Magnetic assembly and switching power supply

Abstract

The utility model provides a magnetic assembly and a switching power supply. The magnetic assembly comprises a magnetic core and a winding. The magnetic core comprises two oppositely arranged main magnetic cores and at least one sub-magnetic core, and the sub-magnetic core is arranged between the main magnetic cores; the main magnetic core comprises a main cover plate, a main wrapping post and at least one public post, one end of the main wrapping post and one end of the public post are connected with the main cover plate; each sub magnetic core comprises a sub cover plate and a sub wrapping post of which one end is connected with the sub cover plate; the winding is arranged on the main winding post and the sub winding post and comprises a primary winding and a secondary winding; and the sub-cover plates are used for separating the primary winding from the secondary winding. Therefore, the leakage inductance of the magnetic assembly can be accurately adjusted, the size of the switching power supply is controlled, and the power density of the switching power supply is improved.

Description

Technical Field

[0001] This application relates to the field of charging technology, specifically to a magnetic component and a switching power supply. Background Technology

[0002] The resonant circuit structure in switching power supplies (such as on-board chargers) typically uses two magnetic components—a transformer and a resonant inductor—to operate. This approach results in an excessive number of magnetic components, leading to higher costs for the switching power supply. To address this, related technologies have developed a solution that integrates leakage inductance. By increasing the leakage inductance of the transformer itself, the leakage inductance is adjusted to match the required inductance of the resonant inductor. This eliminates the need for the resonant inductor, meaning that only one magnetic component is required to achieve the same effect as the original two.

[0003] Currently, there are two main ways to increase the leakage inductance of a transformer: one is to simply increase the distance between the primary and secondary windings; the other is to insert a magnetic sheet between the primary and secondary windings. For the first method, when a larger leakage inductance value is required, the distance between the primary and secondary windings needs to be made larger, which leads to a larger overall transformer size, hindering the improvement of power density in switching power supplies. For the second method, the leakage inductance value of the transformer is difficult to control precisely. Utility Model Content

[0004] Embodiments of this application provide a magnetic component and a switching power supply to at least partially solve the aforementioned technical problems.

[0005] In a first aspect, embodiments of this application provide a magnetic component, including a magnetic core and windings;

[0006] The magnetic core includes two main magnetic cores arranged opposite to each other and at least one sub-magnetic core, wherein the sub-magnetic core is disposed between the main magnetic cores;

[0007] The main magnetic core includes a main cover plate, a main winding post, and a common post. One end of the main winding post and the common post are connected to the main cover plate. The number of the common post is at least one.

[0008] The sub-core includes a sub-cover plate and a sub-winding post with one end connected to the sub-cover plate;

[0009] The winding is disposed on the main winding post and the sub-winding post, and the winding includes a primary winding and a secondary winding; the sub-cover plate is used to separate the primary winding and the secondary winding.

[0010] In some embodiments, the sub-cover plate is configured to at least partially protrude from the sub-winding post in the radial direction; the cross-sectional area of ​​the main winding post is the same as that of the sub-winding post.

[0011] In some embodiments, the sub-core is a T-shaped core, and the sub-cover plate is integrally formed with the sub-winding post.

[0012] In some embodiments, the number of sub-cores is greater than 1, all the sub-cores are spliced ​​together in sequence, and the sub-cover plate is located between two adjacent primary windings and secondary windings.

[0013] In some embodiments, the magnetic component includes at least two adjacent sub-cores arranged opposite or back to each other.

[0014] In some embodiments, the number of sub-cores is 2n, where n≥1, and the two sub-cores located in the middle are arranged opposite or back to back.

[0015] In some embodiments, when n=1 and the two sub-cores are arranged opposite each other, the number of primary windings and secondary windings is 2 each; the primary windings and secondary windings are arranged alternately; or, the primary windings are all arranged on the main winding post and the secondary windings are all arranged on the sub-winding post; or, the primary windings are all arranged on the sub-winding post and the secondary windings are all arranged on the main winding post.

[0016] In some embodiments, the sub-cores are bonded together with the main core, and also bonded together with adjacent sub-cores.

[0017] In some embodiments, the winding is a disc structure, the sub-core is located between the main winding posts of two opposing main cores, and the total length of the main winding posts and the sub-core is equal to the total length of the common post.

[0018] Secondly, embodiments of this application provide a switching power supply including the aforementioned magnetic component.

[0019] The beneficial effects of the embodiments of this application are as follows:

[0020] The magnetic component provided in this application embodiment configures the magnetic core to include independent main and sub-cores. The primary and secondary windings are mounted on the main winding post of the main core and the sub-winding post of the sub-core. A sub-cover plate connected to the sub-winding post in the sub-core separates the primary and secondary windings. This creates a semi-closed magnetic circuit between the sub-cover plate and the primary winding on one side, and another semi-closed magnetic circuit between the sub-cover plate and the secondary winding on the other side. Compared to the case where no sub-cover plate is provided on the sub-winding post, the magnetic circuit length is reduced by half. The shorter magnetic circuit length increases the inductance of the primary and secondary windings, thereby increasing their leakage inductance. The adjusted leakage inductance can serve as a resonant inductance. When the magnetic component is used in a switching power supply, there is no need to separately configure a resonant inductor, nor is it necessary to significantly increase the distance between the primary and secondary windings, thus reducing the overall size of the switching power supply and improving its power density.

[0021] Furthermore, this approach eliminates the need for a frame. By utilizing the magnetic core and windings, the positional relationship between the primary and secondary windings and the sub-cover plate becomes simpler and more stable. When designing the magnetic assembly, it is only necessary to stably fix the windings to the magnetic core, maintaining a fixed relative position between the windings and the sub-cover plate. Then, the leakage inductance of the magnetic assembly can be precisely adjusted by changing the thickness, shape, or material of the sub-cover plate. For example, increasing or decreasing the area of ​​the sub-cover plate will increase or decrease the leakage inductance; similarly, increasing or decreasing the thickness of the sub-cover plate will also increase or decrease the leakage inductance. Additionally, the leakage inductance of the magnetic assembly becomes more stable during use, as vibrations of the magnetic core are less likely to cause fluctuations in the leakage inductance.

[0022] In addition, the magnetic component provided in this application eliminates the frame by directly connecting the magnetic core and the winding. This not only significantly improves the heat dissipation of the winding, but also allows for a further reduction in the size of the magnetic component, or enables a higher power output for the same volume. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a three-dimensional structural schematic diagram of a magnetic component provided in an embodiment of this application;

[0025] Figure 2This is an exploded view of a magnetic component provided in an embodiment of this application;

[0026] Figure 3 This is a three-dimensional structural schematic diagram of a sub-core in a magnetic component provided by an embodiment of this application;

[0027] Figure 4 This is a three-dimensional structural schematic diagram of another sub-core in a magnetic component provided by an embodiment of this application;

[0028] Figure 5 This is a cross-sectional structural schematic diagram of another magnetic component provided in an embodiment of this application;

[0029] Figure 6 This is a cross-sectional structural schematic diagram of another magnetic component provided in an embodiment of this application.

[0030] Figure label:

[0031] 10. Magnetic components;

[0032] 1. Magnetic core;

[0033] 11. Main magnetic core; 111. Main cover plate; 112. Main winding post; 113. Common post; 1131. Recess;

[0034] 12. Sub-core; 121. Sub-cover plate; 122. Sub-winding post;

[0035] 2. Winding; 21. Primary winding; 22. Secondary winding. Detailed Implementation

[0036] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0037] Furthermore, it should be understood that the specific embodiments described herein are for illustrative and explanatory purposes only and are not intended to limit the scope of this application. In this application, unless otherwise stated, directional terms such as "upper" and "lower" generally refer to the upper and lower positions of the device in its actual use or operation, specifically the directions shown in the accompanying drawings; while "inner" and "outer" refer to the outline of the device.

[0038] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the stated features. In the description of this application, "a plurality of" means two or more, unless otherwise explicitly specified.

[0039] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0040] The terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0041] In the description of the embodiments of this application, the words "example" or "for example" are used to indicate exemplification, illustration, or description. Any embodiment or design described as "example" or "for example" in the embodiments of this application is not to be construed as being more preferred or having more advantages than another embodiment or design. The use of the words "example" or "for example" is intended to present relative concepts in a clear manner.

[0042] To facilitate understanding of the present application, the spline curves and arrows used in the reference numerals in the accompanying drawings are explained below: spline curves without arrows indicate solid parts, that is, parts with solid structures; spline curves with arrows indicate virtual parts, that is, parts without solid structures.

[0043] Firstly, please see Figures 1 to 6 This application provides a magnetic component 10, which can be used in a switching power supply and can be a transformer.

[0044] Specifically, the magnetic component 10 includes a magnetic core 1 and a winding 2. The magnetic core 1 is the magnetic circuit part of the magnetic component 10, and the winding 2 is the circuit part of the magnetic component 10. The winding 2 is disposed on the magnetic core 1.

[0045] The winding 2 includes a primary winding 21 and a secondary winding 22, and the magnetic core 1 is used to strengthen the magnetic coupling between the primary winding 21 and the secondary winding 22.

[0046] Winding 2 includes at least one turn of coil. The primary winding 21 is also called the primary coil, and the secondary winding 22 is also called the secondary coil. When alternating current is applied to the primary winding 21, it generates an alternating magnetic field in the magnetic core 1, which in turn induces an electromotive force (EMF) in the secondary winding 22. The ratio of the number of turns in the primary winding 21 to the secondary winding 22 in the magnetic assembly 10 is equal to the voltage ratio. By changing the number of turns in the primary winding 21 and the secondary winding 22, the ratio of their EMFs can be changed, thereby changing the voltage. It is understandable that since the magnetic assembly 10 is a transformer, if the number of turns in the primary winding 21 is greater than the number of turns in the secondary winding 22, the transformer can step down the voltage; conversely, if the number of turns in the primary winding 21 is less than the number of turns in the secondary winding 22, the transformer can step up the voltage.

[0047] It should be noted that in the magnetic component 10, the number of primary windings 21 can be one or more, and the number of secondary windings 22 can also be one or more.

[0048] The magnetic core 1 includes a main magnetic core 11 and sub-cores 12. There are two main magnetic cores 11 in the magnetic core 1, and the two main magnetic cores 11 are arranged opposite each other. There is at least one sub-core 12 in the magnetic core 1, and at least one sub-core 12 is disposed between the two main magnetic cores 11; that is, all sub-cores 12 are disposed between the two main magnetic cores 11. As an example, when there is only one sub-core 12, that sub-core 12 is located between the two main magnetic cores 11; when there are multiple sub-cores 12, all sub-cores 12 are located between the two main magnetic cores 11.

[0049] Both the main magnetic core 11 and the sub-core 12 are structural components made of magnetic materials. Optionally, the magnetic material includes soft magnetic materials. Soft magnetic materials have low coercivity and high permeability, thus making the application of this magnetic component 10 perform better in high-frequency applications. As examples, soft magnetic materials include iron-silicon alloys (silicon steel sheets) and various soft magnetic ferrites.

[0050] The main magnetic core 11 includes a main cover plate 111, a main winding post 112 and a common post 113. One end of the main winding post 112 and the common post 113 are connected to the main cover plate 111, and the number of common posts 113 is at least one.

[0051] One end of both the main winding post 112 and the common post 113 is connected to the main cover plate 111. That is, one end of the main winding post 112 is connected to the main cover plate 111, and one end of the common post 113 is also connected to the main cover plate 111. The main winding post 112 and the common post 113 stand upright on the same side surface of the main cover plate 111 at intervals. Optionally, the main winding post 112, the main cover plate 111, and the common post 113 are integrally formed.

[0052] Typically, a single main magnetic core 11 contains one main winding post 112 and one main cover plate 111, while the number of common posts 113 can be one or more.

[0053] As an example, the main magnetic core 11 is E-shaped. Specifically, there is one main cover plate 111 and one main winding post 112, and two common posts 113. The two common posts 113 and one main winding post 112 are spaced apart and erected on the same side surface of the main cover plate 111, with the main winding post 112 erected between the two common posts 113. The advantage of this arrangement is that the main magnetic core 11 has high mechanical strength.

[0054] As an example, the main magnetic core 11 is U-shaped. There is one main cover plate 111, one common post 113 and one main winding post 112, wherein the common post 113 and the main winding post 112 are erected at intervals on the same side surface of the main cover plate 111.

[0055] As an example, the main magnetic core 11 is X-shaped. In detail, there is one main cover plate 111 and one main winding post 112, and four common posts 113. The four common posts 113 and one main winding post 112 are erected at intervals on the same side surface of the main cover plate 111, and the four common posts 113 are arranged around the main winding post 112.

[0056] For easier distinction, please refer to Figure 2 The two main magnetic cores 11 are referred to as the first main magnetic core 1101 and the second main magnetic core 1102, respectively, and are arranged opposite to each other. Specifically, the main winding post 112 of the first main magnetic core 1101 and the main winding post 112 of the second main magnetic core 1102 are opposite to each other, that is, the free end of the main winding post 112 on the first main magnetic core 1101 (i.e., the end away from the main cover plate 111) and the free end of the main winding post 112 on the second main magnetic core 1102 face each other; the common post 113 of the first main magnetic core 1101 and the common post 113 of the second main magnetic core 1102 are opposite to each other, that is, the free end of the common post 113 on the first main magnetic core 1101 (i.e., the end away from the main cover plate 111) and the free end of the common post 113 on the second main magnetic core 1102 face each other.

[0057] Optionally, all sub-cores 12 are disposed between two main cores 11, specifically, all sub-cores 12 are disposed between the main winding posts 112 of two oppositely disposed main cores 11.

[0058] It is understood that the length of the main winding post 112 is less than the length of the common post 113. When the first main magnetic core 1101 and the second main magnetic core 1102 are positioned opposite each other, the free end of the common post 113 on the first main magnetic core 1101 is connected to the free end of the common post 113 on the second main magnetic core 1102, and the free end of the main winding post 112 on the first main magnetic core 1101 is spaced apart from the free end of the main winding post 112 on the second main magnetic core 1102. All sub-cores 12 are located between the free ends of the main winding posts 112 on the first main magnetic core 1101 and the free ends of the main winding posts 112 on the second main magnetic core 1102. In this way, the free ends of the common posts 113 of the two main magnetic cores 11 are connected, and the free ends of the main winding posts 112 of the two main magnetic cores 11 are connected through the sub-cores 12, thereby forming a closed magnetic circuit.

[0059] The sub-core 12 includes a sub-cover plate 121 and a sub-winding post 122, with one end of the sub-winding post 122 fixedly disposed to the sub-cover plate 121.

[0060] The winding 2 is mounted on the magnetic core 1, specifically on the main winding post 112 and the secondary winding post 122. That is, the winding 2 does not need to be connected to the magnetic core 1 via a bobbin. The main winding post 112 can support either the primary winding 21 or the secondary winding 22; similarly, the secondary winding post 122 can support either the primary winding 21 or the secondary winding 22. As an example, the primary winding 21 is mounted on either the main winding post 112 or the secondary winding post 122. As an example, the secondary winding 22 is mounted on either the main winding post 112 or the secondary winding post 122.

[0061] Regardless of the connection relationship between the primary winding 21 and the secondary winding 22 and the main winding post 112 and the sub-winding post 122, the sub-cover plate 121 is always kept between the primary winding 21 and the secondary winding 22, and the sub-cover plate 121 is used to separate the primary winding 21 and the secondary winding 22.

[0062] The sub-cover plate 121 effectively adjusts the leakage inductance of the magnetic component 10. Specifically, the sub-cover plate 121 forms a semi-closed magnetic circuit with the primary winding 21 on one side and with the secondary winding 22 on the other side. Compared to the case where the sub-cover plate 121 is not present on the sub-winding post 122, the magnetic circuit length is halved. This shorter magnetic circuit length increases the inductance of the primary winding 21 and the secondary winding 22, thereby increasing the leakage inductance. The adjusted leakage inductance can then serve as a resonant inductance. When the magnetic component 10 is used in a switching power supply, there is no need to separately set up a resonant inductor, nor is it necessary to significantly increase the distance between the primary winding 21 and the secondary winding 22, thus reducing the overall size of the switching power supply and increasing its power density.

[0063] Typically, different switching power supplies require different leakage inductance values. When designing the magnetic component 10, how to accurately control the leakage inductance value between the primary winding 21 and the secondary winding 22 has always been an industry challenge.

[0064] In related technologies, magnetic sheets fixed to a frame are mainly used to adjust the leakage inductance of magnetic components. However, the inventors of this application discovered during their research that, in addition to the size, shape, and material of the magnetic sheet, the leakage inductance value is also affected by the fit between the magnetic sheet and the frame, as well as the fit between the magnetic core and the frame.

[0065] Based on this, this application provides a new solution. By configuring the magnetic core 1 to include an independent main magnetic core 11 and a sub-core 12, the primary winding 21 and secondary winding 22 of the winding 2 are mounted on the main winding post 112 of the main magnetic core 11 and the sub-winding post 122 of the sub-core 12. A sub-cover plate 121 connected to the sub-winding post 122 in the sub-core 12 separates the primary winding 21 and the secondary winding 22, thereby reducing the leakage inductance of the magnetic assembly 10. This solution omits the skeleton and, by utilizing the cooperation between the magnetic core 1 and the winding 2, makes the positional relationship between the primary winding 21 and the secondary winding 22 and the sub-cover plate 121 simpler and more stable and reliable. When designing the magnetic assembly 10, it is only necessary to stably fix the winding 2 on the magnetic core 1, keep the relative position between the winding 2 and the sub-cover plate 121 fixed, and then adjust the thickness, shape, or material of the sub-cover plate 121 to precisely adjust the leakage inductance value of the magnetic assembly 10. As an example, the leakage inductance of the magnetic component 10 can be increased or decreased by increasing or decreasing the area of ​​the sub-cover plate 121; the leakage inductance of the magnetic component 10 can also be increased or decreased by increasing or decreasing the thickness of the sub-cover plate 121. In addition, during use, the leakage inductance of the magnetic component 10 will be more stable, and the vibration of the magnetic core 1 will not easily cause fluctuations in the leakage inductance.

[0066] In addition, the magnetic component 10 provided in this application embodiment eliminates the frame by directly connecting the magnetic core 1 and the winding 2. This not only significantly improves the heat dissipation effect of the winding 2, but also allows the volume of the magnetic component 10 to be further reduced, or the power of the magnetic component 10 to be higher within the same volume.

[0067] In some embodiments, the sub-cover plate 121 is configured to at least partially protrude from the sub-winding post 122 radially. Thus, when the winding 2 is mounted on the sub-winding post 122, the sub-cover plate 121 can stop the winding 2, and when the sub-core 12 is joined with the main core 11 or other sub-cores 12, the sub-cover plate 121 can directly separate the primary winding 21 and the secondary winding 22, reducing the assembly difficulty of the magnetic assembly 10.

[0068] When designing the magnetic component 10, the leakage inductance of the magnetic component 10 can be adjusted by changing the number, shape, thickness, and size of the sub-covers 121. Generally, a smaller cross-sectional area of ​​the sub-covers 121 will reduce the leakage inductance, while an increase in the thickness of the sub-covers 121 will increase the leakage inductance.

[0069] Here, the number of sub-covers 121 can be one or more. See, for example... Figure 3 and Figure 4 There is one sub-cover plate 121, which is fixedly installed at one end of the sub-winding post 122. The sub-cover plate 121 can extend outwards at equal intervals, that is, extend along the radial direction of the sub-winding post 122. The top end of the sub-cover plate 121 is equidistant from the outer peripheral surface of the sub-winding post 122. See [link to details] for further information. Figure 3 The sub-cover plate 121 can also extend outwards at non-equidistant distances, with the top of the sub-cover plate 121 not being equidistant from the outer periphery of the sub-winding post 122. Please refer to [link / reference] for details. Figure 4 .

[0070] In some embodiments, the sub-cover plate 121 is located on the outer peripheral surface of the sub-winding post 122, and the sub-cover plate 121 surrounds the sub-winding post 122 circumferentially.

[0071] In some embodiments, there may be multiple sub-cover plates 121, which are distributed around the outer periphery of the sub-winding post 122 at intervals.

[0072] Typically, the sub-cover plate 121 can be perpendicular to the outer peripheral surface of the sub-winding post 122, or it can be inclined relative to the outer peripheral surface of the sub-winding post 122. Optionally, the sub-cover plate 121 is perpendicular to the outer peripheral surface of the sub-winding post 122. In this way, when the primary winding 21 and the secondary winding 22 are respectively arranged on both sides of the sub-cover plate 121, the primary winding 21 and the secondary winding 22 can abut against the two side surfaces of the sub-cover plate 121, shortening the distance between the primary winding 21 and the secondary winding 22, thereby reducing the volume of the magnetic component 10.

[0073] In some embodiments, the cross-section of the main winding post 112 is the same as the cross-section of the sub-winding post 122, that is, the cross-section of the main winding post 112 and the sub-winding post 122 have the same shape and the same area. Thus, when the sub-core 12 is placed between the two main cores 11, the main winding post 112 and the sub-winding post 122 can be coaxially arranged, that is, the central axis of the main winding post 112 and the central axis of the sub-winding post 122 are collinear and projected along their common central axis. The orthographic projection of the main winding post 112 on the plane where the sub-cover plate 121 is located overlaps with the orthographic projection of the sub-winding post 122 on the plane where the sub-cover plate 121 is located. When the sub-cover plate 121 is set to protrude at least partially from the sub-winding post 122 in the radial direction, the sub-cover plate 121 also protrudes at least partially from the main winding post 112 in the radial direction. When the winding 2 is placed on the main winding post 112 and the sub-winding post 122, the sub-cover plate 121 can effectively separate the primary winding 21 and the secondary winding 22.

[0074] In some embodiments, the sub-cover plate 121 and the sub-winding post 122 are integrally formed. Understandably, there is no gap between the sub-winding post 122 and the sub-cover plate 121 at the connection point, thereby allowing for more precise control of the leakage inductance value. It should be noted that both the sub-winding post 122 and the sub-cover plate 121 are made of magnetic materials; however, they can be made of the same magnetic material or different magnetic materials. Optionally, the sub-winding post 122 and the sub-cover plate 121 are made of the same magnetic material, which is convenient and simplifies the manufacturing process when the sub-winding post 122 and the sub-cover plate 121 are integrally formed.

[0075] In some implementations, please refer to Figures 2 to 4The sub-core 12 is a T-shaped core, meaning the sub-cover plate 121 is integrally designed to protrude radially from the sub-winding post 122. For example, the sub-cover plate 121 is located on one end face of the sub-winding post 122. This design further reduces the manufacturing difficulty of the sub-core 12 and the difficulty of installing the winding 2 with the sub-core 12. Especially when the sub-winding post 122 and the sub-cover plate 121 are integrally formed, molding is usually used during the manufacturing process. By placing the sub-cover plate 121 at the end of the sub-winding post 122, the difficulty of product demolding or mold design can be reduced. Additionally, the winding 2 can also be designed as a coil structure, with the coil structure winding 2 fitted onto the sub-winding post 122, improving assembly efficiency.

[0076] Since the magnetic core 1 is configured to include an independent main magnetic core 11 and a sub-core 12, the main magnetic core 11 and the sub-core 12 need to be spliced ​​together when assembling the magnetic assembly 10. When splicing the main magnetic core 11 and the sub-core 12, the end of the sub-cover plate 121 away from the sub-winding post 122 can contact the main winding post 112. When there are multiple sub-cores 12, a sub-core 12 that does not contact the main winding post 112 can contact another sub-core 12; specifically, the end of the sub-cover plate 121 away from the sub-winding post 122 can contact the sub-winding post 122 of another sub-core 12. Furthermore, the end of the sub-cover plate 121 away from the sub-winding post 122 can also contact the sub-cover plate 121 of another sub-core 12. This configuration simplifies the assembly of the magnetic assembly 10.

[0077] In some embodiments, the winding 2 is a coil structure. By designing the winding 2 as a coil structure, it is easier to quickly mount the winding 2 onto the magnetic core 1, thereby improving the assembly efficiency of the magnetic assembly 10.

[0078] In some embodiments, winding 2 may be made of enameled wire or copper wire. As an example, the conductive part of winding 2 is a multi-strand strand of enameled wire, and the outer side of winding 2 also has an insulating layer.

[0079] In some embodiments, the outer surface of the sub-cover plate 121 is not lower than the outer surface of the winding 2. Here, the outer surface of the sub-cover plate 121 refers to the surface of the sub-cover plate 121 away from the sub-winding post 122; the outer surface of the winding 2 refers to the surface of the winding 2 facing away from the magnetic core 1. Optionally, the outer surface of the sub-cover plate 121 is flush with the outer surface of the winding 2. Optionally, the outer surface of the sub-cover plate 121 protrudes beyond the outer surface of the winding 2. This allows the sub-cover plate 121 to effectively separate the primary winding 21 and the secondary winding 22 in the winding 2.

[0080] In some embodiments, the main winding post 112 is cut radially, and the cross-section (also called the cross-section) of the main winding post 112 is one of a circle, an ellipse, a square, and a racetrack shape. The sub-winding post 122 is cut radially, and the cross-section (also called the cross-section) of the sub-winding post 122 is one of a circle, an ellipse, a square, and a racetrack shape.

[0081] In some embodiments, the common post 113 is cut radially, and the area of ​​the cross section (also called the cross-section) of the common post 113 is larger than the cross-sectional area of ​​the main winding post 112, which can improve the mechanical strength of the main magnetic core 11.

[0082] In some implementations, please refer to Figure 2 A recess 1131 is also formed on the common post 113. The recess 1131 is used to avoid the sub-cover plate 121, so as to prevent the sub-cover plate 121 from contacting the common post 113 and causing magnetic saturation when the main magnetic core 11 and the sub-core 12 are spliced. Specifically, the recess 1131 is formed by the surface of the common post 113 facing the main winding post 112 recessing into the interior of the common post 113. The setting of the recess 1131 can effectively reduce the risk of contact between the sub-cover plate 121 and the common post 113, and can also reduce the size of the main magnetic core 11, thereby reducing the volume of the magnetic assembly 10. Optionally, the inner surface of the recess 1131 is used to support the winding 2. As an example, when the magnetic core 1 and winding 2 are assembled together to form a magnetic assembly 10, the primary winding 21 is fitted onto the main winding post 112, and the secondary winding 22 is fitted onto the sub-winding post 122. The main winding post 112 is connected to the sub-core 12, and a sub-cover plate 121 is located between the main winding post 112 and the sub-winding post 122. The primary winding 21 and the secondary winding 22 are supported on the inner surface of the recess 1131, and the side edge of the sub-cover plate 121 is spaced apart from the inner surface of the recess 1131. In this case, all sub-cores 12 are located on the same side of the common post 113.

[0083] In some embodiments, the sub-core 12 is joined to the main core 11, specifically, the sub-core 12 and the main core 11 are bonded together. As an example, the main winding post 112 of the main core 11 is bonded to the sub-cover plate 121 of the sub-core 12. Of course, in some embodiments, the main winding post 112 of the main core 11 can also be bonded to the sub-winding post 122 of the sub-core 12.

[0084] In some embodiments, two main magnetic cores 11 are arranged opposite to each other, and the common post 113 of one main magnetic core 11 is bonded to the common post 113 of the other main magnetic core 11.

[0085] In some embodiments, there are multiple sub-cores 12, and different sub-cores 12 are bonded together. As an example, the sub-cover plate 121 of one sub-core 12 is bonded to the sub-winding post 122 of another sub-core 12; or, the sub-winding post 122 of one sub-core 12 is bonded to the sub-winding post 122 of another sub-core 12.

[0086] The sub-core 12 is connected to the main core 11 and different sub-cores 12 by bonding, which facilitates manufacturing.

[0087] In some embodiments, the sub-core 12 is located between the main winding posts 112 of two opposing main cores 11, and the total length of the main winding posts 112 and the sub-core 12 is equal to the total length of the common post 113. Here, the total length of the main winding posts 112 and the sub-core 12 refers to the sum of the lengths of the main winding posts 112 of the two main cores 11 and the lengths of all the sub-cores 12. The total length of the common post 113 is the sum of the lengths of the common posts 113 of the two main cores 11. In this case, the winding 2 can be configured as a coil structure, with the winding 2 nested between the main winding posts 112 and the sub-winding posts 122, which helps to improve the assembly efficiency of the magnetic assembly 10.

[0088] In some implementations, please refer to Figure 2 , Figure 5 and Figure 6The number of sub-cores 12 is greater than one. All sub-cores 12 are sequentially spliced ​​together, and the sub-cover plate 121 is located between two adjacent primary windings 21 and secondary windings 22. That is, one primary winding 21 is located on one side of the sub-cover plate 121 and adjacent to it, and one secondary winding 22 is located on the other side of the sub-cover plate 121 and also adjacent to it. Specifically, all sub-cores 12 are sequentially arranged along a first direction, which is the direction from one main core 11 to another main core 11, such as the direction from the first main core 1101 to the second main core 1102. That is, the first direction can be the radial direction along the winding post of the magnetic assembly. The advantage of this arrangement is that the magnetic assembly 10 is not only compact in structure, but also easy to control in volume. The number of sub-cores 12 is greater than one, that is, the number of sub-cores 12 is two or more. As an example, the number of sub-cores 12 is 2, 3, 4, 5, 6, 7 or 8. It should be noted that when there are multiple sub-cores 12, each sub-core 12 can be identical or different. Optionally, the sub-cores 12 can be identical, meaning that the material, dimensions, etc., of each sub-core 12 are the same. This simplifies the production process of the sub-cores 12 and reduces the production cost of the magnetic assembly 10. Optionally, the sub-cores 12 can be different, meaning that at least one aspect of each sub-core 12 is different, such as material or dimensions. For example, the thickness of the sub-cover plate 121 or the length of the sub-winding post 122 may differ between different sub-cores 12. By differentiating the sub-cores 12, the performance of the magnetic assembly 10 can be further adjusted.

[0089] In the first direction, all sub-cores 12 are sequentially spliced ​​together, specifically meaning that all sub-cores 12 are distributed sequentially and arranged sequentially. It should be noted that when all sub-cores 12 are sequentially spliced ​​together, they can all face the same direction, or some sub-cores 12 can face opposite directions. Furthermore, when facing opposite directions, adjacent sub-cores 12 can be arranged face-to-face or back-to-back. Here, face-to-face arrangement between adjacent sub-cores 12 means that the winding post 122 of one sub-core 12 faces the winding post 122 of another sub-core 12; back-to-back arrangement between adjacent sub-cores 12 means that the cover plate 121 of one sub-core 12 is connected to the cover plate 121 of another sub-core 12.

[0090] In some embodiments, among all the sub-cores 12 that are sequentially assembled, between any two adjacent sub-cores 12, the sub-cover plate 121 of one sub-core 12 contacts the sub-winding post 122 of the other sub-core 12. It is understood that in this case, all the sub-cores 12 have the same orientation.

[0091] In some embodiments, the magnetic assembly 10 includes at least two adjacent sub-cores 12 disposed opposite each other. That is, the magnetic assembly 10 includes a plurality of sub-cores 12, and at least two adjacent sub-cores 12 are disposed opposite each other. See also... Figure 5 and Figure 6 In all the sub-cores 12 that are sequentially assembled, at least two adjacent sub-cores 12 are arranged opposite each other. This simplifies the manufacturing process of the magnetic assembly 10 and reduces production costs.

[0092] In some embodiments, the number of sub-cores 12 is 2n, where n≥1, that is, the number of sub-cores 12 is an even number. The two sub-cores 12 located in the middle can be arranged opposite each other, which further simplifies the manufacturing process of the magnetic component 10 and reduces production costs. Of course, in other cases, the two sub-cores 12 at the beginning of all sub-cores 12 can also be arranged opposite each other, or the two sub-cores 12 at the end can be arranged opposite each other.

[0093] In some implementations, please refer to Figure 2 When n=1, there are two primary windings 21 and two secondary windings 22. Specifically, when n=1, there are two sub-cores 12, and the two sub-cores 12 are arranged opposite each other. It can be understood that in the first direction, the main winding post 112, sub-cover plate 121, sub-winding post 122, sub-winding post 122, sub-cover plate 121, and main winding post 112 are arranged in sequence. It can be seen that the sub-winding posts 122 of the two sub-cores 12 are adjacent, and there is no sub-cover plate 121 between the two sub-winding posts 122. The same type of winding 2 can be set on the two sub-winding posts 122. For example, the primary winding 21 can be set on both sub-winding posts 122, or the secondary winding 22 can be set on both. Alternatively, the opposite type of winding 2 can be set on the two sub-winding posts 122. For example, the primary winding 21 can be set on one sub-winding post 122, and the secondary winding 22 can be set on the other sub-winding post 122.

[0094] Optionally, along the first direction, the primary winding 21 and the secondary winding 22 are alternately distributed, that is, along the first direction, the windings 2 are arranged in the following order: primary winding 21, secondary winding 22, primary winding 21, secondary winding 22. In this way, the first group of primary windings 21 and secondary windings 22 is separated by a sub-cover plate 121, and the second group of primary windings 21 and secondary windings 22 is separated by another sub-cover plate 121.

[0095] Optionally, along the first direction, the primary windings 21 are all disposed on the main winding post 112, and the secondary windings 22 are all disposed on the secondary winding post 122. That is, along the first direction, the windings 2 are arranged in the following order: primary winding 21, secondary winding 22, secondary winding 22, primary winding 21. This can also form a first group of primary windings 21 and secondary windings 22 separated by a sub-cover plate 121, and a second group of primary windings 21 and secondary windings 22 separated by another sub-cover plate 121.

[0096] Optionally, along the first direction, the secondary windings 22 are all disposed on the primary winding post 112, and the primary windings 21 are all disposed on the secondary winding post 122. That is, along the first direction, the windings 2 are arranged in the following order: secondary winding 22, primary winding 21, primary winding 21, secondary winding 22. In this way, the first group of secondary windings 22 and primary windings 21 can still be separated by a sub-cover plate 121, and the second group of secondary windings 22 and primary windings 21 can be separated by another sub-cover plate 121.

[0097] In some implementations, please refer to Figure 5 and Figure 6 When n=2, the number of sub-cores 12 is four. Specifically, along the first direction (in Figure 5 and Figure 6 (From left to right) Four sub-cores 12 are arranged sequentially. The first and second sub-cores 12 face the same direction, while the second and third sub-cores 12 face opposite directions. Specifically, the second and third sub-cores 12 are positioned opposite each other, and the third and fourth sub-cores 12 face the same direction. Additionally, there are three primary windings 21 and three secondary windings 22. Since there are four sub-cores 12, there are four sub-winding posts 122. Since there are two main cores 11, there are two main winding posts 112. Thus, the three primary windings 21 and three secondary windings 22 can be respectively set on the four sub-winding posts 122 and the two sub-winding posts 122. Typically, one primary winding 21 or one secondary winding 22 is set on one sub-winding post 122, and one primary winding 21 or one secondary winding 22 is also set on one main winding post 112.

[0098] See also Figure 5 and Figure 6As can be seen, except for the absence of a sub-cover plate 121 between the sub-winding post 122 of the second sub-core 12 and the sub-winding post 122 of the third sub-core 12, sub-cover plates 121 are provided between other sub-winding posts 122 and between sub-winding posts 122 and the main winding post 112. When setting the winding 2, the primary winding 21 and the secondary winding 22 can be alternately set in the opposite direction of the first direction, starting from the winding type (primary winding 21 or secondary winding 22) on the sub-winding post 122 of the second sub-core 12, and the primary winding 21 and the secondary winding 22 can be alternately set in the first direction, starting from the winding type on the sub-winding post 122 of the third sub-core 12.

[0099] Optionally, the same type of winding 2 is provided on both the sub-winding post 122 of the second sub-core 12 and the sub-winding post 122 of the third sub-core 12. See [example description missing] for an example. Figure 5 Primary windings 21 are provided on the sub-winding posts 122 of the second and third sub-cores 12. Then, in the opposite direction of the first direction, secondary windings 22 are provided on the sub-winding posts 122 of the first sub-core 12, and primary windings 21 are provided on the main winding post 112 on the left. In the same direction, secondary windings 22 are provided on the sub-winding posts 122 of the fourth sub-core 12, and primary windings 21 are provided on the main winding post 112 on the right. Of course, in some embodiments, secondary windings 22 can also be provided on both the sub-winding post 122 of the second sub-core 12 and the sub-winding post 122 of the third sub-core 12. In this way, in the opposite direction of the first direction, the primary winding 21 is provided on the sub-winding post 122 of the first sub-core 12, and the secondary winding 22 is provided on the main winding post 112 on the left. In the first direction, the primary winding 21 is provided on the sub-winding post 122 of the fourth sub-core 12, and the secondary winding 22 is provided on the main winding post 112 on the right.

[0100] Optionally, windings 2 of opposite types are provided on the sub-winding posts 122 of the second and third sub-cores 12, respectively. See [example description missing] for an example. Figure 6 A primary winding 21 is set on the sub-winding post 122 of the second sub-core 12. In the opposite direction of the first direction, a secondary winding 22 is set on the sub-winding post 122 of the first sub-core 12, and a primary winding 21 is set on the main winding post 112 on the left. A secondary winding 22 is set on the sub-winding post 122 of the third sub-core 12. In the first direction, a primary winding 21 is set on the sub-winding post 122 of the fourth sub-core 12, and a secondary winding 22 is set on the main winding post 112 on the right.

[0101] In some embodiments, the magnetic assembly 10 includes at least two adjacent sub-cores 12 arranged opposite to each other. That is, the magnetic assembly 10 includes a plurality of sub-cores 12, and at least two adjacent sub-cores 12 are arranged opposite each other.

[0102] In some embodiments, the number of sub-cores 12 is 2n, where n≥1, that is, the number of sub-cores 12 is an even number, and the two middle sub-cores 12 can be arranged back to back. Of course, in other cases, the two first sub-cores 12 or the two last sub-cores 12 can also be arranged back to back.

[0103] In some embodiments, when n=1, there is one primary winding 21 and one secondary winding 22. Specifically, when n=1, there are two sub-cores 12, and the two sub-cores 12 are arranged opposite to each other. It can be understood that in the first direction, the main winding post 112, the sub-winding post 122, the sub-cover plate 121, the sub-cover plate 121, the sub-winding post 122, and the main winding post 112 are arranged in sequence. One primary winding 21 is disposed on a pair of adjacent main winding posts 112 and sub-winding posts 122, and one secondary winding 22 is disposed on another pair of adjacent winding posts 112 and sub-winding posts 122. In this case, the two sub-cover plates 121 are located between one primary winding 21 and one secondary winding 22.

[0104] In some embodiments, when n=2, the number of sub-cores 12 is four. Specifically, the four sub-cores 12 are arranged sequentially along the first direction, wherein the first sub-core 12 and the second sub-core 12 have the same orientation, and the second sub-core 12 and the third sub-core 12 have opposite orientations. Specifically, the second sub-core 12 and the third sub-core 12 are arranged opposite each other, and the third sub-core 12 and the fourth sub-core 12 have the same orientation. It can be seen that one or two sub-cover plates 121 are provided between the sub-wound posts 122 of different sub-cores 12, but there are no sub-cover plates 121 between the sub-wound posts 122 of the sub-core 12 and the main winding post 112 of the main core 11. When setting the winding 2, along the first direction, the primary winding 21 and the secondary winding 22 can be alternately distributed on all the sub-wound posts 122, and the winding type on the main winding post 112 can be the same as the winding type on the adjacent sub-wound post 122.

[0105] In some embodiments, the magnetic component 10 includes a plurality of sub-cores 12, wherein some sub-cores 12 are arranged opposite each other and some sub-cores 12 are arranged opposite each other.

[0106] As an example, the magnetic component 10 includes four sub-cores 12 arranged sequentially along a first direction, wherein the first sub-core 12 and the second sub-core 12 are arranged opposite each other, the second sub-core 12 and the third sub-core 12 are arranged opposite each other, and the third sub-core 12 and the fourth sub-core 12 are arranged opposite each other.

[0107] In some implementations, the number of sub-cores 12 may also be an odd number, such as one, three, five, or more.

[0108] In some embodiments, there is one sub-core 12. The sub-cover plate 121 of the sub-core 12 is connected to one of the main winding posts 112, and the sub-winding post 122 of the sub-core 12 is connected to the other main winding post 112. Optionally, a primary winding 21 is provided on one of the main winding posts 112, and a secondary winding 22 is provided on the sub-winding post 122 and the other main winding post 112. Optionally, a secondary winding 22 is provided on one of the main winding posts 112, and a primary winding 21 is provided on the sub-winding post 122 and the other main winding post 112.

[0109] In some embodiments, the number of sub-cores 12 is three. The winding 2 includes two primary windings 21 and two secondary windings 22.

[0110] Optionally, the three sub-cores 12 are oriented in the same direction. As an example, along the first direction, the primary winding 21 and the secondary winding 22 are alternately arranged, in which a sub-winding post 122 and the main winding post 112 connected to it jointly carry the same primary winding 21 or secondary winding 22.

[0111] Optionally, in the three sub-cores 12, two adjacent sub-cores 12 are arranged opposite each other, and the two adjacent sub-cores 12 face the same direction. As an example, along the first direction, the primary winding 21 and the secondary winding 22 are arranged alternately, but the sub-winding posts 122 of the two opposite sub-cores 12 carry the same primary winding 21 or secondary winding 22.

[0112] It should be noted that, in this embodiment, the lengths of the main winding posts 112 on the two main magnetic cores 11 can be the same or different. When there are multiple sub-magnetic cores 12, the lengths of the sub-winding posts 122 on different sub-magnetic cores 12 can be the same or different. When designing the magnetic assembly 10, adjusting the lengths of the main winding posts 112 and the sub-winding posts 122 allows for more flexible design of the magnetic assembly 10, enhancing its versatility.

[0113] Secondly, embodiments of this application also provide a switching power supply, which includes the aforementioned magnetic component 10.

[0114] In some implementations, the switching power supply includes a charger. As an example, the charger is an on-board charger.

[0115] The embodiments of this application have been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of this application. The description of the above embodiments is only for the purpose of helping to understand the method and core ideas of this application. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of this application. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A magnetic component, characterized in that, Includes magnetic core and windings; The magnetic core includes two main magnetic cores arranged opposite to each other and at least one sub-magnetic core, wherein the sub-magnetic core is disposed between the main magnetic cores; The main magnetic core includes a main cover plate, a main winding post, and a common post. One end of the main winding post and the common post are connected to the main cover plate. The number of the common post is at least one. The sub-core includes a sub-cover plate and a sub-winding post with one end connected to the sub-cover plate; The winding is disposed on the main winding post and the sub-winding post, and the winding includes a primary winding and a secondary winding; the sub-cover plate is used to separate the primary winding and the secondary winding.

2. The magnetic component according to claim 1, characterized in that, The sub-cover plate is configured to at least partially protrude from the sub-winding post in the radial direction; the cross-sectional area of ​​the main winding post is the same as that of the sub-winding post.

3. The magnetic component according to claim 2, characterized in that, The sub-core is a T-shaped core, and the sub-cover plate and the sub-winding post are integrally formed.

4. The magnetic component according to claim 3, characterized in that, The number of sub-cores is greater than 1, and all the sub-cores are spliced ​​together in sequence. The sub-cover plate is located between two adjacent primary windings and secondary windings.

5. The magnetic component according to claim 4, characterized in that, It includes at least two adjacent sub-cores arranged opposite or back to each other.

6. The magnetic component according to claim 5, characterized in that, The number of sub-cores is 2n, where n≥1, and the two sub-cores located in the middle are arranged opposite or back to back.

7. The magnetic component according to claim 6, characterized in that, When n=1 and the two sub-cores are arranged opposite each other, the number of the primary winding and the secondary winding is 2 each; The primary winding and the secondary winding are alternately arranged; or, all the primary windings are arranged on the main winding post and all the secondary windings are arranged on the sub-winding post; or, all the primary windings are arranged on the sub-winding post and all the secondary windings are arranged on the main winding post.

8. The magnetic component according to any one of claims 4-7, characterized in that, The sub-cores are bonded together with the main core, as are adjacent sub-cores.

9. The magnetic component according to claim 8, characterized in that, The winding is a disc structure, and the sub-core is located between the main winding posts of the two main cores arranged opposite each other. The total length of the main winding posts and the sub-core is equal to the total length of the common post.

10. A switching power supply, characterized in that, Includes the magnetic component as described in any one of claims 1-9.

Images