, areas, levels, or steps, and are not used to describe a specific order (unless otherwise specified in the scope of the patent application). Furthermore, the term "comprising" and any variations thereof are intended to cover non-exclusive inclusion. The term "consisting of" is interpreted as exclusive inclusion, meaning that any additional structural configuration and / or material addition is not covered by the term. However, those skilled in the art should understand that in actual testing, any material may be subject to unintended contamination or doped with trace impurities. These detected trace impurities do not substantially affect the material, properties, and / or structure defined by the term and therefore do not fall under the category of additional structural and / or material additions, as stated herein.

[0019] The terms "connection" or "coupling" used in this application do not imply that there can be no space between the objects. That is, the connection or coupling between two objects can mean that the two objects are directly connected / coupled to each other, or that they are connected / coupled to each other through other objects.

[0020] In all descriptions related to specific numerical values ​​in this application, although not explicitly stated, they all contain the meaning of "approximately" or "substantially," meaning that the specific numerical values ​​will cover a possible range of numerical error to indicate possible unintended effects and deviations in the process or material selection. The range of numerical error may include numerical changes that do not significantly alter the material structure, properties, or effects, such as a deviation of 0% to 10%, which is clear to those skilled in the art.

[0021] The spatial relationships mentioned in this application, such as "above", "below", "upward", "downward", "to the left", "to the right", etc., are all exemplary descriptions based on the relative positions presented in the diagrams and are not intended to limit the actual configuration of the material structure.

[0022] In embodiments of the present invention, the magnetic element includes a transformer and an inductor. For clarity, the following content will distinguish between the illustrations and embodiments of the transformer and the inductor.

[0023] Please see Figure 1A and Figure 1B This is a perspective view and cross-sectional view of an embodiment of a transformer with multiple enclosed iron cores. As described in the prior art, in addition to the circuit architecture and component selection, the design of magnetic components such as transformers and inductors is receiving increasing attention in the design of power converters. For example, for power converter architectures requiring high power of 5kW or more, using a multi-phase power converter architecture can improve the problems of single-phase power converters. Figure 1A and Figure 1B In the diagram, the multiphase power converter uses a structure of three transformers T1, T2, and T3 as the power conversion architecture. Taking the three-phase full-bridge LLC circuit architecture as an example, if a high-power design is changed to a three-phase LLC circuit architecture, it can disperse the temperature and current stress of components, and the output current ripple can cancel each other out, thereby reducing output ripple and achieving high efficiency.

[0024] Please see Figures 2A to 2C , Figure 2A This is a perspective view of an embodiment of a transformer with a single accommodating space. Figure 2B and Figure 2C This is a schematic diagram of the transient change in magnetic flux, where Figure 2B The diagram shows the magnetic flux waveforms on each of the transformer's intermediate columns. Figure 2C This is a waveform diagram showing the sum of magnetic flux on the upper cover and lower frame of the transformer. Figure 2AThe transformer T4 structure includes coils and an iron core. The iron core includes an upper cover T41, a lower frame T42, and three intermediate columns T43, T44, and T45. Each intermediate column T43, T44, and T45 has a coil wound around it. Each coil receives a first coil current, a second coil current, and a third coil current, respectively. Based on these currents, a first magnetic flux Ф41, a second magnetic flux Ф42, and a third magnetic flux Ф43 are induced along the magnetic flux path formed between the upper cover T41, the lower frame T42, and the three intermediate columns T43, T44, and T45. Each coil includes a primary coil T46 and a secondary coil T47. After the primary coil T46 receives the coil current, the secondary coil T47 generates magnetic flux based on the induced coil current. Figure 2B As can be seen from the magnetic flux waveform diagram, since the phase of the first magnetic flux Ф41 leads the phase of the second magnetic flux Ф42, and the phase of the second magnetic flux Ф42 leads the phase of the third magnetic flux Ф43, the magnetic flux paths formed between each of the middle pillars T43, T44, T45 and the upper cover T41 and lower frame T42 all pass through at least a portion of the upper cover T41 and lower frame T42. Furthermore, the cross-sectional areas of the upper cover T41 and lower frame T42 cause the first magnetic flux Ф41, the second magnetic flux Ф42, and the third magnetic flux Ф43 passing through at least a portion to cancel each other out, resulting in the maximum value of the sum of the first magnetic flux Ф41, the second magnetic flux Ф42, and the third magnetic flux Ф43 on the upper cover T41 and lower frame T42 being less than the maximum value of the first magnetic flux Ф41, the second magnetic flux Ф42, and the third magnetic flux Ф43 on each of the middle pillars. For example... Figure 2B and Figure 2C As shown, the maximum magnetic flux Wb1 on the central columns T43, T44, and T45 is 1, and the peak-to-peak value Wb2 is 2. Furthermore, in this embodiment, the accommodating space formed by the upper cover T41 and lower frame T42 of the transformer core T4 is a single accommodating space. Since this accommodating space is not a closed space, the magnetic flux waveform obtained from this embodiment shows that the transformer without the non-closed accommodating space formed by the side columns can only achieve the effect of compensating and offsetting part of the magnetic flux on the upper cover T41 and lower frame T42, and reducing part of the core volume and core loss. Additionally, it should be noted that in the embodiments of this invention, the leading or lagging phase of either the coil current or the magnetic flux is used to indicate the phase difference relationship between two coil currents and two magnetic fluxes, not to limit the absolute leading or lagging phase relationship between the two coil currents and two magnetic fluxes. Furthermore, since the change in phase current is proportional to the change in magnetic flux, the change in magnetic flux described in the embodiments and figures of this invention can be represented by the measurement of phase current in practical verification applications. That is, if the change in phase current measured on the transformer or inductor has a similar... Figures 2B to 2C as well as Figures 4A to 4CThe changing trend indicates that the transformer has the above-mentioned magnetic flux compensation and cancellation effects.

[0025] See Figure 3A and Figure 3B This is a perspective view and a cross-sectional view of another embodiment of the transformer with a flux compensation structure according to the present invention. In this embodiment, the transformer 1 with the flux compensation structure has a single sealed accommodating space, and all coils and intermediate columns are arranged in the single sealed accommodating space. The transformer 1 with the flux compensation structure includes an iron core 10, a first coil 11 and a second coil 12. The iron core 10 has a first intermediate column 14, a second intermediate column 15 and a frame F. The first intermediate column 14 and the second intermediate column 15 are arranged adjacently in the accommodating space G01 of the frame F, and the first intermediate column 14 and the second intermediate column 15 are respectively connected to the frame F by a first air gap G11 and a second air gap G12, and the first air gap G11 and the second air gap G12 communicate with the accommodating space G01. The first coil 11 and the second coil 12 receive the first coil current and the second coil current, respectively, and induce a first magnetic flux Ф11 and a second magnetic flux Ф12 on the magnetic flux path formed between the frame F and the first central column 14 and the second central column 15 according to the first coil current and the second coil current. The first coil 11 includes a first primary side coil 11A and a first secondary side coil 11B of the transformer, and the first primary side coil 11A and the first secondary side coil 11B are wound together on the first central column 14. The first primary side coil 11A receives the first coil current (i.e., the first primary side current), so that the first secondary side coil 11B induces the first magnetic flux Ф11 according to the first primary side current. The second coil 12 includes a second primary coil 12A and a second secondary coil 12B of the transformer, and the second primary coil 12A and the second secondary coil 12B are wound together on the second central column 15. The second primary coil 12A receives the second coil current (i.e., the second primary side current), causing the second secondary coil 12B to generate a second magnetic flux Ф12 based on the second primary side current. The first current phase of the first primary side current leads the second current phase of the second primary side current, so that the first magnetic flux phase of the first magnetic flux Ф11 leads the second magnetic flux phase of the second magnetic flux Ф12.

[0026] Please refer to the following: Figure 3A and Figure 3BThe transformer 1 with a flux compensation structure also includes a third central column 16 and a third coil 13. The third central column 16 is disposed in the accommodating space G01 of the frame F, and there is a third air gap G13 between the third central column 16 and the frame F, which connects to the accommodating space G01. The third coil 13 receives a third coil current and induces a third magnetic flux Ф13 on the flux path formed between the frame F and the third central column 16 according to the third coil current. The third coil 13 includes a third primary side coil 13A and a third secondary side coil 13B of the transformer, and the third primary side coil 13A and the third secondary side coil 13B are wound together on the third central column 16. The third primary side coil 13A receives the third coil current (i.e., the third primary side current), causing the third secondary side coil 13B to induce a third magnetic flux Ф13 according to the third primary side current. In contrast, the second current phase of the second primary current leads the third current phase of the third primary current, causing the second magnetic flux phase of the second magnetic flux Ф12 to lead the third magnetic flux phase of the third magnetic flux Ф13. Since the phase of the first magnetic flux Ф11 leads the phase of the second magnetic flux Ф12, and the phase of the second magnetic flux Ф12 leads the phase of the third magnetic flux Ф13, the magnetic flux paths formed between the first central column 14, the second central column 15, the third central column 16, and the frame F all pass through at least a portion of the frame F. Furthermore, the cross-sectional area of ​​the frame F causes the first magnetic flux Ф11, the second magnetic flux Ф12, and the third magnetic flux Ф13 passing through at least a portion to cancel each other out, resulting in the maximum value of the sum of the first magnetic flux Ф11, the second magnetic flux Ф12, and the third magnetic flux Ф13 on the frame F being less than the maximum value of the first magnetic flux Ф11, the second magnetic flux Ф12, and the third magnetic flux Ф13 on each central column.

[0027] Please refer to the following: Figure 3B In one embodiment of the present invention, the frame F includes an upper cover F1 and a lower frame F2. The lower frame F2 includes two side pillars F21 and a lower cover F22. The heights of the first central pillar 14, the second central pillar 15, and the third central pillar 16 are lower than the heights of the two side pillars F21, such that the upper cover F1 covers the two side pillars F21 of the lower frame F2, forming a first air gap G11, a second air gap G12, and a third air gap G13 between the upper cover F1 and the first central pillar 14, the second central pillar 15, and the third central pillar 16, respectively. Furthermore, an accommodating space G01 is formed between the upper cover F1 and the lower frame F2. In one embodiment of the present invention, the two side pillars F21, the lower cover F22, the first central pillar 14, the second central pillar 15, and the third central pillar 16 are integrally formed.

[0028] Please see Figures 4A to 4C See also Figure 3B Cross-sectional view, Figures 4A to 4C for Figure 3A and Figure 3BA schematic diagram of the transient change of magnetic flux in a transformer embodiment with a magnetic flux compensation structure, wherein... Figure 4A This is a waveform diagram of the magnetic flux of a transformer with a magnetic flux compensation structure at each of its central columns. Figure 4B This is a schematic diagram showing the compensation of magnetic flux on the upper and lower covers of the frame of a three-phase transformer. Figure 4C This diagram illustrates the compensation of magnetic flux in a three-phase transformer on the two side posts of the frame. As shown in the formula for magnetic flux, the magnitude of the magnetic field passing through a curved surface is the magnetic flux. When a coil receives primary current, the induced magnetic field generates magnetic flux through the area of ​​the surface, passing through the upper cover F1, the two side posts F21, and the lower cover F22 of the frame F. Furthermore, since the air gaps are relatively high impedance paths compared to the material of the frame F, the magnetic flux will not travel through the air gaps, effectively isolating the magnetic flux through these gaps. Therefore, by setting air gaps within the core 10, the magnetic flux induced by each coil within the core 10 can flow to the upper cover F1, the two side posts F21, and the lower cover F22, avoiding mutual interference between the magnetic flux generated by the coils and further preventing any impact on the operation of the power converter.

[0029] Furthermore, by controlling the phase difference between the currents of the aforementioned coils, the magnetic flux flowing through the upper cover F1, the two side pillars F21, and the lower cover F22 of the frame F can be compensated and canceled out. In a further embodiment where the transformer 1 with the magnetic flux compensation structure includes only the first coil 11 and the second coil 12, controlling the phase of the first coil current to lead the phase of the second coil current by 180 degrees can compensate for and cancel out the first magnetic flux Ф11 and the second magnetic flux Ф12. That is, when the phase of the first magnetic flux Ф11 and the phase of the second magnetic flux Ф12 are opposite, a compensation and cancellation effect can be achieved. In the embodiment of the transformer 1 with the above-mentioned magnetic flux compensation structure, which includes a first coil 11, a second coil 12, and a third coil 13, when the phase of the first coil current is controlled to lead the phase of the second coil current by 120 degrees, and the phase of the second coil current is controlled to lead the phase of the third coil current by 120 degrees, the first magnetic flux Ф11, the second magnetic flux Ф12, and the third magnetic flux Ф13 can be compensated and canceled. That is, when the phases of the first magnetic flux Ф11, the second magnetic flux Ф12, and the third magnetic flux Ф13 are in the same direction and opposite direction respectively, the effect of compensation and cancellation can be produced. Furthermore, in Figure 4B and Figure 4CIn the magnetic flux compensation diagram, although the phase currents through the upper cover F1, lower cover F22, and two side posts F21 should include the phase currents on the first coil 11, second coil 12, and third coil 13, and correspondingly induce the first magnetic flux Ф11, the second magnetic flux Ф12, and the third magnetic flux Ф13, in actual measurement, it is impossible to individually measure the phase currents on the first coil 11, second coil 12, and third coil 13 through the upper cover F1, lower cover F22, and two side posts F21. Therefore, it is also impossible to correspondingly measure the individually induced first magnetic flux Ф11, second magnetic flux Ф12, and third magnetic flux Ф13. Therefore, in Figure 4B In the magnetic flux compensation diagram, only a two-point line is used to represent the sum of the first magnetic flux Ф11, the second magnetic flux Ф12, and the third magnetic flux Ф13 passing through the upper cover F1, and a solid line is used to represent the sum of the first magnetic flux Ф11, the second magnetic flux Ф12, and the third magnetic flux Ф13 passing through the lower cover F22. Figure 4C In the magnetic flux compensation diagram, only the dashed lines represent the sum of the first magnetic flux Ф11, the second magnetic flux Ф12, and the third magnetic flux Ф13 passing through the left column, and the dotted line represents the sum of the first magnetic flux Ф11, the second magnetic flux Ф12, and the third magnetic flux Ф13 passing through the right column.

[0030] Please refer to the following: Figures 4A to 4C , Figure 4A Phase diagrams showing the first magnetic flux Ф11, the second magnetic flux Ф12, and the third magnetic flux Ф13 before they are canceled or compensated. Figure 4B The display shows that when the phase difference between the first magnetic flux Ф11, the second magnetic flux Ф12, and the third magnetic flux Ф13 is 120 degrees, and they are in the same direction and opposite directions respectively, the magnetic fluxes flowing through the upper cover F1 and the lower cover F22 of the frame F will cancel each other out and compensate for each other. However, the first magnetic flux Ф11, the second magnetic flux Ф12, and the third magnetic flux Ф13 flowing through the first central column 14, the second central column 15, and the third central column 16 respectively will not have a magnetic flux cancellation effect. Figure 4A As shown, when the maximum magnetic flux Wb3 on the first central column 14, the second central column 15, and the third central column 16 is 1, the peak-to-peak value is 2 (i.e., 2Wb3), then in Figure 4B The maximum magnetic flux Wb4 on the upper cover F1 and lower cover F22 of the frame F is 0.5, and the peak-to-peak value is 1 (i.e., 2Wb4). Figure 4C This displays the result of the first magnetic flux Ф11, the second magnetic flux Ф12, and the third magnetic flux Ф13 flowing through the two pillars F21 of the frame F compensating and canceling each other out. Compared to Figure 4AThe results of the non-canceling magnetic flux clearly show that the transformer 1 with magnetic flux compensation structure of the present invention can effectively reduce the maximum value and peak-to-peak value of magnetic flux of the upper cover F1, lower cover F22 and two side columns F21 of the frame F. Reducing the maximum value of magnetic flux means that the volume of the transformer core 10 can be reduced, and reducing the peak-to-peak value of magnetic flux means that the loss (iron loss) of the transformer core 10 can be reduced. That is, the transformer 1 with magnetic flux compensation structure of the present invention can simultaneously reduce the volume of the core 10 and the iron loss.

[0031] As mentioned above, based on the magnetic saturation characteristic, before magnetic saturation, if the applied magnetic field intensity of the iron core 10 made of ferromagnetic material is increased, the material will become magnetized, and the magnetic flux density will increase accordingly. When the magnetic field intensity increases to a certain level, the magnetic flux density will slowly increase to a limit value due to the free permeability; this is magnetic saturation. Generally, the saturation magnetic flux density of the iron core 10 is approximately 0.3. According to the formulas in physics, magnetic flux (Ф) is the product of magnetic flux density (B) and cross-sectional area (Area). When the magnetic flux density reaches saturation, the cross-sectional area of ​​the transformer iron core 10 can be calculated by calculating the magnetic flux, and further, the volume of the transformer iron core 10 can be calculated. For the calculation of magnetic flux, the magnitude of the primary current input to the transformer can be calculated based on the maximum output power of the circuit structure corresponding to the transformer structure, and the magnitude of the magnetic flux can be further calculated from the magnitude of the primary current. Therefore, as described above, by reducing the calculated maximum magnetic flux, the shrinkable volume of the transformer core 10 and the reduced iron loss can be further calculated. In other words, the cross-sectional area of ​​the frame F of the transformer 1 with the magnetic flux compensation structure is calculated based on the magnetic flux saturation density of the core 10 material and the magnitudes of the first magnetic flux Ф11, the second magnetic flux Ф12, and the third magnetic flux Ф13 flowing through the cross-sectional area, and the volume of the core 10 is further calculated based on the cross-sectional area of ​​the frame F.

[0032] Please see Figure 5A and Figure 5BThis is a perspective view and a cross-sectional view of another embodiment of the transformer with a flux compensation structure according to the present invention. In this embodiment, the transformer with the flux compensation structure has a single sealed accommodating space, and all coils and intermediate columns are arranged in the single sealed accommodating space. The transformer flux compensation structure 2 includes an iron core 20, a first coil 21, a second coil 22 and a third coil 23, a first intermediate column 24, a second intermediate column 25 and a third intermediate column 26. The iron core 20 includes an accommodating space G02, and the first coil 21, the second coil 22, the third coil 23, the first intermediate column 24, the second intermediate column 25 and the third intermediate column 26 are arranged in the accommodating space G02. The first coil 21 includes a first primary coil 21A and a first secondary coil 21B, which are wound together on the first central post 24. The first primary coil 21A receives a first primary current (i.e., the first coil current), causing the first secondary coil 21B to generate a first magnetic flux Ф21 based on the first primary current. The second coil 22 includes a second primary coil 22A and a second secondary coil 22B, which are wound together on the second central post 25. The second primary coil 22A receives a second primary current (i.e., the second coil current), causing the second secondary coil 22B to generate a second magnetic flux Ф22 based on the second primary current. The third coil 23 includes a third primary coil 23A and a third secondary coil 23B, which are wound together on the third central post 26. The third primary coil 23A receives the third primary current (i.e., the third coil current), causing the third secondary coil 23B to generate a third magnetic flux Ф23 based on the third primary current. The first coil 21, the second coil 22, and the third coil 23 respectively form a first magnetic flux Ф21, a second magnetic flux Ф22, and a third magnetic flux Ф23 with leading and lagging phases on the iron core 20, so as to produce the effect of magnetic flux compensation and cancellation. Since the phase of the first magnetic flux Ф21 leads the phase of the second magnetic flux Ф22, and the phase of the second magnetic flux Ф22 leads the phase of the third magnetic flux Ф23, the magnetic flux paths formed between the first central column 24, the second central column 25, and the third central column 26 and the frame of the iron core 20 all pass through at least a portion of the frame. Furthermore, the cross-sectional area of ​​the frame causes the first magnetic flux Ф21, the second magnetic flux Ф22, and the third magnetic flux Ф23 passing through at least a portion to cancel each other out, resulting in the maximum value of the sum of the first magnetic flux Ф21, the second magnetic flux Ф22, and the third magnetic flux Ф23 on the frame being less than the maximum value of the first magnetic flux Ф21, the second magnetic flux Ф22, and the third magnetic flux Ф23 on each central column.

[0033] The difference from the above embodiment lies in that the iron core 20 is a one-piece molded frame, and the first central column 24 includes several first magnetic flux columns 241, the second central column 25 includes several second magnetic flux columns 251, and the third central column 26 includes several third magnetic flux columns 261. Furthermore, several first air gaps G21 are provided between the several first magnetic flux columns 241, and between the several first magnetic flux columns 241 and the iron core 20. Several second air gaps G22 are provided between the several second magnetic flux columns 251, and between the several second magnetic flux columns 251 and the iron core 20. Several third air gaps G23 are provided between the several third magnetic flux columns 261, and between the several third magnetic flux columns 261 and the iron core 20. The several first air gaps G21, several second air gaps G22, and several third air gaps G23 are respectively connected to the accommodating space G02. In this embodiment, by forming a multi-segment air gap structure between each intermediate column and between each intermediate column and the transformer core 20, the maximum value of the magnetic flux induced by each coil can be reduced, and the loss of the core 20 can be further reduced, thus reducing iron loss. Several first air gaps G21, several second air gaps G22, and several third air gaps G23 are each filled with a non-magnetic material. In this embodiment of the invention, the non-magnetic material includes adhesive to bond the magnetic flux columns in each intermediate column.

[0034] Please see Figure 6A and Figure 6B This is a perspective view and a cross-sectional view of an inductor with a flux compensation structure. The inductor 3 with the flux compensation structure includes an iron core 30, a first coil 31, and a second coil 32. The iron core 30 has a first center post 34, a second center post 35, and a frame H. The first center post 34 and the second center post 35 are disposed in the accommodating space G03 of the frame H. The first coil 31 is wound around the first center post 34, receives a first coil current, and generates a first magnetic flux Ф31 based on the first coil current. The second coil 32 is wound around the second center post 35, receives a second coil current, and generates a second magnetic flux Ф32 based on the second coil current. The first current phase of the first coil current leads the second current phase of the second coil current, such that the first magnetic flux phase of the first magnetic flux Ф31 leads the second magnetic flux phase of the second magnetic flux Ф32. The first central column 34 and the second central column 35 are respectively connected to the iron core 30 by a first air gap G31 and a second air gap G32, and the first air gap G31 and the second air gap G32 are connected to the accommodating space G03.

[0035] Please refer to the following: Figure 6A and Figure 6BThe inductor 3 with a flux compensation structure also includes a third central column 36 and a third coil 33. The third central column 36 is disposed in the accommodating space G03 of the frame H. The third coil 33 is wound around the third central column 36. The frame H includes an upper cover H1 and a lower frame H2. The lower frame H2 includes two side columns H21 and a lower cover H22. The upper cover H1 is disposed on the two side columns H21 and forms the accommodating space G03. The lower cover H22, the two side columns H21, the first central column 34, the second central column 35, and the third central column 36 are integrally formed. The height of the first central column 34, the second central column 35, and the third central column 36 is lower than the height of the two side columns H21, so that the first central column 34, the second central column 35, and the third central column 36 and the upper cover H1 respectively form a first air gap G31, a second air gap G32, and a third air gap G33, and the third air gap G33 is also connected to the accommodating space G03. The third coil 33 receives the third coil current and generates a third magnetic flux Ф33 based on the third coil current. The second current phase of the second coil current leads the third current phase of the third coil current, such that the second magnetic flux phase of the second magnetic flux Ф32 leads the third magnetic flux phase of the third magnetic flux Ф33. Similarly, by controlling the first current phase to lead the second current phase by 180 degrees, the first magnetic flux Ф31 and the second magnetic flux Ф32 can be compensated or canceled. Alternatively, in the embodiment of the inductor 3 with the above-described flux compensation structure, which includes a first coil 31, a second coil 32, and a third coil 33, by controlling the first current phase to lead the second current phase by 120 degrees, and the second current phase to lead the third current phase by 120 degrees, the first magnetic flux Ф31, the second magnetic flux Ф32, and the third magnetic flux Ф33 can be compensated or canceled. Since the phase of the first magnetic flux Ф31 leads the phase of the second magnetic flux Ф32, and the phase of the second magnetic flux Ф32 leads the phase of the third magnetic flux Ф33, the magnetic flux paths formed between the first central column 34, the second central column 35, the third central column 36 and the frame H all pass through at least a portion of the frame H. Furthermore, the cross-sectional area of ​​the frame H causes the first magnetic flux Ф31, the second magnetic flux Ф32, and the third magnetic flux Ф33 passing through at least a portion to cancel each other out, resulting in the maximum value of the sum of the first magnetic flux Ф31, the second magnetic flux Ф32, and the third magnetic flux Ф33 on the frame H being less than the maximum value of the first magnetic flux Ф31, the second magnetic flux Ф32, and the third magnetic flux Ф33 on each central column.

[0036] In contrast, the magnetic element with flux compensation structure and its manufacturing method of the present invention can be applied not only to the structure of transformers but also to inductors. That is, it can be selectively installed in the circuits of various power converters, or both the transformer 1 and 2 with flux compensation structure and the inductor 3 with flux compensation structure of the present invention can be installed simultaneously. The main difference between the transformer 1 and 2 with flux compensation structure and the inductor 3 with flux compensation structure is that the transformer 1 and 2 with flux compensation structure include a primary winding and a secondary winding, while the inductor 3 with flux compensation structure includes a single-polarity winding. Therefore, the flux compensation principle and content of the inductor 3 with flux compensation structure are as described above for the transformer 1 and 2 with flux compensation structure, and will not be repeated here.

[0037] In summary, the magnetic element with a flux compensation structure and its manufacturing method of the present invention, by arranging multiple sets of coils in the internal structure of the same iron core and reducing the number of side posts, allows the magnetic flux induced by each coil in the iron core to cancel and compensate for each other. Furthermore, by setting an air gap, the problem of mutual interference between the magnetic flux generated by each coil is avoided. Therefore, the iron core loss and iron core saturation can be reduced, the heat generated by the power converter can be further reduced, and the power conversion efficiency of the power converter can be further improved.

[0038] Furthermore, by using a multi-segment air gap design, a single air gap is dispersed into multiple smaller air gaps, which reduces air gap losses and further improves the power conversion efficiency of the power converter. Moreover, the magnetic element with a flux compensation structure and its manufacturing method of this invention, while arranging multiple sets of coils within the same iron core structure, reduces the number of iron core side posts of the magnetic element, further reducing the overall size of the magnetic element.

[0039] Furthermore, the magnetic element with flux compensation structure and its manufacturing method of the present invention improve the power conversion efficiency of power converters by reducing the size of the magnetic element and increasing the conversion efficiency of the magnetic element.

[0040] Furthermore, when the magnetic element with magnetic flux compensation structure and its manufacturing method are applied to the magnetic elements of transformers and inductors, the present invention can be widely used in single-phase full-bridge LLC circuits, three-phase LLC circuits, three-phase LLC resonant inductor circuits, phase-shifted full-bridge circuits, and other circuit architectures by integrating polynomial transformers. It can also be extended to multi-phase circuits with more phases such as four-phase, five-phase, and six-phase circuits with integrated magnetic components. This allows various circuits to improve transformer conversion efficiency and reduce the size of transformers and inductors in various circuits such as single-phase full-bridge LLC circuits, three-phase LLC circuits, and three-phase LLC resonant inductor circuits while reducing core losses, heat generation, and core saturation (i.e., reducing the maximum magnetic flux).

[0041] This application is not limited to the embodiments described above. Embodiments obtained by appropriately combining the technical means disclosed in different embodiments are also included within the technical scope of this application. Furthermore, by combining the technical means disclosed in each embodiment, new technical features can be formed.

[0042] It should also be noted that any numerical values ​​mentioned in this application are not intended to limit the invention to only the specified numerical values. Those skilled in the art will understand that there are permissible errors in each numerical value / composition ratio. As long as they do not significantly affect the results / functions to be achieved in each experimental example, any value that is similar to the disclosed numerical range is considered to be within the scope disclosed in this invention.

Claims

1. A magnetic element with a flux compensation structure, comprising: An iron core, the iron core comprising a plurality of central posts and a frame, wherein each of the central posts is disposed adjacently in an accommodating space of the frame; as well as Multiple coils are wound around the central column, so that when the magnetic element receives a current in each coil, each central column and the frame form a magnetic flux path, and a corresponding magnetic flux is generated on each magnetic flux path. The structure of the iron core is such that the magnetic flux paths formed by the central pillars and the frame pass through at least a portion of the frame, and the cross-sectional area of ​​the frame causes the magnetic flux passing through the at least a portion to cancel each other out, resulting in a maximum value of the magnetic flux on the frame being less than a maximum value of the magnetic flux on each central pillar.

2. The magnetic element with a flux compensation structure as described in claim 1, characterized in that, The plurality of central columns include a first central column and a second central column, the plurality of coils include a first coil and a second coil, the current includes a first coil current and a second coil current, and the magnetic flux includes a first magnetic flux and a second magnetic flux. The first central column and the second central column are arranged adjacent to each other in the accommodating space of the frame. The first coil and the second coil are respectively wound around the first central column and the second central column, and the first coil receives the first coil current and the second coil receives the second coil current through the first coil, and generates the first magnetic flux according to the first coil current and the second magnetic flux according to the second coil current.

3. The magnetic element with a flux compensation structure as described in claim 2, characterized in that, A first current phase of the first coil current leads a second current phase of the second coil current, such that a first magnetic flux phase of the first magnetic flux leads a second magnetic flux phase of the second magnetic flux, and such that the first magnetic flux and the second magnetic flux passing through the cross-sectional area of ​​the frame cancel each other out.

4. The magnetic element with a flux compensation structure as described in claim 3, characterized in that, The first central column and the second central column are respectively provided with a first air gap and a second air gap between them and the frame, and the first air gap and the second air gap are connected to the accommodating space.

5. The magnetic element with a flux compensation structure as described in claim 4, characterized in that, The plurality of central columns further includes a third central column, the coil further includes a third coil, the current further includes a third coil current, and the magnetic flux further includes a third magnetic flux. The third central column is disposed adjacent to the second central column in the accommodating space of the frame. The third coil is wound around the third central column and receives the third coil current through the third coil, and generates the third magnetic flux according to the third coil current. The first coil current, the second coil current, and the third coil current are three-phase currents, and the second current phase of the second coil current leads the third current phase of the third coil current, such that the second magnetic flux phase of the second magnetic flux leads the third magnetic flux phase of the third magnetic flux, and the first magnetic flux, the second magnetic flux, and the third magnetic flux passing through the cross-sectional area of ​​the frame cancel each other out. The third central column and the frame have a third air gap, and the third air gap is connected to the accommodating space.

6. The magnetic element with a flux compensation structure as described in claim 1, characterized in that, The accommodating space of the frame is a single accommodating space.

7. The magnetic element with a flux compensation structure as described in claim 1, characterized in that, The frame of the iron core is a closed frame.

8. The magnetic element with a flux compensation structure as described in claim 5, characterized in that, The frame has a cross-sectional area through which the first magnetic flux, the second magnetic flux, and the third magnetic flux pass. The cross-sectional area is calculated based on the magnetic flux saturation density of a material of the iron core, the magnitude of the first magnetic flux, the second magnetic flux, and the third magnetic flux, and the volume of the iron core is calculated based on the cross-sectional area of ​​the frame.

9. The magnetic element with a flux compensation structure as described in claim 5, characterized in that, The frame includes an upper cover and a lower frame. The lower frame includes two side pillars and a lower cover. The height of the first, second, and third central pillars is lower than the height of the two side pillars, so that the upper cover covers the two side pillars of the lower frame. The upper cover and the first, second, and third central pillars respectively form the first air gap, the second air gap, and the third air gap, and together with the lower frame, form the accommodating space.

10. The magnetic element with a flux compensation structure as described in claim 5, characterized in that, The first central column comprises several first magnetic flux columns, and several first air gaps are formed between the several first magnetic flux columns and between the several first magnetic flux columns and the frame. The second central column comprises several second magnetic flux columns, and several second air gaps are formed between the several second magnetic flux columns and between the several second magnetic flux columns and the frame. The third central column comprises several third magnetic flux columns, and several third air gaps are formed between the several third magnetic flux columns and between the several third magnetic flux columns and the frame.

11. The magnetic element with a flux compensation structure as described in claim 10, characterized in that, Each of the first air gaps, the second air gaps, and the third air gaps is filled with a non-magnetic material.

12. The magnetic element with a flux compensation structure as described in claim 5, characterized in that, The first coil includes a first primary coil and a first secondary coil. The first primary coil receives the first coil current, causing the first secondary coil to generate the first magnetic flux according to the first coil current; and The second coil includes a second primary side coil and a second secondary side coil. The second primary side coil receives the second coil current, so that the second secondary side coil generates the second magnetic flux according to the second coil current.

13. The magnetic element with a flux compensation structure as described in claim 12, characterized in that, The third coil includes a third primary side coil and a third secondary side coil. The third primary side coil receives the current of the third coil, so that the third secondary side coil generates the third magnetic flux according to the current of the third coil.

14. The magnetic element with a flux compensation structure as described in claim 13, characterized in that, The magnetic element includes a transformer and an inductor.

15. A method for manufacturing a magnetic element with a flux compensation structure, characterized in that, include: A magnetic element is provided with an iron core, wherein the iron core includes a plurality of central posts and a frame, and each of the central posts is disposed adjacently in a receiving space of the frame; and A coil is wound around each of the central columns so that when the magnetic element receives a current in each of the coils, each of the central columns and the frame forms a magnetic flux path and generates a corresponding magnetic flux on each magnetic flux path. The core is configured such that the magnetic flux paths formed by the central pillars and the frame pass through at least a portion of the frame, and a cross-sectional area of ​​the frame is configured such that the magnetic flux passing through the at least a portion of the cross-sectional area cancels each other out, resulting in the maximum magnetic flux on the frame being less than the maximum magnetic flux of each central pillar.

16. A magnetic element with a flux compensation structure, characterized in that, include: An iron core, the iron core including a first central column, a second central column, a third central column and a frame, wherein the first central column, the second central column and the third central column are arranged adjacently in an accommodating space of the frame; A first coil is wound around the first central column, such that when the magnetic element receives a first coil current, the first central column and the frame form a first magnetic flux path, and a corresponding first magnetic flux is generated on the first magnetic flux path according to the first coil current. A second coil is wound around the second central column, so that when the magnetic element receives a second coil current in the second coil, the second central column and the frame form a second magnetic flux path, and a corresponding second magnetic flux is generated on the second magnetic flux path according to the second coil current. A third coil is wound around the third central column, so that when the magnetic element receives a third coil current, the third central column and the frame form a third magnetic flux path, and a corresponding third magnetic flux is generated on the third magnetic flux path according to the third coil current. The structure of the iron core is such that the first magnetic flux path, the second magnetic flux path, and the third magnetic flux path formed by the first central column, the second central column, and the third central column and the frame all pass through at least a portion of the frame, and the cross-sectional area of ​​the frame is such that the first magnetic flux, the second magnetic flux, and the third magnetic flux passing through the at least a portion cancel each other out, so that the maximum value of the sum of the first magnetic flux, the second magnetic flux, and the third magnetic flux on the frame is less than the maximum value of the first magnetic flux, the maximum value of the second magnetic flux, and the maximum value of the third magnetic flux; The first central column, the second central column, the third central column and the frame are respectively provided with a first air gap, a second air gap and a third air gap, and the first air gap, the second air gap and the third air gap are connected to the accommodating space; The first coil current, the second coil current, and the third coil current are three-phase currents, and a second current phase of the second coil current leads a third current phase of the third coil current, such that a second magnetic flux phase of the second magnetic flux leads a third magnetic flux phase of the third magnetic flux, and such that the first magnetic flux, the second magnetic flux, and the third magnetic flux passing through the cross-sectional area of ​​the frame cancel each other out.

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