Magnetic core structure, coupling inductance element, power converter, direct current conversion device and vehicle

Abstract

The utility model discloses a magnetic core structure, a coupling inductance element, a power converter, a direct current conversion device and a vehicle. The magnetic core structure comprises a magnetic core upper yoke, a magnetic core lower yoke and a plurality of magnetic blocks. And the magnetic core upper yoke and the magnetic core lower yoke are oppositely arranged. The plurality of magnetic blocks are arranged between the magnetic core upper yoke and the magnetic core lower yoke, and a plurality of air gaps are formed. At least two of the plurality of air gaps are non-linear air gaps. Therefore, the influence of the edge magnetic flux of the high-frequency and high-power inductor can be effectively reduced, and the loss is reduced, so that the efficiency of the power converter is improved; meanwhile, the inductor bias current can be effectively improved, and the energy storage capacity is improved. In addition, under the condition that the original magnetic core saturation characteristic of the coupling inductance element is kept, the size is reduced, and therefore the occupied space is saved.

Description

Technical Field

[0001] The present application relates to the technical field of coupled inductors, and in particular to a magnetic core structure, a coupled inductor element, a power converter, a DC conversion device, and a vehicle. Background Art

[0002] In the DC / DC converter of new energy vehicles, since the high-power converter and hydrogen fuel cell are connected in series, the total efficiency is the product of the efficiency of the hydrogen fuel cell and the efficiency of the high-power converter. Therefore, the overall efficiency of the DC / DC converter can be improved by improving the efficiency of the high-power converter. Currently, how to improve the efficiency of the high-power converter has become an urgent problem to be solved. Utility Model Content

[0003] The embodiments of the present application provide a magnetic core structure, a coupled inductor element, a power converter, a DC conversion device, and a vehicle to solve at least one of the above-mentioned technical problems.

[0004] The magnetic core structure of the embodiment of the present application includes:

[0005] Magnetic core upper yoke;

[0006] A magnetic core lower yoke, wherein the magnetic core upper yoke and the magnetic core lower yoke are arranged opposite to each other;

[0007] A plurality of magnetic blocks are arranged between the upper yoke of the magnetic core and the lower yoke of the magnetic core to form a plurality of air gaps, at least two of the plurality of air gaps being nonlinear air gaps.

[0008] In certain embodiments, the plurality of air gaps comprises:

[0009] a first air gap between the plurality of magnetic blocks and the upper yoke of the magnetic core; and / or

[0010] A second air gap between the plurality of magnetic blocks; and / or

[0011] A third air gap between the plurality of magnetic blocks and the lower yoke of the magnetic core; and / or

[0012] A fourth air gap is formed between the upper yoke of the magnetic core and the lower yoke of the magnetic core.

[0013] In some embodiments, the upper yoke of the magnetic core and the lower yoke of the magnetic core are both one of an E-shaped magnetic core, a T-shaped magnetic core, and a straight-shaped magnetic core.

[0014] In some embodiments, the magnetic core upper yoke and the magnetic core lower yoke each include a first side leg, a middle column, and a second side leg, wherein the first side leg and the second side leg are respectively located on both sides of the middle column;

[0015] The plurality of magnetic blocks include at least one first magnetic block, wherein the at least one first magnetic block is disposed between two opposite first legs and forms at least two air gaps; and / or

[0016] The plurality of magnetic blocks include at least one second magnetic block, wherein the at least one second magnetic block is disposed between two opposite second side legs and forms at least two air gaps; and / or

[0017] The plurality of magnetic blocks include at least one third magnetic block, and the at least one third magnetic block is disposed between two opposite center pillars to form at least two air gaps.

[0018] In some embodiments, the nonlinear air gap includes one or more of a step air gap, a slanted air gap, a curved air gap, and a quadratic function air gap.

[0019] In some embodiments, the end surface of the nonlinear air gap is one or more of a convex surface, a concave surface, an inclined surface, a curved surface, and a multi-step surface.

[0020] In some embodiments, the length of the center column is greater than the length of the first side leg and the length of the second side leg respectively;

[0021] The multiple magnetic blocks include at least one first magnetic block and at least one second magnetic block, the at least one first magnetic block constitutes a first side column, the at least one second magnetic block constitutes a second side column, the first side column and the middle column form a first magnetic yoke, the second side column and the middle column form a second magnetic yoke, and the magnetic field directions of the first magnetic yoke and the second magnetic yoke are opposite.

[0022] In some embodiments, the cross-sectional areas of the center column, the first side leg, the second side leg, the first side column, and the second side column are the same.

[0023] In some embodiments, the plurality of magnetic blocks are shaped as one of a cylinder, a triangular prism, a cuboid, or a polygonal column;

[0024] The cross-sections of the central column, the first side leg, and the second side leg are respectively circular, triangular, rectangular, or polygonal.

[0025] In some embodiments, the material of the magnetic core structure includes one or more of ferrite material, iron silicon material, sendust material, iron nickel material, iron powder core material, and amorphous material.

[0026] The coupled inductor element according to the embodiment of the present application includes:

[0027] The magnetic core structure of any of the above embodiments;

[0028] a plurality of isolation plates, the plurality of isolation plates being disposed between the magnetic core upper yoke, the magnetic core lower yoke, and the plurality of magnetic blocks to form the plurality of air gaps;

[0029] A plurality of coils are wound around the magnetic core structure.

[0030] In certain embodiments, the isolation board is an insulating epoxy resin board.

[0031] In some embodiments, the cross-section of the plurality of coils is one of circular, triangular, rectangular, and polygonal.

[0032] In some embodiments, the plurality of coils are made of one of enameled round wire, enameled flat wire, self-adhesive round wire, self-adhesive flat wire, and Litz wire.

[0033] The power converter according to the embodiment of the present application includes the coupled inductor element according to any one of the above embodiments.

[0034] The DC conversion device according to the embodiment of the present application includes the above-mentioned power converter.

[0035] The vehicle according to the embodiment of the present application includes the above-mentioned DC converter.

[0036] In the magnetic core structure, coupled inductor element, power converter, DC converter, and vehicle of the embodiments of the present application, multiple magnetic blocks are arranged between the upper yoke of the magnetic core and the lower yoke of the magnetic core, and multiple air gaps are formed, at least two of the multiple air gaps being nonlinear air gaps. In this way, the influence of the edge flux of high-frequency, high-power inductors can be effectively reduced, and losses can be reduced, thereby improving the efficiency of the power converter; at the same time, the inductor bias current can be effectively increased, thereby improving the energy storage capacity. In addition, the coupled inductor element can be reduced in size while maintaining the original magnetic core saturation characteristics, thereby saving space.

[0037] Additional aspects and advantages of the present application will be given in part in the description below, and in part will become obvious from the description below, or will be learned through practice of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] In order to more clearly illustrate the technical solutions in the embodiments of the present application or related technologies, the following briefly introduces the drawings required for the embodiments or related technical descriptions. Obviously, the drawings described below are only some embodiments of the present application. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without inventive work. Among them:

[0039] Figure 1 is a schematic diagram of a magnetic core structure of certain embodiments of the present application;

[0040] Figure 2 is a schematic diagram of a magnetic core structure of certain embodiments of the present application;

[0041] Figure 3 is a schematic diagram of the three-dimensional structure of a coupled inductor element in certain embodiments of the present application;

[0042] Figure 4 is a front view of a coupled inductor element according to some embodiments of the present application;

[0043] Figure 5 is a schematic diagram of an exploded structure of a coupled inductor element according to certain embodiments of the present application;

[0044] Figure 6 is a schematic diagram of a module of a power converter according to certain embodiments of the present application;

[0045] Figure 7 is a schematic diagram of a module of a DC converter device according to certain embodiments of the present application;

[0046] Figure 8 It is a schematic structural diagram of a vehicle according to certain embodiments of the present application.

[0047] Description of reference numerals:

[0048] Magnetic core structure 100, magnetic core upper yoke 10, magnetic core lower yoke 20, first side leg 21, middle column 22, second side leg 23, magnetic block 30, first magnetic block 31, second magnetic block 32, third magnetic block 33, first side column 40, second side column 50, multiple air gaps 60, first air gap 61, second air gap 62, third air gap 63, fourth air gap 64, coupled inductor element 200, multiple isolation plates 210, coil 220, power converter 300, DC converter 400, battery 410, vehicle 1000. DETAILED DESCRIPTION

[0049] The embodiments of the present application are described in detail below. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals represent the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present application, and should not be understood as limiting the present application.

[0050] See also Figure 1 、 Figure 2 and Figure 5 The embodiment of the present application provides a magnetic core structure 100. The magnetic core structure 100 includes a magnetic core upper yoke 10, a magnetic core lower yoke 20 and a plurality of magnetic blocks 30. The magnetic core upper yoke 10 and the magnetic core lower yoke 20 are arranged opposite to each other. The plurality of magnetic blocks 30 are arranged between the magnetic core upper yoke 10 and the magnetic core lower yoke 20, and form a plurality of air gaps 60 (such as Figure 5At least two of the plurality of air gaps 60 are nonlinear air gaps.

[0051] See also Figures 3 to 5 The present application also provides a coupled inductor component 200. Coupled inductor component 200 includes a magnetic core structure 100, a plurality of isolation plates 210, and a plurality of coils 220. The isolation plates 210 are disposed between the magnetic core upper yoke 10, the magnetic core lower yoke 20, and the plurality of magnetic blocks 30 to form a plurality of air gaps 60. The plurality of coils 220 are wound around the magnetic core structure 100.

[0052] In the magnetic core structure 100 and coupled inductor element 200 of the embodiment of the present application, multiple magnetic blocks 30 are arranged between the upper yoke 10 and the lower yoke 20 of the magnetic core, forming multiple air gaps 60, at least two of which are nonlinear air gaps. In this way, the influence of the edge flux of high-frequency, high-power inductors can be effectively reduced, reducing losses, thereby improving the efficiency of the power converter 300; at the same time, the inductor bias current can be effectively increased, thereby improving the energy storage capacity. In addition, the coupled inductor element 200 can be reduced in size while maintaining the original magnetic core saturation characteristics, thereby saving space.

[0053] Specifically, the coupled inductor component 200 includes a magnetic core structure 100 , a plurality of isolation plates 210 , and a plurality of coils 220 .

[0054] The magnetic core structure 100 includes a magnetic core upper yoke 10, a magnetic core lower yoke 20 and a plurality of magnetic blocks 30. Figure 1 and Figure 2 As shown, the upper yoke 10 and the lower yoke 20 of the magnetic core are arranged opposite to each other in the upper and lower directions, and the two can be symmetrical in structure. A plurality of magnetic blocks 30 are arranged between the upper yoke 10 and the lower yoke 20 of the magnetic core to generate and conduct the magnetic field. When the plurality of magnetic blocks 30 are arranged between the upper yoke 10 and the lower yoke 20 of the magnetic core, a plurality of air gaps 60 are formed, and the air gaps affect the distribution, intensity and direction of the magnetic field. At least two of the plurality of air gaps 60 are nonlinear air gaps. For example, the shape, size or distribution of at least two of the air gaps are not uniform, so that the distribution, intensity or direction of the magnetic field can be changed.

[0055] Multiple isolation plates 210 are disposed between the upper core yoke 10, the lower core yoke 20, and the multiple magnetic blocks 30 to form multiple air gaps 60. In other words, the multiple air gaps 60 in the embodiments of the present application can be generated by the isolation plates 210. By placing the isolation plates 210 between the upper core yoke 10, the lower core yoke 20, and the multiple magnetic blocks 30, multiple air gaps 60 are formed. The multiple isolation plates 210 can correspond to the multiple air gaps 60 one-to-one. The thickness of the isolation plates 210 determines the size of the air gaps, and the specific thickness can be designed based on the desired air gap size.

[0056] Multiple coils 220 are wound around the magnetic core structure 100. When current flows through the coils 220, a magnetic field is generated. The magnetic field generated by the multiple coils 220 passes through the magnetic core structure 100 and interacts with the magnetic block 30, the upper yoke 10, and the lower yoke 20 therein to generate or change the magnetic field.

[0057] In the related art, in the magnetic core structure, a single large air gap structure is usually used between the middle columns of the upper yoke of the magnetic core and the lower yoke of the magnetic core, which will generate a large edge magnetic flux passing through the coil. The high-frequency magnetic flux will cause eddy current loss in the coil, thereby reducing the efficiency of the coupled inductor element.

[0058] In the embodiment of the present application, a plurality of magnetic blocks 30 are arranged between the upper yoke 10 of the magnetic core and the lower yoke 20 of the magnetic core, and a plurality of air gaps 60 are formed, so that the size of each air gap can be set relatively small. At the same time, at least two of the plurality of air gaps 60 are nonlinear air gaps, and the nonlinear air gaps can change the end face shape of the air gap. In this way, the original single larger air gap can be transformed into multiple nonlinear small air gaps. By increasing the number of air gaps, reducing the size of the air gaps and changing the end face shape of the air gaps, the influence of the edge flux of the high-frequency and high-power inductors can be effectively reduced, the loss can be reduced, and the efficiency of the power converter 300 can be improved; at the same time, the inductor bias current can be effectively increased, and the energy storage capacity can be improved. In addition, the coupled inductor element 200 can be reduced in volume while maintaining the original core saturation characteristics, thereby saving space.

[0059] See also Figure 5 In some embodiments, the multiple air gaps 60 include: a first air gap 61 between the multiple magnetic blocks 30 and the upper yoke 10 of the magnetic core; and / or a second air gap 62 between the multiple magnetic blocks 30; and / or a third air gap 63 between the multiple magnetic blocks 30 and the lower yoke 20 of the magnetic core; and / or a fourth air gap 64 between the upper yoke 10 of the magnetic core and the lower yoke 20 of the magnetic core.

[0060] Specifically, in each of the above cases, the number of the first air gap 61, the second air gap 62, the third air gap 63, and the fourth air gap 64 can be one or more. The plurality of air gaps 60 can include one or more of the first air gap 61, the second air gap 62, the third air gap 63, and the fourth air gap 64.

[0061] When the plurality of air gaps 60 include a first air gap 61, the isolation plate 210 is disposed between the plurality of magnetic blocks 30 and the magnetic core upper yoke 10 to form the first air gap 61. When the plurality of air gaps 60 include a second air gap 62, the isolation plate 210 is disposed between the plurality of magnetic blocks 30 to form the second air gap 62. When the plurality of air gaps 60 include a third air gap 63, the isolation plate 210 is disposed between the plurality of magnetic blocks 30 and the magnetic core lower yoke 20 to form the third air gap 63. When the plurality of air gaps 60 include a fourth air gap 64, the isolation plate 210 is disposed between the magnetic core upper yoke 10 and the magnetic core lower yoke 20 to form the fourth air gap 64.

[0062] See also Figure 1 and Figure 2 In some embodiments, the upper yoke 10 and the lower yoke 20 of the magnetic core are both one of an E-shaped magnetic core, a T-shaped magnetic core, and a straight-shaped magnetic core.

[0063] Specifically, the E-shaped core has three protruding "legs" with a groove in the middle to facilitate winding and installation. The T-shaped core has a vertical "column" and two horizontal "arms", which are convenient for arranging coils in certain specific spaces. The I-shaped core is straight as a whole, and is relatively simple to design and manufacture. In the embodiment of the present application, the upper yoke 10 and the lower yoke 20 of the core can select any one of the E-shaped core, T-shaped core, and I-shaped core according to actual application requirements, working conditions and costs, without limitation here.

[0064] See also Figure 1 and Figure 5 In some embodiments, the upper yoke 10 and the lower yoke 20 each include a first leg 21, a center column 22, and a second leg 23. The first leg 21 and the second leg 23 are located on both sides of the center column 22, respectively.

[0065] In which: the multiple magnetic blocks 30 include at least one first magnetic block 31, which is arranged between two opposite first side legs 21 and forms at least two air gaps; and / or the multiple magnetic blocks 30 include at least one second magnetic block 32, which is arranged between two opposite second side legs 23 and forms at least two air gaps; and / or the multiple magnetic blocks 30 include at least one third magnetic block 33 (not shown in the figure), which is arranged between two opposite center columns 22 and forms at least two air gaps.

[0066] Specifically, the upper yoke 10 and the lower yoke 20 of the core in the embodiment of the present application both adopt an E-shaped core. It can be understood that when the upper yoke 10 and the lower yoke 20 of the core both adopt a T-shaped core, the upper yoke 10 and the lower yoke 20 of the core only include the middle column 22, and do not have the first side leg 21 and the second side leg 23. When the upper yoke 10 and the lower yoke 20 of the core both adopt a straight-line core, the upper yoke 10 and the lower yoke 20 of the core do not have the middle column 22, the first side leg 21 and the second side leg 23. In the embodiment of the present application, the EE-shaped core structure formed by the upper yoke 10 and the lower yoke 20 of the core can achieve the effect of reducing the volume due to the shared middle column 22. The lengths of the first side leg 21 and the second side leg 23 can be the same, and they are symmetrically arranged relative to the middle column 22.

[0067] When the plurality of magnetic blocks 30 include at least one first magnetic block 31, the at least one first magnetic block 31 is disposed between two opposing first legs 21 to form at least two air gaps. Specifically, when the plurality of magnetic blocks 30 include one first magnetic block 31, an isolation plate 210 is disposed between the first magnetic block 31 and the first leg 21 of the upper core yoke 10 to form a first air gap 61; and, the isolation plate 210 is disposed between the first magnetic block 31 and the first leg 21 of the lower core yoke 20 to form a third air gap 63. When the plurality of magnetic blocks 30 include multiple first magnetic blocks 31, the isolation plate 210 is disposed between the first magnetic block 31 and the first leg 21 of the upper core yoke 10 to form a first air gap 61; and, the isolation plate 210 is disposed between the multiple first magnetic blocks 31 to form a second air gap 62; and, the isolation plate 210 is disposed between the first magnetic block 31 and the first leg 21 of the lower core yoke 20 to form a third air gap 63.

[0068] When the plurality of magnetic blocks 30 include at least one second magnetic block 32, the at least one second magnetic block 32 is disposed between two opposing second legs 23 to form at least two air gaps. Specifically, when the plurality of magnetic blocks 30 include one second magnetic block 32, the isolation plate 210 is disposed between the second magnetic block 32 and the second leg 23 of the upper core yoke 10 to form a first air gap 61; and the isolation plate 210 is disposed between the second magnetic block 32 and the second leg 23 of the lower core yoke 20 to form a third air gap 63. When the plurality of magnetic blocks 30 include multiple second magnetic blocks 32, the isolation plate 210 is disposed between the second magnetic block 32 and the second leg 23 of the upper core yoke 10 to form a first air gap 61; and the isolation plate 210 is disposed between the multiple second magnetic blocks 32 to form a second air gap 62; and the isolation plate 210 is disposed between the second magnetic block 32 and the second leg 23 of the lower core yoke 20 to form a third air gap 63.

[0069] When the plurality of magnetic blocks 30 include at least one third magnetic block 33 (such as Figure 5), at least one third magnetic block 33 is disposed between two opposing center columns 22 to form at least two air gaps. Specifically, when the plurality of magnetic blocks 30 includes one third magnetic block 33, the isolation plate 210 is disposed between the third magnetic block 33 and the center column 22 of the magnetic core upper yoke 10 to form a first air gap 61; and the isolation plate 210 is disposed between the third magnetic block 33 and the center column 22 of the magnetic core lower yoke 20 to form a third air gap 63. When the plurality of magnetic blocks 30 includes multiple third magnetic blocks 33, the isolation plate 210 is disposed between the third magnetic block 33 and the center column 22 of the magnetic core upper yoke 10 to form a first air gap 61; and the isolation plate 210 is disposed between the multiple third magnetic blocks 33 to form a second air gap 62; and the isolation plate 210 is disposed between the third magnetic block 33 and the center column 22 of the magnetic core lower yoke 20 to form a third air gap 63.

[0070] In the above-mentioned various situations, it is sufficient that at least two of the multiple air gaps 60 are nonlinear air gaps. Specifically, when there are multiple first magnetic blocks 31, second magnetic blocks 32, and third magnetic blocks 33, it is further advantageous to convert the original large air gaps into a larger number of small nonlinear air gaps, distributing the air gaps in different parts of the magnetic core structure 100, making the magnetic flux distribution more uniform, reducing the influence of the fringing flux of high-frequency, high-power inductors, reducing losses, and thus improving the efficiency of the power converter 300.

[0071] In some embodiments, the nonlinear air gap includes one or more of a step air gap, a slanted air gap, a curved air gap, and a quadratic function air gap.

[0072] In other words, nonlinear air gaps can include one or more combinations of step gaps, skew gaps, curved gaps, and quadratic function gaps. A step gap refers to an air gap whose width varies in steps at different locations on the core. A skew gap refers to an air gap whose width gradually changes along a certain direction of the core, forming an inclined surface. A curved gap refers to an air gap whose shape resembles a curve or surface. A quadratic function gap refers to an air gap whose width varies according to a quadratic function, meaning that the relationship between the air gap width and the core position can be described by a quadratic function.

[0073] In the embodiments of the present application, the nonlinear air gap adopts one or more of a stepped air gap, a slanted air gap, a curved air gap, and a quadratic function air gap, which can optimize the magnetic flux distribution, making the path and distribution of the magnetic flux in the magnetic core more uniform, and further optimizing the performance of the coupled inductor element 200. There are various types of nonlinear air gaps, and an appropriate nonlinear air gap can be selected according to different needs to better meet the needs.

[0074] In certain embodiments, the end surface of the nonlinear air gap is one or more of a convex surface, a concave surface, an inclined surface, a curved surface, and a multi-step surface.

[0075] Specifically, the nonlinear air gap includes one or more of a stepped air gap, an inclined air gap, a curved air gap, and a quadratic function air gap. Correspondingly, the end surface of the nonlinear air gap is one or more of a convex surface, a concave surface, an inclined surface, a curved surface, and a multi-step surface. By changing the shape of the air gap end surface, the flow path and distribution of the magnetic flux in the magnetic core can be changed, thereby achieving a more uniform magnetic flux distribution and reducing problems such as flux concentration and local saturation.

[0076] See also Figure 1 In some embodiments, the length of the center leg 22 is greater than the length of the first side leg 21 and the length of the second side leg 23. The plurality of magnetic blocks 30 include at least one first magnetic block 31 and at least one second magnetic block 32. The at least one first magnetic block 31 forms a first side leg 40, and the at least one second magnetic block 32 forms a second side leg 50. The first side leg 40 and the center leg 22 form a first magnetic yoke, and the second side leg 50 and the center leg 22 form a second magnetic yoke. The magnetic fields of the first and second magnetic yokes are in opposite directions.

[0077] Specifically, because the center column 22 is longer than the first and second side legs 21 and 23, the plurality of magnetic blocks 30 may include a first magnetic block 31 and a second magnetic block 32, respectively forming a first side column 40 and a second side column 50. The first side column 40 is composed of at least one first magnetic block 31, and the second side column 50 is composed of at least one second magnetic block 32. The number of first magnetic blocks 31 can be equal to the number of second magnetic blocks 32. The first side columns 40 and the second side columns 50 are respectively located on either side of the center column 22. The first side column 40 is located between the two opposing first side legs 21, and the first side column 40 is located between the two opposing second side legs 23.

[0078] The coil 220 is respectively wound on the first side column 40 and the second side column 50 in the magnetic core structure 100. The first side column 40 and the middle column 22 form a first magnetic yoke, and the second side column 50 and the middle column 22 form a second magnetic yoke. The magnetic field directions of the first magnetic yoke and the second magnetic yoke are opposite to each other to achieve a specific magnetic field configuration and electromagnetic performance.

[0079] The number of coils 220 can be 2, 4, or 2N, and the number of coils 220 corresponds to the number of side poles. The number of turns of coil 220 on one side can be 1, 2, or N, depending on the winding space and electrical requirements.

[0080] See also Figure 1 and Figure 5 In some embodiments, the cross-sectional areas of the center column 22, the first side leg 21, the second side leg 23, the first side column 40, and the second side column 50 are the same.

[0081] Specifically, the cross-sectional areas of center leg 22, first leg 21, second leg 23, first leg 40, and second leg 50 are identical, which helps achieve a more uniform distribution of magnetic flux throughout the magnetic circuit, thereby reducing the risk of local magnetic flux saturation and improving the performance and stability of the inductor. The term "identical cross-sectional area" refers to the same cross-sectional shape and size.

[0082] In addition, the isolation plate 210 can also have the same cross-sectional area as the center column 22, the first side leg 21, the second side leg 23, the first side column 40, and the second side column 50 of the magnetic core structure 100, so that the cross-sectional area of the path through which the magnetic circuit passes is the same, thereby playing the role of a uniform magnetic circuit.

[0083] See also Figure 1 and Figure 5 In some embodiments, the plurality of magnetic blocks 30 are shaped as a cylinder, a triangular prism, a cuboid, or a polygonal column. The cross-sections of the center column 22, the first side leg 21, and the second side leg 23 are correspondingly shaped as a circle, a triangle, a rectangle, or a polygon.

[0084] Specifically, the different shapes of the multiple magnetic blocks 30 can affect the distribution and characteristics of the magnetic circuit to a certain extent. The specific shape can be selected based on the installation space, making full use of the limited space. The cross-sections of the multiple magnetic blocks 30 are one of circular, triangular, rectangular, or polygonal. Because the cross-sections of the magnetic blocks 30 are the same as those of the center column 22, the first leg 21, and the second leg 23, the cross-sections of the center column 22, the first leg 21, and the second leg 23 are correspondingly one of circular, triangular, rectangular, or polygonal. In addition, the cross-section of the isolation plate 210 can also correspond to one of circular, triangular, rectangular, or polygonal.

[0085] See also Figure 5 In some embodiments, the cross-section of the plurality of coils 220 is one of circular, triangular, rectangular, and polygonal.

[0086] Specifically, the cross-section of the coil 220 wound around the side pole can be circular, triangular, rectangular, or polygonal. This can be adjusted based on the shapes of the magnetic block 30 and the isolation plate 210. A smaller distance between the coil 220 and the side pole can enhance the closure of the magnetic circuit, increase the efficiency of magnetic flux transfer, and thus increase inductance.

[0087] See also Figure 5 In some embodiments, the isolation board 210 is an insulating epoxy resin board.

[0088] Specifically, the isolation plate 210 may be an insulating epoxy resin plate, which has an electromagnetic insulation function and is used to form an air gap in the magnetic core structure 100 .

[0089] See also Figure 5In some embodiments, the plurality of coils 220 are made of one of enameled round wire, enameled flat wire, self-bonding round wire, self-bonding flat wire, and Litz wire.

[0090] Specifically, enameled round wire is relatively low in cost, while enameled flat wire can be used in situations where the coil needs to be bent frequently. Enameled wire has a high degree of insulation and can be used in situations where the power is relatively high. The self-adhesive properties of self-adhesive round wire and self-adhesive flat wire allow for better adhesion to flat surfaces, enhancing installation stability. Litz wire has good anti-interference properties and can be used in high-frequency transformers. Coil 220 can adopt any of the above wire types to meet the needs of specific application scenarios.

[0091] See also Figure 1 The material of the magnetic core structure 100 includes one or more of ferrite material, iron silicon material, sendust material, iron nickel material, iron powder core material, and amorphous material.

[0092] Specifically, ferrite materials are relatively low in price, have low high-frequency losses, and high resistivity, making them suitable for high-frequency applications. Iron silicon materials have medium saturation flux density and relatively low core loss. Sendust materials have high magnetic permeability and good DC bias characteristics. Iron nickel materials have extremely high initial and maximum permeabilities, and extremely low coercive force and core loss. Iron powder core materials are relatively low in price and have high saturation flux density. Amorphous materials have high saturation flux density and very low core loss, especially in medium and high-frequency applications. Specifically, you can choose the appropriate material according to the needs of different application scenarios, and there is no restriction here.

[0093] See also Figure 5 , the following introduces the assembly process of the coupled inductor element 200 according to the embodiment of the present application.

[0094] Prepare multiple magnetic blocks 30 by pressing and forming them into a predetermined shape. Each magnetic block 30 has an end surface with a nonlinear air gap. Enameled copper wire is wound into a coil 220 according to the predetermined shape. Select multiple isolation plates 210 of a predetermined thickness and cut them into the predetermined shape. Before placing the isolation plates 210, apply epoxy glue to both sides of the isolation plates 210 to facilitate securing them to the upper and lower yokes 10 and 20 of the magnetic core, and to the magnetic blocks 30.

[0095] Place the first isolation plate 210 and the second isolation plate 210 on the first side leg 21 and the second side leg 23 of the lower yoke 20 of the magnetic core respectively; place the first first magnetic block 31 and the first second magnetic block 32 on the above-mentioned first isolation plate 210 and the second isolation plate 210 respectively; place the third isolation plate 210 and the fourth isolation plate 210 on the above-mentioned first first magnetic block 31 and the first second magnetic block 32 respectively; then place the second first magnetic block 31 and the second second magnetic block 32 on the above-mentioned third isolation plate 210 and the fourth isolation plate 210 respectively; place the fifth isolation plate 210 and the sixth isolation plate 210 on the above-mentioned second first magnetic block 31 and the second second magnetic block 32 respectively; place the third first magnetic block 31 and the third second magnetic block 32 on the above-mentioned fifth isolation plate 210 and the sixth isolation plate 210. When the isolation plates 210 and magnetic blocks 30 are stacked and interlaced to a certain height, they can be cured by baking to secure the stacked isolation plates 210 to the magnetic blocks 30, the first leg 21, and the second leg 23. The seventh and eighth isolation plates 210 are then placed on the third first magnetic block 31 and the third second magnetic block 32, respectively. The first and second coils 220 are then placed at the center of the first and second leg 40, 50, respectively. The ninth isolation plate 210 is then placed on the center leg 22 of the lower yoke 20 of the magnetic core. Finally, the upper yoke 10 of the magnetic core is placed on the seventh, ninth, and eighth isolation plates 210, and the process is cured by baking again to form the entire coupled inductor element 200.

[0096] See also Figure 6 The embodiment of the present application further provides a power converter 300. The power converter 300 includes the coupled inductor element 200 according to any of the above embodiments.

[0097] Specifically, the coupled inductor element 200 can be applied to the power converter 300 to achieve functions such as energy transfer, filtering, or voltage-current conversion.

[0098] See also Figure 7 The embodiment of the present application further provides a DC converter 400. The DC converter 400 includes a battery 410 and the power converter 300 of any of the above embodiments.

[0099] Specifically, battery 410 may be a hydrogen fuel cell, and power converter 300 may be a high-power converter (e.g., a power converter with a power greater than 300W). Battery 410 and power converter 300 are connected in series. The total efficiency of DC converter 400 is the product of the efficiency of battery 410 and the efficiency of power converter 300. Power converter 300 can convert the electrical energy of battery 410 into voltage for use by loads in vehicle 1000.

[0100] See also Figure 8 , an embodiment of the present application further provides a vehicle 1000. The vehicle 1000 includes the DC converter 400 according to any one of the above embodiments.

[0101] Specifically, the DC converter 400 may be provided on the vehicle body and may be a DC / DC converter for converting high-voltage DC power into low-voltage DC power for supplying loads in the vehicle 1000, such as a power steering system, air conditioning, and other auxiliary equipment.

[0102] In summary, in the magnetic core structure 100, coupled inductor element 200, power converter 300, DC converter 400 and vehicle 1000 of the embodiment of the present application, multiple magnetic blocks 30 are arranged between the upper yoke 10 of the magnetic core and the lower yoke 20 of the magnetic core, and multiple air gaps 60 are formed, and at least two of the multiple air gaps 60 are nonlinear air gaps. In this way, the influence of the edge flux of high-frequency, high-power inductors can be effectively reduced, and the loss can be reduced, thereby improving the efficiency of the power converter 300; at the same time, the inductor bias current can be effectively increased, and the energy storage capacity can be improved. In addition, the coupled inductor element 200 can also be reduced in size while maintaining the original magnetic core saturation characteristics, thereby saving space.

[0103] In the description of the present application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present application. In addition, the terms "first" and "second" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more features. In the description of the present application, "multiple" means two or more, unless otherwise clearly and specifically defined.

[0104] In the description of this application, it should be noted that, unless otherwise expressly specified or limited, the terms "installed," "connected," and "connected" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integral connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and can refer to internal communication between two components or the interaction between two components. A person of ordinary skill in the art will be able to understand the specific meanings of the above terms in this application based on the specific circumstances.

[0105] In this application, unless otherwise expressly specified or limited, a first feature being "above" or "below" a second feature may include the first and second features being in direct contact, or may include the first and second features being in contact not directly but through another feature between them. Moreover, a first feature being "above," "above," and "above" a second feature may include the first feature being directly above or obliquely above the second feature, or may simply mean that the first feature is higher in level than the second feature. A first feature being "below," "below," and "below" a second feature may include the first feature being directly below or obliquely below the second feature, or may simply mean that the first feature is lower in level than the second feature.

[0106] The disclosure above provides many different embodiments or examples for realizing different structures of the present application. In order to simplify the disclosure of the present application, the components and settings of specific examples are described above. Of course, they are merely examples and are not intended to limit the present application. In addition, the present application may repeat reference numbers and / or reference letters in different examples, and such repetition is for the purpose of simplicity and clarity, and does not itself indicate the relationship between the various embodiments and / or settings discussed. In addition, the present application provides examples of various specific processes and materials, but those of ordinary skill in the art will appreciate the application of other processes and / or the use of other materials.

[0107] Throughout this specification, reference to terms such as "one embodiment," "some embodiments," "illustrative embodiments," "example," "specific example," and "some examples" means that a specific feature, structure, material, or characteristic described in conjunction with an embodiment or example is included in at least one embodiment or example of the present application. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0108] Although the embodiments of the present application have been shown and described above, those skilled in the art will appreciate that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and purpose of the present application, and that the scope of the present application is defined by the claims and their equivalents.

Claims

1. A magnetic core structure (100), characterized in that: include: a magnetic core upper yoke (10); A magnetic core lower yoke (20), wherein the magnetic core upper yoke (10) and the magnetic core lower yoke (20) are arranged opposite to each other; A plurality of magnetic blocks (30) are provided between the magnetic core upper yoke (10) and the magnetic core lower yoke (20) to form a plurality of air gaps (60), at least two of the plurality of air gaps (60) being nonlinear air gaps.

2. The magnetic core structure (100) according to claim 1, characterized in that The plurality of air gaps (60) include: a first air gap (61) between the plurality of magnetic blocks (30) and the upper yoke (10) of the magnetic core; and / or A second air gap (62) between the plurality of magnetic blocks (30); and / or a third air gap (63) between the plurality of magnetic blocks (30) and the magnetic core lower yoke (20); and / or A fourth air gap (64) is formed between the magnetic core upper yoke (10) and the magnetic core lower yoke (20).

3. The magnetic core structure (100) according to claim 1, characterized in that The magnetic core upper yoke (10) and the magnetic core lower yoke (20) are both one of an E-shaped magnetic core, a T-shaped magnetic core, and a straight-shaped magnetic core.

4. The magnetic core structure (100) according to claim 1, characterized in that The magnetic core upper yoke (10) and the magnetic core lower yoke (20) each comprise a first side leg (21), a center column (22), and a second side leg (23), wherein the first side leg (21) and the second side leg (23) are respectively located on both sides of the center column (22); The plurality of magnetic blocks (30) include at least one first magnetic block (31), wherein the at least one first magnetic block (31) is disposed between two opposing first side legs (21) and forms at least two air gaps; and / or The plurality of magnetic blocks (30) include at least one second magnetic block (32), wherein the at least one second magnetic block (32) is disposed between two opposing second side legs (23) and forms at least two air gaps; and / or The plurality of magnetic blocks (30) include at least one third magnetic block (33), and the at least one third magnetic block (33) is arranged between two opposite middle columns (22) to form at least two air gaps.

5. The magnetic core structure (100) according to claim 1, characterized in that The nonlinear air gap includes one or more of a step air gap, an oblique air gap, a curved air gap, and a quadratic function air gap.

6. The magnetic core structure (100) according to claim 1, characterized in that The end surface of the nonlinear air gap is one or more of a convex surface, a concave surface, an inclined surface, a curved surface, and a multi-step surface.

7. The magnetic core structure (100) according to claim 4, characterized in that The length of the center column (22) is respectively greater than the length of the first side leg (21) and the length of the second side leg (23); The plurality of magnetic blocks (30) include at least one first magnetic block (31) and at least one second magnetic block (32), wherein the at least one first magnetic block (31) forms a first side column (40), and the at least one second magnetic block (32) forms a second side column (50), wherein the first side column (40) and the center column (22) form a first magnetic yoke, and the second side column (50) and the center column (22) form a second magnetic yoke, and the magnetic field directions of the first magnetic yoke and the second magnetic yoke are opposite.

8. The magnetic core structure (100) according to claim 7, characterized in that The cross-sectional areas of the center column (22), the first side leg (21), the second side leg (23), the first side column (40), and the second side column (50) are the same.

9. The magnetic core structure (100) according to claim 4, characterized in that The plurality of magnetic blocks (30) are in the shape of a cylinder, a triangular prism, a cuboid or a polygonal column; The cross-sections of the center column (22), the first side leg (21), and the second side leg (23) are correspondingly circular, triangular, rectangular, or polygonal.

10. The magnetic core structure (100) according to claim 1, characterized in that The material of the magnetic core structure (100) includes one or more of ferrite material, iron silicon material, sendust material, iron nickel material, iron powder core material, and amorphous material.

11. A coupled inductor element (200), characterized in that: include: The magnetic core structure (100) according to any one of claims 1 to 10; a plurality of isolation plates (210), the plurality of isolation plates (210) being disposed between the magnetic core upper yoke (10), the magnetic core lower yoke (20), and the plurality of magnetic blocks (30) to form the plurality of air gaps (60); A plurality of coils (220), wherein the plurality of coils (220) are wound around the magnetic core structure (100).

12. The coupled inductor element (200) according to claim 11, characterized in that The isolation plate (210) is an insulating epoxy resin plate.

13. The coupled inductor element (200) according to claim 11, characterized in that The cross-section of the plurality of coils (220) is one of circular, triangular, rectangular and polygonal.

14. The coupled inductor element (200) according to claim 11, characterized in that The plurality of coils (220) are made of one of enameled round wire, enameled flat wire, self-adhesive round wire, self-adhesive flat wire, and Litz wire.

15. A power converter (300), characterized in that: The coupled inductor element (200) comprises the coupled inductor element (200) according to any one of claims 11 to 14.

16. A DC conversion device (400), characterized in that: The invention comprises a battery (410) and the power converter (300) according to claim 15.

17. A vehicle (1000), characterized in that It comprises the DC conversion device (400) according to claim 16.

Images