Magnetic integration device and apparatus
By employing magnetically integrated devices in inductors or transformers and utilizing the design of common magnetic pillars and ring structures, uniform magnetic flux distribution and cancellation are achieved, solving the loss problem caused by uneven magnetic flux, improving power supply efficiency and reducing size.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-03-21
- Publication Date
- 2026-03-27
AI Technical Summary
Existing inductors and transformers suffer from large size and low efficiency, especially due to significant losses caused by uneven magnetic flux distribution.
A magnetic integration device is adopted, which connects the first base plate and the second base plate through a common magnetic column to form a ring structure. A winding column is set in the ring. Two magnetic devices are constructed using the common magnetic column to make the magnetic flux distribution more uniform. Magnetic flux cancellation is achieved by setting magnetic resistance to reduce losses.
It improves power efficiency, reduces core size, lowers losses, increases power density, and enhances device consistency and manufacturing precision.
Smart Images
Figure CN224052977U_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application mainly relates to the field of power electronics, in particular to a magnetic integrated device and equipment. BACKGROUND
[0002] In modern power electronics and power management systems, inductors and transformers are key electromagnetic components in power converters, which are mainly used for electromagnetic conversion in circuits to achieve energy transmission, electrical isolation, etc., and are widely used in all power conversion devices such as charging piles, network power supplies, vehicle-mounted power supplies, etc. However, in existing inductors or transformers, there are still limitations of technical problems such as volume and weight, efficiency bottleneck, etc. CONTENT OF THE INVENTION
[0003] The main purpose of the present application is to provide a magnetic integrated device and equipment to solve the problems of large volume of inductor or transformer and large loss caused by uneven distribution of magnetic flux, resulting in low efficiency, so as to reduce the volume of the device and improve the efficiency.
[0004] To solve the above problems, the present application provides a magnetic integrated device, which comprises a first bottom plate, a second bottom plate, a common magnetic column, a first side column, a second side column, a third side column, a fourth side column and a plurality of winding columns; the common magnetic column is arranged between the first bottom plate and the second bottom plate; one end of the first side column is connected with the first bottom plate, and the other end is connected with the common magnetic column; one end of the second side column is connected with the first bottom plate, and the other end is connected with the common magnetic column, forming a first annular; one end of the third side column is connected with the second bottom plate, and the other end is connected with the common magnetic column; one end of the fourth side column is connected with the second bottom plate, and the other end is connected with the common magnetic column, forming a second annular; the same number of winding columns are distributed in the first annular and the second annular; in the first annular, one end of each winding column is connected with the first bottom plate, and the other end is connected with the common magnetic column; in the second annular, one end of each winding column is connected with the second bottom plate, and the other end is connected with the common magnetic column; a coil is sleeved on each winding column.
[0005] In an embodiment, the first bottom plate, the second bottom plate and the common magnetic column are distributed in parallel with each other; the two ends of the first bottom plate, the two ends of the second bottom plate and the two ends of the common magnetic column are flush.
[0006] In an embodiment, the first side column and the second side column are distributed in parallel; the third side column and the fourth side column are distributed in parallel; the first side column and the third side column are oppositely arranged, and the second side column and the fourth side column are oppositely arranged.
[0007] In an embodiment, the winding columns in the first annular and the winding columns in the second annular are arranged one by one in the first direction.
[0008] In an embodiment, the first annular interior and the second annular interior are each provided with three winding posts, and the three winding posts in the first annular interior and the three winding posts in the second annular interior are distributed one-to-one to form a two-way three-phase structure.
[0009] In an embodiment, the magnetic integration device further comprises a plurality of first magnetic resistances, which are arranged between the first side post and the common magnetic post, between the second side post and the common magnetic post, between the third side post and the common magnetic post, and between the fourth side post and the common magnetic post.
[0010] In an embodiment, the first bottom plate comprises at least a first sub-bottom plate, a second sub-bottom plate, and a third sub-bottom plate; a second magnetic resistance is arranged between the first sub-bottom plate and the second sub-bottom plate; a second magnetic resistance is arranged between the second sub-bottom plate and the third sub-bottom plate; the second bottom plate comprises at least a fourth sub-bottom plate, a fifth sub-bottom plate, and a sixth sub-bottom plate; a second magnetic resistance is arranged between the fourth sub-bottom plate and the fifth sub-bottom plate; a second magnetic resistance is arranged between the fifth sub-bottom plate and the sixth sub-bottom plate.
[0011] In an embodiment, the first sub-bottom plate and the first side post are in an integrated structure, the third sub-bottom plate and the second side post are in an integrated structure, the fourth sub-bottom plate and the third side post are in an integrated structure, and the sixth sub-bottom plate and the fourth side post are in an integrated structure.
[0012] In an embodiment, the number of sub-bottom plates in the first bottom plate is the same as the number of winding posts in the first annular interior, the number of sub-bottom plates in the second bottom plate is the same as the number of winding posts in the second annular interior, and the winding posts and the sub-bottom plates correspond one-to-one.
[0013] In an embodiment, the common magnetic post comprises at least a first common magnetic post, a second common magnetic post, and a third common magnetic post; a third magnetic resistance is arranged between the first common magnetic post and the second common magnetic post; a third magnetic resistance is arranged between the second common magnetic post and the third common magnetic post.
[0014] In an embodiment, a first middle post is arranged between adjacent winding posts in the first annular interior; one end of the first middle post is connected to the first bottom plate, and the other end is connected to the common magnetic post; a second middle post is arranged between adjacent winding posts in the second annular interior; one end of the second middle post is connected to the second bottom plate, and the other end is connected to the common magnetic post.
[0015] In an embodiment, a fifth magnetic resistance is arranged between the other end of the first middle post and the common magnetic post; a fifth magnetic resistance is arranged between the other end of the second middle post and the common magnetic post.
[0016] In an embodiment, the number of common magnetic posts is the same as the number of winding posts in the first annular interior, and the winding posts and the common magnetic posts correspond one-to-one.
[0017] To solve the above problems, the application further provides a magnetic integrated device, which comprises: a magnetic integrated device, the magnetic integrated device being as described in any one of the above embodiments; a switch module, one end of the switch module being coupled to the magnetic integrated device; and a power supply, the power supply being coupled to the other end of the switch module and the magnetic integrated device, so as to realize step-up and step-down control by controlling the on-off of the switch module.
[0018] The application provides a magnetic integrated device and equipment, two magnetic devices are constructed by a common magnetic column, so that the magnetic flux distribution in the magnetic core is more uniform and has a larger partial cancellation effect, so as to solve the problem that the local magnetic density of the side column and the bottom plate of the magnetic core is too large due to the unbalanced magnetic flux distribution in the actual application of magnetic integration, which leads to a large loss, so as to improve the power efficiency and reduce the volume. BRIEF DESCRIPTION OF DRAWINGS
[0019] In order to more clearly illustrate the technical solutions in the embodiments of the application, the drawings needed to be used in the embodiment description will be briefly introduced as follows. Obviously, the drawings in the following description are only some embodiments of the application, and other drawings can be obtained by those skilled in the art without creative labor. Among them:
[0020] Figure 1 is a structural schematic diagram of a first embodiment of the magnetic integrated device provided by the application;
[0021] Figure 2 is a structural schematic diagram of a second embodiment of the magnetic integrated device provided by the application;
[0022] Figure 3 is a structural schematic diagram of a third embodiment of the magnetic integrated device provided by the application;
[0023] Figure 4 is a structural schematic diagram of a fourth embodiment of the magnetic integrated device provided by the application;
[0024] Figure 5 is a structural schematic diagram of a fifth embodiment of the magnetic integrated device provided by the application;
[0025] Figure 6 is a structural schematic diagram of a sixth embodiment of the magnetic integrated device provided by the application;
[0026] Figure 7 is a structural schematic diagram of a seventh embodiment of the magnetic integrated device provided by the application;
[0027] Figure 8a is Figure 2 the corresponding simulation effect schematic diagram in the scheme;
[0028] Figure 8b is Figure 3A corresponding simulation effect schematic diagram in the scheme;
[0029] Figure 9 is a structural schematic diagram of an embodiment of the winding post provided in the present application;
[0030] Figure 10 is a structural schematic diagram of the eighth embodiment of the magnetic integration device provided in the present application;
[0031] Figure 11 is a structural schematic diagram of the ninth embodiment of the magnetic integration device provided in the present application;
[0032] Figure 12 is a structural schematic diagram of the tenth embodiment of the magnetic integration device provided in the present application;
[0033] Figure 13 is a structural schematic diagram of an embodiment of the magnetic integration device provided in the present application;
[0034] Figure 14 is a structural schematic diagram of an embodiment of the switch module provided in the present application.
[0035] Reference signs:
[0036] 100, magnetic integration device; 110, first ring; 120, second ring; 10a, sub bottom plate; 10, first bottom plate; 11, first sub bottom plate; 12, second sub bottom plate; 13, third sub bottom plate; 20, second bottom plate; 21, fourth sub bottom plate; 22, fifth sub bottom plate; 23, sixth sub bottom plate; 30, common magnetic post; 31, first common magnetic post; 32, second common magnetic post; 33, third common magnetic post; 40, first side post; 41, second side post; 42, third side post; 43, fourth side post; 50, winding post; 51, segmented magnetic post; 52, fourth magnetic resistance; 60, first magnetic resistance; 70, second magnetic resistance; 71, first sub magnetic resistance; 80, third magnetic resistance; 81, second sub magnetic resistance; 90, first middle post; 91, second middle post; 92, fifth magnetic resistance; 200, magnetic integration device; 210, switch module; 220, power supply. DETAILED DESCRIPTION
[0037] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. It can be understood that the specific embodiments described herein are only used to explain the present application, rather than limit the present application. In addition, it should be noted that, for the convenience of description, only the parts related to the present application are shown in the drawings, rather than all the structures. Based on the embodiments in the present application, all the other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.
[0038] The terms "first", "second", etc. in this application are used to distinguish different objects, rather than to describe a particular order. In addition, the terms "include" and "have" and any variations thereof are intended to cover non-exclusive inclusion. For example, a process, method, system, product or device including a series of steps or units is not limited to the listed steps or units, but can optionally further include steps or units not listed, or can optionally further include other steps or units inherent to the process, method, product or device.
[0039] Reference herein to "embodiments" means that a particular feature, structure, or characteristic described in connection with an embodiment can be included in at least one embodiment of the application. The appearance of the phrase in various places in the specification does not necessarily all refer to the same embodiment, nor is it necessarily independent of other embodiments. It will be explicitly understood by one skilled in the art that the embodiments described herein can be combined with other embodiments.
[0040] In a conventional inductor or transformer, a discrete structure is usually used, such as a conventional EE, EQ type electric core, but using the above structure has the problems of large volume, many assembly processes, the need for many components, large space occupation, the need for multiple assemblies, large loss, large total volume of multiple devices and no mutual offset of magnetic flux, poor device consistency, actual processing, and difficulty in ensuring consistent performance of each device, etc. Or a three-phase integrated transformer, the side column is fixed by side bonding, in which the three-phase (three winding columns) inductor or transformer is integrated in the same pair of magnetic cores, the total volume is small, but this scheme also has the problems of magnetic core side column point fixing, introducing large magnetic resistance, affecting the uniformity of integrated magnetic flux distribution, large loss, the thickness of the adhesive layer of the magnetic core bonding is greatly affected by the operation factors, the loss fluctuation is large, and it is not easy to control; there is a scheme of four common magnetic columns that need to be bonded, the middle two magnetic columns occupy length space, the integration degree is low, the volume is large, etc.
[0041] Therefore, the present application provides a magnetic integrated device and equipment to solve the above problems.
[0042] Referring to Figure 1 As shown, Figure 1 is a structural schematic diagram of a first embodiment of a magnetic integrated device provided by the present application; the magnetic integrated device 100 comprises a first bottom plate 10, a second bottom plate 20, a common magnetic column 30, a first side column 40, a second side column 41, a third side column 42, a fourth side column 43, and a plurality of winding columns 50.
[0043] The common magnetic post 30 is disposed between the first base plate 10 and the second base plate 20; one end of the first side post 40 is connected to the first base plate 10 and the other end is connected to the common magnetic post 30; one end of the second side post 41 is connected to the first base plate 10 and the other end is connected to the common magnetic post 30, forming a first ring 110; one end of the third side post 42 is connected to the second base plate 20 and the other end is connected to the common magnetic post 30; one end of the fourth side post 43 is connected to the second base plate 20 and the other end is connected to the common magnetic post 30, forming a second ring 120; the same number of winding posts 50 are distributed in the first ring 110 and the second ring 120; in the first ring 110, one end of each winding post 50 is connected to the first base plate 10 and the other end is connected to the common magnetic post 30; in the second ring 120, one end of each winding post 50 is connected to the second base plate 20 and the other end is connected to the common magnetic post 30; a coil is sleeved on each winding post 50.
[0044] The coils include, but are not limited to, wire windings and PCB windings, and can be other forms that produce the same excitation function. The direction of the magnetic flux generated by the coil in the magnetic circuit can be adjusted according to the actual application. Furthermore, the core shapes mentioned above include, but are not limited to, those described. While ensuring the above integrated configuration, the shape and spacing of the magnetic pillars are adjustable.
[0045] In one embodiment, the first base plate 10, the second base plate 20, and the common magnetic post 30 are distributed in parallel to each other; the two ends of the first base plate 10, the two ends of the second base plate 20, and the two ends of the common magnetic post 30 are flush.
[0046] In one embodiment, the first side post 40 and the second side post 41 are distributed in parallel; the third side post 42 and the fourth side post 43 are distributed in parallel; the first side post 40 and the third side post 42 are arranged opposite to each other, and the second side post 41 and the fourth side post 43 are arranged opposite to each other.
[0047] Specifically, such as Figure 1 As shown, the first base plate 10 and the second base plate 20 are arranged in parallel, the first side post 40 and the second side post 41 are arranged in parallel, and the third side post 42 and the fourth side post 43 are arranged in parallel. Similarly, the winding posts 50 within the same ring, for example, multiple winding posts 50 within the first ring 110 or the second ring 120, are also arranged in parallel. Conversely, the first base plate 10, the second base plate 20, and the common magnetic post 30 are also arranged in parallel. Furthermore, the two ends of the first base plate 10, the two ends of the second base plate 20, and the two ends of the common magnetic post 30 are flush.
[0048] In this application, the first base plate 10, the second base plate 20, and the common magnetic column 30 are arranged in parallel. The vertical distance between the common magnetic column 30 and the first base plate 10 is the same as or different from the vertical distance between the common magnetic column 30 and the second base plate 20. Preferably, the vertical distance between the common magnetic column 30 and the first base plate 10 is the same as the vertical distance between the common magnetic column 30 and the second base plate 20.
[0049] In this application, the first side post 40 and the second side post 41 are perpendicularly distributed to the first base plate 10 and the common magnetic post 30; the third side post 42 and the fourth side post 43 are perpendicularly distributed to the common magnetic post 30 and the second base plate 20; the winding post 50 in the first ring 110 is perpendicular to the first base plate 10 and the common magnetic post 30; the winding post in the second ring 120 is perpendicular to the common magnetic post 30 and the second base plate 20.
[0050] In one embodiment, three winding posts 50 are respectively provided inside the first ring 110 and the second ring 120. The three winding posts 50 in the first ring and the three winding posts 50 in the second ring 120 are distributed in a one-to-one correspondence to form a two-way three-phase structure.
[0051] In one embodiment, the winding posts 50 in the first annulus 110 and the winding posts 50 in the second annulus 120 are arranged in a one-to-one correspondence along a first direction. The first direction is as follows: Figure 1 As shown, specifically, the first direction is the direction perpendicular to the common magnetic post 30.
[0052] like Figure 1 As shown, in one embodiment, there are six winding posts 50. Three winding posts 50 are located in the first ring 110, and three winding posts 50 are located in the second ring 120. The three winding posts 50 in the first ring 110 and the three winding posts 50 in the second ring 120 are arranged in a one-to-one correspondence along a first direction to form a two-way three-phase structure. In this magnetic integrated device 100, there are six excitation magnetic coils, each wound on one of the winding posts 50, generating magnetic fluxes of equal amplitude and the same direction on each of the six winding posts 50. The magnetic fluxes L1_1&L1_2, L2_1&L2_2, and L3_1&L3_2 are either identical or have a phase difference, for example, 90°, 180°, etc. The phase difference between L1_1&L2_1&L3_1 and L1_2&L2_2&L3_2 is 120°, forming a specific function power converter with the corresponding conversion circuit.
[0053] In the above configuration, the DC magnetic fluxes of L1_1&L1_2, L2_1&L2_2, and L3_1&L3_2 almost completely cancel each other out in the common pillars of their corresponding regions. The AC magnetic fluxes are superimposed or canceled out. In one embodiment, the overall magnetic flux is reduced by cancellation, and the thickness of the magnetic pillars can be reduced to decrease the volume. At the same time, since the phase difference between L1_1&L2_1&L3_1 and L1_2&L2_2&L3_2 is 120°, their magnetic fluxes cancel out in the bottom and side pillars, which can also reduce the effective cross-sectional area of the bottom and side pillars to reduce the overall volume of the magnetic core, or significantly reduce the overall loss of the magnetic core without reducing the volume.
[0054] By employing the above method and combining 3 components into 2 channels, the cross-sectional area of the magnetic core is highly utilized, magnetic flux cancellation is sufficient, and magnetic density distribution is uniform. Compared with traditional integration methods, the average core loss is reduced by 30%+, effectively improving power efficiency. Simultaneously, the magnetic flux distribution of the core can be adjusted to be uniform (Φd1=Φd2), where Φd1 and Φd2 refer to the magnetic flux in different regions of the bottom magnetic core. There are no high magnetic density points or local saturation problems; the cross-sectional area in the middle of the core base plate can be reduced by 20%+, and the total core volume can be reduced by 20%+, achieving higher power density. The inductance tolerance, magnetic flux distribution, and processing consistency of the integrated magnetic components are significantly improved.
[0055] In one embodiment, such as Figure 2 As shown, Figure 2 This is a schematic diagram of the structure of the second embodiment of the magnetic integration device provided in this application; wherein, the magnetic integration device 100 further includes: a plurality of first magnetic reluctances 60, the plurality of first magnetic reluctances 60 being disposed between the first side post 40 and the common magnetic post 30, between the second side post 41 and the common magnetic post 30, between the third side post 42 and the common magnetic post 30, and between the fourth side post 43 and the common magnetic post 30.
[0056] In the magnetic circuit, multiple first magnetoresistances 60 are provided, which can be implemented in ways including but not limited to bonded air gaps. These gaps can be made of any material with a relative permeability smaller than that of the main magnetic core μr, or they can be divided into multiple bonded sections. Here, the relative permeability μr is the ratio of the material's permeability to the vacuum permeability μ0, and is used to measure the material's magnetic permeability performance.
[0057] In one embodiment, such as Figure 3 As shown, Figure 3is a structural schematic diagram of a third embodiment of the magnetic integrated device provided in the present application; the first bottom plate 10 comprises at least a first sub-bottom plate 11, a second sub-bottom plate 12 and a third sub-bottom plate 13; the first sub-bottom plate 11 and the second sub-bottom plate 12 are provided with a second magnetic resistance 70; the second sub-bottom plate 12 and the third sub-bottom plate 13 are provided with a second magnetic resistance 70; the second bottom plate 20 comprises at least a fourth sub-bottom plate 21, a fifth sub-bottom plate 22 and a sixth sub-bottom plate 23; the fourth sub-bottom plate 21 and the fifth sub-bottom plate 22 are provided with a second magnetic resistance 70; the fifth sub-bottom plate 22 and the sixth sub-bottom plate 23 are provided with a second magnetic resistance 70.
[0058] In another embodiment, the second magnetic resistance 70 is arranged between adjacent winding columns 50, as shown in detail in Figure 3 .
[0059] It can be understood that the implementation of the second magnetic resistance 70 also includes but is not limited to bonding air gaps, and can be any material with a relative magnetic permeability smaller than that of the main magnetic core μr(bonding or filling), or can be divided into multiple bonding forms.
[0060] In the above embodiments, the first magnetic resistance 60 and the second magnetic resistance 70 can be used alone or in combination, and by adjusting the first magnetic resistance 60 and the second magnetic resistance 70 together, a more uniform magnetic flux distribution of the side column and / or the bottom plate can be obtained, lower magnetic core loss can be achieved, and the parameters are easy to produce and control.
[0061] In an embodiment, as shown in Figure 3 , the first sub-bottom plate 11 and the first side column 40 are integrated, the third sub-bottom plate 13 and the second side column 41 are integrated, the fourth sub-bottom plate 21 and the third side column 42 are integrated, and the sixth sub-bottom plate 23 and the fourth side column 43 are integrated.
[0062] In an embodiment, as shown in Figure 3 , the number of sub-bottom plates in the first bottom plate 10 is the same as the number of winding columns 50 in the first annular 110, and the sub-bottom plates in the first bottom plate 10 correspond one-to-one to the winding columns in the first annular 110, and the second magnetic resistance 70 is arranged between the adjacent two sub-bottom plates in the first bottom plate 10, and the second magnetic resistance 70 is arranged between the adjacent two winding columns 50 in the adjacent first annular 110; the number of sub-bottom plates in the second bottom plate 20 is the same as the number of winding columns 50 in the second annular 120, and the second magnetic resistance 70 is arranged between the adjacent two sub-bottom plates in the second bottom plate 20, and the second magnetic resistance 70 is arranged between the adjacent two winding columns 50 in the second annular 120, and the winding columns 50 in the second annular 120 correspond one-to-one to the sub-bottom plates in the second bottom plate 20.
[0063] As shown in Figure 3As shown, the number of winding posts 50 therein is taken as an example of 6, wherein the winding posts 50 within the first annular 110 are arranged as 3, the winding posts 50 within the second annular 120 are arranged as 3, and one-to-one corresponding. Therefore, the number of sub-panels in the first bottom plate 10 and the second bottom plate 20 is also arranged as 3, and the second magnetic resistance 70 is arranged between adjacent sub-panels. It can be understood that the arrangement of the second magnetic resistance 70 therein is also arranged in correspondence, and the position of the arrangement is located between the two adjacent winding posts 50. It can be understood that in other embodiments, the number of sub-panels can also correspond to the number of second magnetic resistances 70 arranged therebetween, and the number of second magnetic resistances 70 and their arrangement positions can be adjusted between the sub-panels, and the positions are not limited to the positions shown in the figure, and can be arranged left and right on the bottom plate.
[0064] Similarly, in this embodiment, it can also be arranged in the manner of using multiple sub-panels and second magnetic resistances 70 in the above-mentioned embodiments. As shown in Figure 4 Figure 4 is a structural schematic diagram of a fourth embodiment of the magnetic integrated device provided by the present application; in this embodiment, the second magnetic resistance 70 is arranged between adjacent winding posts 50, specifically, the second magnetic resistance 70 includes a plurality of sub-panels 10a, and the plurality of sub-panels 10a are connected to each other; further, in another embodiment, on the basis of the above, the second magnetic resistance 70 includes a plurality of sub-panels 10a and a plurality of first sub-magnetic resistances 71, and the first sub-magnetic resistances 71 are arranged between the plurality of sub-panels 10a, and the adjacent sub-panels 10a are connected through the first sub-magnetic resistances 71. It can be understood that the number of sub-panels 10a and the number of first sub-magnetic resistances 71 are not specifically limited, and can be adjusted according to actual conditions, and the number of sub-panels 10a and the number of first sub-magnetic resistances 71 are arranged in correspondence. The first sub-magnetic resistance 71 can also include but is not limited to a bonded air gap, can be any material with a relative magnetic permeability μr less than the main magnetic core, or can be divided into multiple bonded forms.
[0065] In an embodiment, as shown in Figure 5 Figure 5 is a structural schematic diagram of a fifth embodiment of the magnetic integrated device provided by the present application; the common magnetic column 30 at least includes a first common magnetic column 31, a second common magnetic column 32 and a third common magnetic column 33; the first common magnetic column 31 and the second common magnetic column 32 are provided with a third magnetic resistance 80; and the second common magnetic column 32 and the third common magnetic column 33 are provided with a third magnetic resistance 80.
[0066] It can be understood that the implementation of the third magnetic resistance 80 also includes but is not limited to the adhesive air gap, which can be any material with a relative permeability less than the main magnetic core μr (relative permeability), or can be divided into multiple segments of adhesive form. For example, the first, second and third magnetic resistances 70 and 80 can be implemented by means including but not limited to glass bead adhesive to generate air gap or lower μr magnetic core composite adhesive or magnetic powder adhesive, magnetic ink filling, etc.
[0067] In an embodiment, as shown in Figure 5 , the number of common magnetic columns 30 is the same as the number of winding columns 50 in the first annular 110, and the winding columns 50 correspond one-to-one to the common magnetic columns 30. Specifically, the third magnetic resistance 80 is located between the adjacent two winding columns 50 in the same annular.
[0068] In combination with the above embodiment, in another embodiment, the common magnetic columns 30 can include multiple, and the corresponding number can also be set to correspond to the number of winding columns 50 in the first annular 110 or the second annular 120, or to correspond to the number of third magnetic resistances 80, and the third magnetic resistances 80 are arranged between adjacent common magnetic columns 30, and the number of third magnetic resistances 80 is multiple, for example, when the third magnetic resistance 80 is 2, the corresponding number of common magnetic columns 30 is 3.
[0069] In another embodiment, referring to Figure 6 , specifically, Figure 6 is a structural schematic diagram of the sixth embodiment of the magnetic integrated device provided by the present application; in this embodiment, the third magnetic resistance 80 includes multiple common magnetic columns 30, which are connected to each other. In another embodiment, the third magnetic resistance 80 includes multiple common magnetic columns 30 and multiple second sub-magnetic resistances 81, and the second sub-magnetic resistances 81 are arranged between adjacent common magnetic columns 30, and the multiple common magnetic columns 30 are connected through the second sub-magnetic resistances 81; specifically, the specific number of the multiple common magnetic columns 30 and the multiple second sub-magnetic resistances 81 is not limited and can be adjusted according to the actual situation, and the number of common magnetic columns 30 and the number of second sub-magnetic resistances 81 are correspondingly set.
[0070] In combination with the above embodiment, as shown in Figure 7 , specifically, Figure 7 is a structural schematic diagram of the seventh embodiment of the magnetic integrated device provided by the present application; it can be understood that Figure 7 is a comprehensive specific scheme in combination with the above embodiments. By arranging the second magnetic resistance 70 on the first bottom plate 10 and the second bottom plate 20, and arranging the third magnetic resistance 80 on the common magnetic column 30, the entire magnetic integrated device 100 is debugged to meet the demand of magnetic flux balance, reduce loss and improve power efficiency. Further, for the scheme of this embodiment, in other embodiments, reference can be made to Figure 4 and / orFigure 6 The adjustment of the quantity of the second magnetic resistance 70 and / or the quantity of the third magnetic resistance 80 in the scheme is not limited to the description in the above scheme, and can be adjusted according to actual conditions.
[0071] For the above embodiment scheme, as shown in Figure 8a and Figure 8b , the simulation effect schematic diagram corresponding to the scheme is Figure 8a . Figure 2 The simulation effect schematic diagram corresponding to the scheme is Figure 8b ; it can be understood that after the separate or joint debugging setting of the second magnetic resistance 70 and / or the third magnetic resistance 80, the magnetic density is more uniform, and further, the effect in Figure 3 can also be achieved in other schemes using the second magnetic resistance 70 and / or the third magnetic resistance 80, and is not limited to the scheme in Figure 8b . Figure 3
[0072] For the winding post 50, as shown in Figure 9 , the structure schematic diagram of an embodiment of the winding post provided by the present application is Figure 9 ; the winding post 50 comprises a segmented magnetic post 51 and a fourth magnetic resistance 52; wherein the plurality of first, second, third and fourth magnetic resistances corresponding to the magnetic post are usually distributed equally, and the fourth magnetic resistance 52 of the middle winding post 50 can also be finely adjusted to be equal to the inductance of the other two winding posts 50, and the other parts can also be adjusted in size according to the actual magnetic core form to meet the demand of magnetic flux balance. When setting the inductor or transformer coil, the area thickness of the first, second, third and fourth magnetic resistances of ≥3 times needs to be avoided to reduce the loss caused by leakage magnetic of the low magnetic resistance part (air gap, low μr material, etc.).
[0073] In an embodiment, as shown in Figure 10 , the structure schematic diagram of the eighth embodiment of the magnetic integrated device provided by the present application is Figure 10 ; the first middle post 90 is arranged between the adjacent winding posts 50 in the first ring 110; one end of the first middle post 90 is connected with the first bottom plate 10, and the other end is connected with the common magnetic post 30; the second middle post 91 is arranged between the adjacent winding posts 50 in the second ring 120, one end of the second middle post 91 is connected with the second bottom plate 20, and the other end is connected with the common magnetic post 30.
[0074] It can be understood that the setting of the middle post can be performed in combination with the scheme of any one of the above embodiments, wherein the quantity of the middle post in the first ring 110 and the second ring 120 can also be freely set, and the specific scheme can refer to the above description about the setting of the second magnetic resistance 70, that is, the corresponding setting related to the quantity of the winding post 50.
[0075] In an embodiment, as shown in Figure 11 , Figure 11 is a structural schematic diagram of the ninth embodiment of the magnetic integrated device provided in the present application; a fifth magnetic resistance 92 is arranged between the other end of the first middle column 90 and the common magnetic column 30; a fifth magnetic resistance 92 is arranged between the other end of the second middle column 91 and the common magnetic column 30.
[0076] In some embodiments, the first middle column 90 and the second middle column 91 are arranged in parallel. In other embodiments, the first middle column 90 and the second middle column 91 are arranged in parallel with the corresponding winding column 50, the first side column 40, the second side column 41, the third side column 42, and the fourth side column 43.
[0077] It can be understood that, based on the first middle column 90 and the second middle column 91 in this embodiment, the arrangement scheme of the second magnetic resistance 70 and the third magnetic resistance 80 described above is combined, as shown in Figure 12 , Figure 12 is a structural schematic diagram of the tenth embodiment of the magnetic integrated device 100 provided in the present application; in other embodiments, the second magnetic resistance 70 and the third magnetic resistance 80 can be arranged separately, that is, only the second magnetic resistance 70 or the third magnetic resistance 80 is arranged; or they are arranged in combination, that is, the second magnetic resistance 70 and the third magnetic resistance 80 are arranged at the same time. In some embodiments, referring to the schemes in Figure 4 and Figure 6 , the number of the second magnetic resistance 70 and / or the third magnetic resistance 80 can be multiple, and the specific number is not limited and can be arranged according to the actual scheme. In some embodiments, the positions of the second magnetic resistance 70 and the third magnetic resistance 80 are as shown in Figure 12 , arranged between the winding column 50 and the first middle column 90, and between the winding column 50 and the second middle column 91. The specific positions can be adjusted left and right according to the actual situation, and are not limited.
[0078] In the above way, by arranging the current excitation of the above two inductors or transformers, the magnetic integration mode, and / or combining the adjustment of the second magnetic resistance 70 and the third magnetic resistance 80, the magnetic flux distribution in the magnetic core is more uniform and has a larger part of the cancellation effect, which not only solves the problem of excessive local magnetic density of the magnetic core side column and the bottom plate caused by the unbalanced magnetic flux distribution of the traditional three-phase integration in the actual application, thereby generating a larger loss, but also further reduces the total loss of the two magnetic cores. Compared with the traditional integration and assembly method, the magnetic core loss is reduced by 16% to 60%, and the power efficiency is effectively improved. For example, the above-mentioned magnetic core inductor has a size of 103 mm*26 mm*36 mm, a current frequency of 200 kHz, a magnetic core material of DMR96A, and a magnetic flux density peak value of 0.12 T. The magnetic flux size and distribution, and the magnetic core loss comparison are as follows:
[0079] Using the traditional discrete component method, six sets of components are required: two inductors / transformers. Total power conversion loss: 2.75W * 6 = 16.5W.
[0080] Using the existing 3-phase integrated method described above, two sets of components are required: two inductors / transformers. The total power conversion loss is 6.5W*2=13W.
[0081] The above comparison shows that the embodiments of this application can effectively reduce conversion losses and improve power efficiency.
[0082] Using the above method, the magnetic flux distribution of the bottom column and the side column is uniform, with no high-density points. The local cross-sectional area of the magnetic core can be reduced by about 20%, effectively reducing the volume of the magnetic core and achieving higher power density. Furthermore, with the combination of the second magnetoresistive 70 and the third magnetoresistive 80, the order-of-magnetic difference between the second magnetoresistive 70 and the third magnetoresistive 80 and the first magnetoresistive 60 is reduced. The inductance tolerance, magnetic flux distribution and processing consistency of the integrated magnetic components are well improved, making the parameters easier to control.
[0083] To address the aforementioned problems, this application also provides a magnetic integration device 200, see reference. Figure 13 As shown, Figure 13 This is a schematic diagram of the structure of an embodiment of the magnetic integrated device provided in this application; wherein, the magnetic integrated device 200 includes: a magnetic integrated device 100, which is the magnetic integrated device 100 as described in any of the embodiments above; a switch module 210, one end of which is coupled to the magnetic integrated device 100; and a power supply 220, which is coupled to the other end of the switch module 210 and the magnetic integrated device 100, so as to realize step-up and step-down control by controlling the on and off of the switch module 210.
[0084] Furthermore, in combination Figure 14 As shown, Figure 14 This is a schematic diagram of a switch module embodiment provided in this application; wherein, corresponding to the above embodiment, it is applied to a three-phase six-switch PFC circuit with two inductors per phase. It is understood that the above-mentioned magnetic integrated device 200 includes, but is not limited to, the above-mentioned three-phase six-switch PFC circuit, and can be a circuit topology such as two-channel LLC.
[0085] The magnetic integrated device 100 and the equipment provided by the application include a first bottom plate 10, a second bottom plate 20, a common magnetic column 30, a first side column 40, a second side column 41, a third side column 42, a fourth side column 43 and a plurality of winding columns 50. The common magnetic column 30 is arranged between the first bottom plate 10 and the second bottom plate 20. The first side column 40 is connected to the first bottom plate 10 at one end and connected to the common magnetic column 30 at the other end. The second side column 41 is connected to the first bottom plate 10 at one end and connected to the common magnetic column 30 at the other end, forming a first ring 110. The third side column 42 is connected to the second bottom plate 20 at one end and connected to the common magnetic column 30 at the other end. The fourth side column 43 is connected to the second bottom plate 20 at one end and connected to the common magnetic column 30 at the other end, forming a second ring 120. The same number of winding columns 50 are distributed in the first ring 110 and the second ring 120. In the first ring 110, one end of each winding column 50 is connected to the first bottom plate 10 and the other end is connected to the common magnetic column 30. In the second ring 120, one end of each winding column 50 is connected to the second bottom plate 20 and the other end is connected to the common magnetic column 30. A coil is sleeved on each winding column 50. In the above manner, two magnetic devices are constructed by using the common magnetic column 30, so that the magnetic flux distribution in the magnetic core is more uniform and has a larger partial cancellation effect, thereby solving the problem of excessive local magnetic density of the side column and the bottom plate of the magnetic core caused by the unbalanced magnetic flux distribution in the actual application of the magnetic integration, resulting in a large loss, and improving the efficiency and reducing the size of the power supply 220.
[0086] The above describes the embodiments of the application in detail, and the principles and implementation modes of the application are described by applying specific examples. The above description of the embodiments is only used to help understand the method of the application and its core idea. Meanwhile, according to the idea of the application, the specific implementation mode and application range can be changed by those skilled in the art. In summary, the content of the specification should not be understood as a limitation of the application.
Claims
1. A magnetic integrated device, characterized by, The magnetic integrated device comprises a first bottom plate, a second bottom plate, a common magnetic column, a first side column, a second side column, a third side column, a fourth side column and a winding column; The common magnetic column is arranged between the first bottom plate and the second bottom plate; One end of the first side column is connected with the first bottom plate, and the other end is connected with the common magnetic column; one end of the second side column is connected with the first bottom plate, and the other end is connected with the common magnetic column, forming a first annular shape; One end of the third side column is connected with the second bottom plate, and the other end is connected with the common magnetic column; one end of the fourth side column is connected with the second bottom plate, and the other end is connected with the common magnetic column, forming a second annular shape; The first annular shape and the second annular shape are distributed with the same number of winding columns; in the first annular shape, one end of each winding column is connected with the first bottom plate, and the other end is connected with the common magnetic column; in the second annular shape, one end of each winding column is connected with the second bottom plate, and the other end is connected with the common magnetic column; Each winding column is sleeved with a coil.
2. The magnetic integrated device of claim 1, wherein, The first bottom plate, the second bottom plate and the common magnetic column are distributed in parallel with each other; the two ends of the first bottom plate, the two ends of the second bottom plate and the two ends of the common magnetic column are flush.
3. The magnetic integrated device of claim 2, wherein, The first side column and the second side column are distributed in parallel; the third side column and the fourth side column are distributed in parallel; the first side column and the third side column are arranged oppositely, and the second side column and the fourth side column are arranged oppositely.
4. The magnetic integrated device of claim 2, wherein, The winding columns in the first annular shape and the winding columns in the second annular shape are arranged one by one in a first direction.
5. The magnetic integrated device of claim 1, wherein, The inside of the first annular shape and the inside of the second annular shape are respectively provided with three winding columns; the three winding columns in the first annular shape and the three winding columns in the second annular shape are distributed one by one to form a two-way three-phase structure.
6. The magnetic integrated device of claim 1, wherein, The magnetic integrated device further comprises: A plurality of first magnetic resistances, the plurality of first magnetic resistances are arranged between the first side column and the common magnetic column, between the second side column and the common magnetic column, between the third side column and the common magnetic column, and between the fourth side column and the common magnetic column.
7. The magnetic integrated device according to claim 1 or 6, wherein The first bottom plate comprises at least a first sub-bottom plate, a second sub-bottom plate and a third sub-bottom plate; a second magnetic resistance is arranged between the first sub-bottom plate and the second sub-bottom plate; the second magnetic resistance is arranged between the second sub-bottom plate and the third sub-bottom plate; The second bottom plate comprises at least a fourth sub-bottom plate, a fifth sub-bottom plate and a sixth sub-bottom plate; the second magnetic resistance is arranged between the fourth sub-bottom plate and the fifth sub-bottom plate; the second magnetic resistance is arranged between the fifth sub-bottom plate and the sixth sub-bottom plate.
8. The magnetic integrated device of claim 7, wherein, The first sub-bottom plate and the first side column are an integral structure, the third sub-bottom plate and the second side column are an integral structure, the fourth sub-bottom plate and the third side column are an integral structure, and the sixth sub-bottom plate and the fourth side column are an integral structure.
9. The magnetic integrated device of claim 7, wherein, The number of sub-panels in the first bottom panel is the same as the number of winding columns in the first annular, and the winding columns in the first annular correspond one-to-one to the sub-panels in the first bottom panel; the number of sub-panels in the second bottom panel is the same as the number of winding columns in the second annular, and the winding columns in the second annular correspond one-to-one to the sub-panels in the second bottom panel. The second magnetic resistance is arranged between two adjacent winding columns in the same annular.
10. The magnetic integrated device of claim 2, wherein, The common magnetic column at least includes a first common magnetic column, a second common magnetic column and a third common magnetic column; the third magnetic resistance is arranged between the first common magnetic column and the second common magnetic column; the third magnetic resistance is arranged between the second common magnetic column and the third common magnetic column; and the third magnetic resistance is arranged between two adjacent winding columns in the same annular.
11. The magnetic integrated device of claim 1 or 10, wherein, A first middle column is arranged between adjacent winding columns in the first annular; one end of the first middle column is connected with the first bottom panel, and the other end is connected with the common magnetic column. A second middle column is arranged between adjacent winding columns in the second annular; one end of the second middle column is connected with the second bottom panel, and the other end is connected with the common magnetic column. The first middle column in the first annular and the second middle column in the second annular are distributed in a one-to-one corresponding manner.
12. The magnetic integrated device of claim 11, wherein, The other end of the first middle column and the common magnetic column are arranged with a fifth magnetic resistance; the other end of the second middle column and the common magnetic column are arranged with a fifth magnetic resistance.
13. The magnetic integrated device of claim 10, wherein, The number of common magnetic columns is the same as the number of winding columns in the first annular, and the winding columns correspond one-to-one to the common magnetic columns.
14. A magnetic integrated device, characterized by The magnetic integrated device comprises: The magnetic integrated device is as claimed in any one of claims 1-13; One end of the switch module is coupled to the magnetic integrated device; The power supply is coupled to the other end of the switch module and the magnetic integrated device to realize step-up and step-down control by controlling the on-off of the switch module.