Integrated magnetic device

Abstract

The utility model provides an integrated magnetic device, which can increase the inductance value of leakage inductance without increasing the volume. The integrated magnetic device comprises a magnetic core, a winding and a magnetic piece. The magnetic core comprises an upper cover plate, a lower cover plate, a wrapping post and at least one side post, wherein the upper cover plate and the lower cover plate are oppositely arranged, and the wrapping post and the side post are connected between the upper cover plate and the lower cover plate. The winding comprises a first winding and a second winding, the first winding is wound on the periphery of the wrapping post, and the second winding is arranged on the periphery of the first winding; the magnetic part is an independent part independent of the magnetic core, and the magnetic part is used for providing a concentrated leakage magnetic flux path, so that leakage inductance is increased.

Description

Technical Field

[0001] The utility model relates to a magnetic device, in particular to an integrated magnetic device. Background Art

[0002] For magnetic components in switching power supply applications, transformers and inductors are often integrated together to reduce the volume and weight of magnetic components and improve power density. There are various integration methods at present. A common integration method is that the transformer core and the inductor core are partially shared to achieve the purpose of reducing the volume. However, this integrated magnetic device in the prior art still has certain defects. For example, the transformer core and the inductor core are partially shared, resulting in the transformer core and the inductor core usually only being able to use the same material, or the inductor usually still requires additional windings to provide inductance, resulting in limited volume reduction. Summary of the invention

[0003] A main purpose of the utility model is to provide an integrated magnetic device that can overcome the above defects, can flexibly adjust the materials of the transformer core and the inductor core, and increase the leakage inductance as much as possible without increasing the volume.

[0004] In order to achieve the above application purpose, the utility model adopts the following technical solutions:

[0005] According to one aspect of the utility model, an integrated magnetic device includes a magnetic core, a winding and a magnetic part, the magnetic core includes an upper cover plate and a lower cover plate arranged opposite to each other, and a winding column and at least one side column connected between the upper cover plate and the lower cover plate; the winding includes a first winding and a second winding, the first winding is wound around the outer periphery of the winding column, and the second winding is arranged around the outer periphery of the first winding; the magnetic part is an independent component independent of the magnetic core, and the magnetic part is used to provide a concentrated leakage flux path, thereby increasing leakage inductance.

[0006] According to an embodiment of the present invention, the second winding has at least one opening, so that the second winding is disconnected in the circumferential direction.

[0007] According to an embodiment of the present invention, the magnetic component is arranged outside the first winding and corresponds to the opening of the second winding.

[0008] According to one embodiment of the present invention, the size of the magnetic component along the axial direction of the first winding is 1 / 4 to 1 times the axial length of the first winding.

[0009] According to an embodiment of the present invention, the magnetic component includes a plurality of sub-magnetic components, the sizes of the plurality of sub-magnetic components along the axial direction of the first winding are the same or different, and the plurality of sub-magnetic components are arranged at intervals along the axial direction of the first winding.

[0010] According to an embodiment of the present utility model, the two sub-magnetic components located at the two ends of the first winding are flush with the two end surfaces of the first winding.

[0011] According to an embodiment of the present utility model, the winding post is arranged at a position deviated from the center of the upper cover plate, and the magnetic member is arranged between the first winding and the second winding.

[0012] According to an embodiment of the present invention, the winding post is arranged at a position deviated from the center of the upper cover plate, the magnetic member is arranged between the first winding and the second winding, and the magnetic member is far away from the opening of the second winding.

[0013] According to an embodiment of the present utility model, the magnetic component is arranged on the first winding or on the second winding or on the magnetic core.

[0014] According to an embodiment of the present invention, the magnetic component is a rigid magnetic conductive sheet.

[0015] According to an embodiment of the present utility model, the magnetic component has an inner surface and an outer surface that are arranged opposite to each other, and the shape of the inner surface is consistent with the shape of the outer surface of the first winding.

[0016] According to an embodiment of the present invention, the magnetic member is a flexible magnetic tape.

[0017] According to an embodiment of the present invention, the magnetic member includes magnetic tape, and the magnetic tape is adhered to the second winding and close to the opening.

[0018] According to an embodiment of the present invention, the magnetic tape includes at least two sub-tapes, and the at least two sub-tapes are respectively adhered to the second winding and located on both sides of the opening.

[0019] According to one embodiment of the present invention, the pins of the second winding are in a comb-teeth shape.

[0020] According to an embodiment of the present invention, along the radial direction of the winding column, the second winding includes a plurality of sub-windings arranged in a stacked manner, and the pins of the plurality of sub-windings are arranged alternately.

[0021] According to an embodiment of the present invention, the second winding includes a plurality of sub-windings arranged along the axial direction of the winding post.

[0022] According to one embodiment of the utility model, it also includes a winding frame, which is sleeved on the outer periphery of the winding column, the first winding is wound on the outer periphery of the winding frame, the second winding is arranged on the outer periphery of the first winding, and the magnetic member is fixed on the winding frame.

[0023] According to one embodiment of the utility model, the winding rack includes a hollow cylinder and two flanges vertically connected to the two ends of the cylinder and extending toward the periphery, and two limiting columns are provided on the two flanges; the top end and the bottom end of the magnetic part are respectively provided with limiting grooves that can cooperate with the limiting columns.

[0024] The utility model has the following advantages or beneficial effects:

[0025] The integrated magnetic device of the utility model is provided with a magnetic part, and the inductance required by the magnetic part and the winding structure can provide a concentrated leakage flux path, thereby increasing the leakage inductance. The magnetic part occupies a smaller space than the winding, so it is beneficial to reduce the volume of the integrated magnetic device; and the magnetic part can be flexibly arranged at different positions according to the structural layout of the integrated magnetic device, which is beneficial to reducing the volume of the integrated magnetic device on the one hand, and can also adjust the leakage inductance on the other hand.

[0026] In the utility model, the magnetic part is an independent component independent of the magnetic core, can be designed separately, and can be made into different shapes, structures, sizes, and types according to convenience, so as to flexibly adapt to different requirements for inductance in different application scenarios; since the magnetic part is an independent component and can be made separately, various materials different from the magnetic core body can be selected, so that when making the magnetic core, the material and size can be flexibly configured to ensure the saturation performance of the magnetic part, making the production of the magnetic core more convenient and making the parameters such as the inductance of the overall integrated magnetic device easier to control. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The above and other features and advantages of the present invention will become more apparent by describing in detail example embodiments thereof with reference to the attached drawings.

[0028] Figure 1A It is a three-dimensional diagram of the first embodiment of the integrated magnetic device of the utility model;

[0029] Figure 1B It is an exploded view of the first embodiment of the integrated magnetic device of the utility model;

[0030] Figure 2A It is a three-dimensional diagram of the second embodiment of the integrated magnetic device of the utility model;

[0031] Figure 2B It is an exploded view of the second embodiment of the integrated magnetic device of the utility model;

[0032] Figure 3A It is a three-dimensional diagram of the third embodiment of the integrated magnetic device of the utility model;

[0033] Figure 3B It is an exploded view of the third embodiment of the integrated magnetic device of the utility model;

[0034] Figure 4A It is a three-dimensional diagram of a fourth embodiment of the integrated magnetic device of the utility model;

[0035] Figure 4B It is an exploded view of the fourth embodiment of the integrated magnetic device of the utility model;

[0036] Figure 5A is a three-dimensional diagram of a fifth embodiment of the integrated magnetic device of the utility model;

[0037] Figure 5B It is an exploded view of the fifth embodiment of the integrated magnetic device of the utility model;

[0038] Figure 6 It is an exploded view of the sixth embodiment of the integrated magnetic device of the utility model;

[0039] Fig. 7A is a three-dimensional diagram of the seventh embodiment of the integrated magnetic device of the utility model;

[0040] Figure 7B This is an exploded view of the seventh embodiment of the integrated magnetic device of the utility model;

[0041] Fig. 8A is a three-dimensional diagram of an eighth embodiment of the integrated magnetic device of the utility model;

[0042] Figure 8B It is an exploded view of the eighth embodiment of the integrated magnetic device of the utility model. DETAILED DESCRIPTION

[0043] Example embodiments will now be described more fully with reference to the accompanying drawings. However, example embodiments can be implemented in a variety of forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that the present invention will be comprehensive and complete and fully convey the concepts of the example embodiments to those skilled in the art. The same reference numerals in the figures represent the same or similar structures, and thus their detailed description will be omitted.

[0044] Embodiment 1

[0045] like Figure 1A and Figure 1B As shown, the first embodiment of the integrated magnetic device of the utility model includes a magnetic core, a winding and a magnetic member.

[0046] See also Figure 1BThe magnetic core includes an upper cover plate 11 and a lower cover plate 12 which are arranged opposite to each other, and a winding post 13 and two side posts 14 which are connected between the upper cover plate 11 and the lower cover plate 12. In the length L direction of the upper and lower cover plates 11 and 12, the winding post 13 is arranged in the middle position of the upper and lower cover plates 11 and 12, and the two side posts 14 are symmetrically arranged on both sides of the winding post 13.

[0047] In some other embodiments, the number of side poles 14 is not limited to two, and may be only one or a plurality greater than two; the setting positions, shapes, etc. of the winding poles 13 and the side poles 14 may have different structures according to different magnetic cores.

[0048] From the perspective of manufacturing technology, the magnetic core in this embodiment can be formed by connecting two E-shaped parts along the vertical height direction Z.

[0049] The winding includes a first winding 21 and a second winding 22. The first winding 21 can be a primary winding, which is cylindrical and is sleeved on the outer periphery of the winding column 13; the second winding 22 can be a secondary winding, which is cylindrical and is sleeved on the outer periphery of the first winding 21. The second winding 22 includes two sub-windings 221 arranged and stacked together. In some other embodiments, the number of sub-windings 221 is not limited to two, and can also be only one or a plurality greater than 2. Among them, multiple sub-windings 221 can be arranged axially along the winding column, or can be stacked radially along the winding column. Figure 1A Only a plurality of sub-windings 221 are shown to be stacked radially along the winding column.

[0050] The magnetic member 30 may be a rigid magnetic conductive sheet, which is an independent component from the magnetic core. The magnetic member 30 and the winding structure inductance can provide a concentrated leakage flux path, thereby increasing leakage inductance.

[0051] In this embodiment, along the width W direction of the upper and lower cover plates 11 and 12, the winding pole 13 is arranged on one side of the upper and lower cover plates 11 and 12, such as the front side, that is, deviated from the middle position of the upper and lower cover plates 11 and 12; the magnetic member 30 is located on the other side of the lower cover plate 12, such as the rear side. The magnetic member 30 can be located between the first winding 21 and the second winding 22, and the magnetic member 30 can be fixed on the first winding 21, or fixed on the sub-winding 221 of the second winding 22, or fixed on the lower cover plate 12 of the magnetic core.

[0052] The magnetic member 30 has an inner surface and an outer surface that are arranged opposite to each other, wherein the shape of the inner surface matches the shape of the outer surface of the first winding 21, which is conducive to reducing the space occupied by the magnetic core, making the overall structure of the integrated magnetic device compact. In this embodiment, the size of the magnetic member 30 in the vertical height direction Z is approximately 1 / 4 of the size of the winding pole 13 in the vertical height direction Z. In this embodiment, the overall shape of the magnetic member 30 is similar to an arc plate.

[0053] Since the magnetic part 30 is an independent component from the magnetic core, that is, it is not integrally formed with the magnetic core, it can be manufactured separately, and can be flexibly and conveniently designed in various shapes and sizes, and various materials can be flexibly selected; during assembly, it can be flexibly set in different positions, so as to flexibly adjust the leakage inductance according to actual needs.

[0054] Embodiment 2

[0055] like Figure 2A and Figure 2B As shown, the second embodiment of the integrated magnetic device of the utility model is different from the first embodiment mainly in that:

[0056] Along the width W direction of the upper and lower cover plates 11 , 12 , the winding pole 13 of the magnetic core is arranged at the center position of the upper and lower cover plates 11 , 12 .

[0057] The second winding 22, i.e., two stacked sub-windings 221, has an opening 220, so that the second winding 22 is disconnected in the peripheral direction; the magnetic member 30 is arranged outside the first winding 21. The magnetic member 30 can be arranged at a position corresponding to the opening 220 of the second winding 22, that is, the magnetic member 30 can be exposed at least partially from the opening 220 position of the second winding 22, which is conducive to further reducing the volume of the integrated magnetic device. Among them, the magnetic member 30 can provide a concentrated leakage flux path, thereby increasing the leakage inductance.

[0058] like Figure 2B As shown, the second winding 22 is provided with a pin 223 at the opening 220, and the pin 223 may be in a comb-tooth shape. The openings of the two sub-windings 221 constituting the second winding 22 are respectively provided with a pin 223, and the pins 223 of the two sub-windings 221 are arranged alternately (see Figure 2A ).

[0059] In some other embodiments, the number of openings 220 on the second winding 22 is not limited to one, but may be multiple. When the second winding 22 is provided with multiple openings 220, a magnetic component 30 may be provided corresponding to each opening 220, thereby significantly increasing the leakage inductance without increasing the volume of the magnetic component.

[0060] The size of the magnetic member 30 in the vertical height direction Z is relatively high, for example, the same as the size of the first winding 21 in the vertical height direction Z, so that a larger inductance can be generated. The magnetic member 30 can be fixed to the upper cover plate 11 or the lower cover plate 12, or can be directly fixed, for example, pasted to the first winding 21.

[0061] The other structures, functions and effects of the second embodiment are substantially the same as those of the first embodiment and will not be described in detail here.

[0062] Embodiment 3

[0063] like Figure 3A and Figure 3B As shown, the third embodiment of the integrated magnetic device of the utility model is different from the second embodiment mainly in that:

[0064] The dimension H1 of the magnetic member 30 along the axial direction of the first winding 21, i.e., the vertical height direction Z, is 1 / 2 of the dimension H2 of the first winding 21 in the axial direction. The magnetic member 30 can be directly attached to the outer surface of the first winding 21, and the bottom end surface of the magnetic member 30 can be flush with the bottom end surface of the first winding 21. In some other embodiments, it is feasible that the dimension H1 of the magnetic member 30 is 1 / 4-1 times of the dimension H2 of the first winding 21. In some embodiments, the dimension H1 of the magnetic member 30 along the axial direction of the first winding 21, i.e., the vertical height direction Z, can also be 1 / 3 of the dimension H2 of the first winding 21 in the axial direction. The magnetic member 30 can also be arranged in the middle of the first winding 21, i.e., the bottom end surface of the magnetic member 30 can be higher than the bottom end surface of the first winding 21.

[0065] The other structures, functions and effects of the third embodiment are substantially the same as those of the second embodiment and will not be described in detail here.

[0066] Embodiment 4

[0067] like Figure 4A and Figure 4B As shown, the fourth embodiment of the integrated magnetic device of the utility model is different from the second embodiment mainly in that:

[0068] The magnetic component 30 includes two sub-magnetic components 31, and the two sub-magnetic components 31 have the same size along the axial direction of the first winding 21. The two ends of the two sub-magnetic components 31 are respectively flush with the two ends of the first winding 21, and there is a gap between the two sub-magnetic components 31. In other words, the two sub-magnetic components 31 are symmetrically arranged at the two ends of the first winding 21. The integrated magnetic device of this embodiment can effectively control the inductance tolerance and has little effect on the loss.

[0069] In some other embodiments, the number of sub-magnetic components 31 may be more than 2, and the sizes of the multiple sub-magnetic components 31 may be different; the interval between two adjacent sub-magnetic components may be the same or different; the two sub-magnetic components 31 located at both ends of the first winding 21 are flush with the two end surfaces of the first winding 21.

[0070] The other structures, functions and effects of the fourth embodiment are substantially the same as those of the second embodiment and will not be described in detail here.

[0071] Embodiment 5

[0072] like Figure 5A and Figure 5B As shown, the fifth embodiment of the integrated magnetic device of the utility model is different from the second embodiment mainly in that:

[0073] The magnetic member 30 may be a flexible magnetic tape (such as a cast film, etc.), and the magnetic tape includes two sub-tapes 32, which are respectively attached to the sub-winding 221 of the second winding 22 and are located on both sides of the opening 220. Using magnetic tape as the magnetic member 30 can further reduce the size, volume and weight of the integrated magnetic device.

[0074] In some other embodiments, the sub-tapes 32 may also be adhered to the first winding 21 , and the number of the sub-tapes 32 is not limited to two.

[0075] The other structures, functions and effects of the fifth embodiment are substantially the same as those of the second embodiment and will not be described in detail here.

[0076] Embodiment 6

[0077] like Figure 6 As shown, the sixth embodiment of the integrated magnetic device of the utility model is different from the second embodiment mainly in that:

[0078] The sixth embodiment of the integrated magnetic device further includes a winding frame 4 .

[0079] The winding frame 4 includes a hollow cylinder 40 and two flanges 41 vertically connected to the two ends of the cylinder 40 and extending toward the periphery. Two limiting columns 411 are provided on the two flanges 41.

[0080] The cylinder 40 of the winding frame 4 is sleeved on the outer periphery of the winding pole 13 . The first winding 21 is wound on the cylinder 40 and located between two flanges 41 . The two sub-windings 221 are arranged on the outer periphery of the first winding 21 .

[0081] A limiting groove 300 is respectively provided at the top end and the bottom end of the magnetic member 30 . The magnetic member 30 is installed on the winding frame 4 through the two limiting grooves 300 respectively cooperating with the two limiting columns 411 .

[0082] The other structures, functions and effects of the sixth embodiment are substantially the same as those of the second embodiment and will not be described in detail here.

[0083] Embodiment 7

[0084] like Fig. 7A and Figure 7B As shown, the seventh embodiment of the integrated magnetic device of the utility model is different from the first embodiment mainly in that:

[0085] The second winding 22 includes two sub-windings 221 radially stacked along the winding pole 13 and has an opening 220, so that the second winding 22 is disconnected in the peripheral direction. The magnetic member 30 is located on a side away from the opening 220 and is disposed between the first winding 21 and the second winding 221.

[0086] In this embodiment, the second winding 22 is Figure 2A , Figure 2B The other structures, functions and effects of the seventh embodiment are basically the same as those of the first embodiment, and will not be described in detail here.

[0087] Embodiment 8

[0088] like Fig. 8A and Figure 8B As shown, the eighth embodiment of the integrated magnetic device of the utility model is different from the sixth embodiment mainly in that:

[0089] The second winding 22 includes two sub-windings 221 arranged axially along the winding post 13, and the dimension of each sub-winding 221 along the axial direction of the winding post 13 is smaller than the axial dimension of the winding post 13. In other embodiments, the number of sub-windings 221 arranged axially along the winding post 13 is not limited to two, for example, 3, 5, etc.

[0090] The other structures, functions and effects of the eighth embodiment are substantially the same as those of the sixth embodiment and will not be described in detail here.

[0091] The integrated magnetic device described in this utility model can be applied to the following conversion circuit topologies such as LLC, CLLC, CLLLC, Dual Active Bridge (DAB), Boost SRC (Series Resonant Converter), etc., which will not be repeated here.

[0092] It can be understood that the different structures described in the various embodiments provided by the present invention, such as different magnetic core structures, second winding structures, magnetic component structures, magnetic component materials, etc., can be combined with each other without causing any contradiction, and examples will not be given one by one here.

[0093] In the application embodiments, the terms "first", "second", and "third" are used for descriptive purposes only and are not to be understood as indicating or implying relative importance; the term "plurality" refers to two or more, unless otherwise expressly defined. The terms "installed", "connected", "connected", "fixed", etc. should be understood in a broad sense. For example, "connected" can be a fixed connection, a detachable connection, or an integral connection; "connected" can be a direct connection or an indirect connection through an intermediate medium. For those of ordinary skill in the art, the specific meanings of the above terms in the application embodiments can be understood according to the specific circumstances.

[0094] In the description of the application embodiments, it should be understood that the directions or positional relationships indicated by the terms "up", "down", "left", "right", "front", "back", etc. are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the application embodiments and simplifying the description, rather than indicating or implying that the device or unit referred to must have a specific direction, be constructed and operated in a specific orientation, and therefore, should not be understood as a limitation on the application embodiments.

[0095] In the description of this specification, the description of the terms "one embodiment", "some embodiments", "specific embodiments", etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the application embodiment. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0096] The above are only preferred embodiments of the application embodiments and are not intended to limit the application embodiments. For those skilled in the art, the application embodiments may have various modifications and changes. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the application embodiments shall be included in the protection scope of the application embodiments.

Claims

1. An integrated magnetic device, characterized in that: include: A magnetic core, comprising an upper cover plate and a lower cover plate which are arranged opposite to each other, and a winding column and at least one side column connected between the upper cover plate and the lower cover plate; A winding, the winding comprising a first winding and a second winding, the first winding being wound around the outer periphery of the winding column, and the second winding being arranged around the outer periphery of the first winding; and A magnetic member is an independent component from the magnetic core, and is used to provide a concentrated leakage flux path, thereby increasing leakage inductance.

2. The integrated magnetic device according to claim 1, characterized in that The second winding has at least one opening, so that the second winding is disconnected in a circumferential direction.

3. The integrated magnetic device according to claim 2, characterized in that: The magnetic member is arranged outside the first winding and corresponds to the opening of the second winding.

4. The integrated magnetic device according to claim 1, characterized in that: The dimension of the magnetic component along the axial direction of the first winding is 1 / 4 to 1 times the axial length of the first winding.

5. The integrated magnetic device according to claim 1, characterized in that: The magnetic component includes a plurality of sub-magnetic components, the sizes of the plurality of sub-magnetic components along the axial direction of the first winding are the same or different, and the plurality of sub-magnetic components are arranged at intervals along the axial direction of the first winding.

6. The integrated magnetic device according to claim 5, characterized in that: The two sub-magnetic components located at two ends of the first winding are flush with the two end surfaces of the first winding.

7. The integrated magnetic device according to claim 1, characterized in that: The winding post is arranged at a position deviated from the center of the upper cover plate, and the magnetic member is arranged between the first winding and the second winding.

8. The integrated magnetic device according to claim 2, characterized in that: The winding post is arranged at a position deviating from the center of the upper cover plate, the magnetic member is arranged between the first winding and the second winding, and the magnetic member is far away from the opening of the second winding.

9. The integrated magnetic device according to claim 8, characterized in that: The magnetic component is arranged on the first winding or on the second winding or on the magnetic core.

10. The integrated magnetic device according to any one of claims 1 to 9, characterized in that: The magnetic component is a rigid magnetic conductive sheet.

11. The integrated magnetic device according to claim 10, characterized in that: The magnetic member has an inner surface and an outer surface that are arranged opposite to each other, and a shape of the inner surface matches a shape of an outer surface of the first winding.

12. The integrated magnetic device according to any one of claims 1 to 9, characterized in that: The magnetic piece is a flexible magnetic tape.

13. The integrated magnetic device according to claim 2, characterized in that: The magnetic member includes a magnetic tape, and the magnetic tape is adhered to the second winding and is close to the opening.

14. The integrated magnetic device according to claim 13, characterized in that: The magnetic tape includes at least two sub-tapes, and the at least two sub-tapes are respectively adhered to the second winding and located at two sides of the opening.

15. The integrated magnetic device according to any one of claims 1 to 9, 11, 13 to 14, characterized in that: The pins of the second winding are in a comb-teeth shape.

16. The integrated magnetic device according to claim 15, characterized in that: Along the radial direction of the winding column, the second winding includes a plurality of sub-windings arranged in a stacked manner, and the pins of the plurality of sub-windings are arranged alternately.

17. The integrated magnetic device according to claim 15, characterized in that: The second winding includes a plurality of sub-windings arranged along the axial direction of the winding column.

18. The integrated magnetic device according to claim 1, wherein: It also includes a winding frame, which is sleeved on the outer periphery of the winding column, the first winding is wound on the outer periphery of the winding frame, the second winding is arranged on the outer periphery of the first winding, and the magnetic member is fixed on the winding frame.

19. The integrated magnetic device according to claim 18, characterized in that: The winding frame includes a hollow cylinder and two flanges vertically connected to the two ends of the cylinder and extending to the outer circumference, and two limiting columns are provided on the two flanges; the top and bottom ends of the magnetic part are respectively provided with limiting grooves that can cooperate with the limiting columns.

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