Magnetic integrated structure, magnetic integrated device and power supply device
By introducing a second air gap between the top and/or bottom magnetic pillars in the magnetic integrated structure, the problems of high core loss and large size are solved, and the effects of magnetic flux uniformity and miniaturization are achieved.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- SHENZHEN MEGMEET ELECTRICAL CO LTD
- Filing Date
- 2025-01-21
- Publication Date
- 2026-04-24
AI Technical Summary
Existing magnetic integrated devices suffer from high core loss and large size, resulting in uneven magnetic flux in local areas of the magnetic integrated structure, which easily leads to high core loss and makes miniaturization difficult.
A second air gap is introduced into the top magnetic column and/or bottom magnetic column in the magnetic integrated structure, located between the two winding magnetic column groups. The second air gap reduces the magnetic flux in the region between the two winding magnetic column groups on the top and bottom magnetic columns, increases the magnetic flux of the edge magnetic column and other regions, reduces the magnetic flux difference, reduces core loss and reduces the risk of magnetic flux saturation.
It effectively reduces core loss, shrinks the size of magnetic integrated devices, improves the integrity and magnetic flux uniformity of magnetic integrated structures, and reduces the risk of magnetic flux saturation.
Smart Images
Figure CN224164130U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of power conversion technology, and in particular to a magnetic integrated structure, magnetic integrated device and power supply device. Background Technology
[0002] Magnetic integrated devices are widely used in power supply devices such as charging piles, rectifiers, and vehicle power supplies. Related technologies have proposed a magnetic integrated device composed of multiple magnetic pillars. However, these technologies suffer from problems such as high core losses and large device size. Utility Model Content
[0003] This application provides a magnetic integrated structure, a magnetic integrated device, and a power supply device, which can reduce the core loss of the magnetic integrated device and reduce the size of the magnetic integrated device.
[0004] To address the aforementioned technical problems, the first technical solution provided in this application is a magnetic integrated structure comprising a top magnetic pillar, a bottom magnetic pillar, at least one set of wound magnetic pillar groups, and two side magnetic pillars. The set of wound magnetic pillar groups includes two groups of wound magnetic pillars disposed between the top magnetic pillar and the bottom magnetic pillar, with the two groups of wound magnetic pillars spaced apart along a second direction. Each side magnetic pillar includes an upper magnetic pillar disposed at the end of the top magnetic pillar and a lower magnetic pillar disposed at the end of the bottom magnetic pillar, with a first air gap between the upper and lower magnetic pillars of the same side magnetic pillar. The top magnetic pillar and / or the bottom magnetic pillar are provided with a second air gap, the second air gap being located in the region between the two groups of wound magnetic pillars.
[0005] In one possible implementation, the top magnetic column and the bottom magnetic column each include a plurality of sub-magnetic columns, the plurality of sub-magnetic columns are arranged along a second direction, the plurality of sub-magnetic columns are spliced together, and there is a second air gap between two adjacent sub-magnetic columns.
[0006] In one possible implementation, both the top magnetic post and the bottom magnetic post include two sub-magnetic posts.
[0007] In one possible implementation, the top magnetic column and the bottom magnetic column include an integrally formed sub-magnetic column, which has a notch to form the second air gap.
[0008] In one possible implementation, the top magnetic post, the bottom magnetic post, and the side magnetic post are all made of magnetic material; the first air gap on the side magnetic post, the second air gap on the top magnetic post, and the bottom magnetic post are all filled with an adhesive, the permeability of which is less than that of the magnetic material.
[0009] In one possible implementation, the adhesive includes one or more of glass bead adhesive, magnetic powder adhesive, and resin adhesive.
[0010] In one possible implementation, the magnetic integrated structure includes a first magnetic core and a second magnetic core; each of the wound magnetic post groups includes a first wound magnetic post and a second wound magnetic post; the first magnetic core includes: a top magnetic post; upper magnetic posts, two of which are disposed on both sides of the top magnetic post; first wound magnetic posts, two adjacent first wound magnetic posts are spaced apart on the top magnetic post along a second direction; the second magnetic core includes: a bottom magnetic post; lower magnetic posts, two of which are disposed on both sides of the bottom magnetic post; second wound magnetic posts, two adjacent second wound magnetic posts are spaced apart on the bottom magnetic post along a second direction; wherein, a first wound magnetic post and a second wound magnetic post are disposed opposite to each other to form the wound magnetic post group, and a third air gap is provided between the first wound magnetic post and the second wound magnetic post, the third air gap being filled with an adhesive.
[0011] In one possible implementation, the first magnetic core and the second magnetic core have the same shape and size.
[0012] In one possible implementation, the magnetic reluctance of one of the edge magnetic pillars, the magnetic reluctance of the region from the edge magnetic pillar to the winding magnetic pillar group on the top magnetic pillar on one side of the edge magnetic pillar, and the magnetic reluctance of the region from the edge magnetic pillar to the winding magnetic pillar group on the bottom magnetic pillar on the other side of the edge magnetic pillar constitute a first magnetic reluctance; the magnetic reluctance of the region between the two winding magnetic pillar groups on the top magnetic pillar and the magnetic reluctance of the region between the two winding magnetic pillar groups on the bottom magnetic pillar constitute a second magnetic reluctance, the second magnetic reluctance being greater than the first magnetic reluctance.
[0013] In one possible implementation, the second magnetoresistive field is twice that of the first magnetoresistive field.
[0014] To address the aforementioned issues, the second technical solution provided in this application is to provide a magnetic integrated device, which includes a magnetic integrated structure, a first excitation coil, and a second excitation coil; wherein the magnetic integrated structure is the aforementioned magnetic integrated structure; the first excitation coil and the second excitation coil are respectively wound on two winding magnetic column groups of the set of winding magnetic column groups.
[0015] In one possible implementation, the magnetic integrated device includes a PCB disposed between the top magnetic post and the bottom magnetic post, the winding magnetic post assembly passing through the PCB, and the first excitation coil and the second excitation coil integrated on the PCB.
[0016] In one possible implementation, the PCB includes a first PCB and a second PCB, wherein the first PCB and the second PCB are disposed opposite to each other, the first PCB is close to the top magnetic post, and the second PCB is close to the bottom magnetic post; the winding magnetic post assembly passes through the first PCB and the second PCB.
[0017] In one possible implementation, the first excitation coil and the second excitation coil are integrated on the first PCB and the second PCB.
[0018] To address the aforementioned problems, the third technical solution provided in this application is to provide a power supply device that includes the aforementioned magnetic integrated device.
[0019] The beneficial effects are as follows: This application provides a magnetic integrated structure, a magnetic integrated device, and a power supply device. The magnetic integrated structure has a first air gap between the edge magnetic pillars on the top magnetic pillar and the edge magnetic pillars on the bottom magnetic pillar; the top magnetic pillar and / or the bottom magnetic pillar has a second air gap. As described above, the introduction of the second air gap in the region between the two winding magnetic pillar groups on the top and bottom magnetic pillars reduces the magnetic flux in the region between the two winding magnetic pillar groups on the top and bottom magnetic pillars, and increases the magnetic flux of the edge magnetic pillars and other regions on the top and bottom magnetic pillars, thereby reducing the magnetic flux difference of the magnetic integrated structure. On the other hand, the reduced magnetic flux in the region between the two winding magnetic pillar groups on the top and bottom magnetic pillars reduces the risk of magnetic flux saturation, allows for thinning of the top and bottom magnetic pillars, and reduces the size of the magnetic integrated device. Attached Figure Description
[0020] 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 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, wherein:
[0021] Figure 1 This is a schematic diagram of a magnetic integrated structure in the prior art;
[0022] Figure 2 for Figure 1 A schematic diagram of the magnetic flux of a magnetically integrated structure;
[0023] Figure 3 This is a schematic diagram of a magnetic integrated structure according to an embodiment of the present application;
[0024] Figure 4 for Figure 3 A schematic diagram of the magnetic flux transmission path in a magnetically integrated structure;
[0025] Figure 5 for Figure 3 Schematic diagram of the magnetic flux of the top magnetic column in a magnetically integrated structure;
[0026] Figure 6 for Figure 3 Schematic diagram of magnetoresistive and magnetic flux distribution on a magnetically integrated structure;
[0027] Figure 7 This is a schematic diagram of the structure of an embodiment of the magnetic integrated device of this application. Attached image description:
[0029] 10 / 20, Magnetic integrated structure; 11, Magnetic core; 113, Air gap; 21, Top magnetic column; 22, Bottom magnetic column; 112 / 210, Winding magnetic column group; 23, First magnetic core; 24, Second magnetic core; 111 / 25, Side magnetic column; 211, Upper magnetic column; 212, Lower magnetic column; 220, First air gap; 230, Second air gap; 240, Third air gap; 201, First winding magnetic column; 202, Second winding magnetic column; 260, First excitation coil magnetic column group; 261, First coil winding magnetic column; 262, Second coil winding magnetic column; 270, Second excitation coil magnetic column group; 271, Third coil winding magnetic column; 272, Fourth coil winding magnetic column; 30, Magnetic integrated device; 31, First PCB; 32, Second PCB. Detailed Implementation
[0030] 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 a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.
[0031] It should be noted that the terms "first" and "second" in this application are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or apparatus that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products, or apparatuses.
[0032] The magnetic integrated structure composed of two magnetic cores has an excessively high magnetic density in the region between the two wound magnetic pillars, which can easily lead to significant core losses. Furthermore, in order to prevent local oversaturation in the magnetic integrated structure, the thickness at the bottom of the magnetic core needs to be increased, which can easily cause the magnetic integrated structure to become larger in size.
[0033] To address the aforementioned problems, this application proposes a magnetic integrated structure, a magnetic integrated device, and a power supply device. By providing a second air gap between the top and / or bottom magnetic pillars of the magnetic integrated structure, with the second air gap located in the region between two wound magnetic pillar groups, the above-mentioned technical problems can be effectively solved.
[0034] In the example embodiments of this application, the magnetic integrated structure is the magnetic integrated structure in a magnetic integrated transformer. In some other embodiments, the magnetic integrated structure can also be the magnetic integrated structure in other devices such as magnetic integrated inductors, magnetic integrated mutual inductors, magnetic integrated magnetic amplifiers, and magnetic integrated solenoid valves.
[0035] Please see Figure 1 , Figure 1 This is a schematic diagram of a magnetic integrated structure in the prior art. Related technologies have proposed a magnetic integrated structure 10. This magnetic integrated structure 10 includes two magnetic cores 11.
[0036] Between the two magnetic cores 11 are edge magnetic pillars 111 and wound magnetic pillar groups 112. There are two wound magnetic pillar groups 112; one group has a first excitation coil (not shown), and the other has a second excitation coil (not shown). In this magnetic integrated structure 10, the edge magnetic pillars 111 of the two magnetic cores 11 have an air gap 113. The permeability of the rubber in the air gap 113 is less than the permeability of the magnetic cores 11, resulting in a large magnetic reluctance between the edge magnetic pillars 111 of the two magnetic cores 11. The presence of this magnetic reluctance results in a smaller magnetic flux in the region between the edge magnetic pillars 111 and the wound magnetic pillar groups 112 of the magnetic cores 11 in the magnetic integrated structure 10, while the magnetic flux at the top and bottom of the magnetic integrated structure 10 in the region between the two wound magnetic pillar groups 112 is larger. Please refer to [reference needed]. Figure 2 , Figure 2 for Figure 1 A schematic diagram of the magnetic flux of the magnetic integrated structure 10. (See diagram below.) Figure 2 As shown in the figure, the darker the color, the smaller the magnetic flux; the lighter the color, the larger the magnetic flux. It can be seen from the figure that the non-uniformity of the magnetic flux in the magnetic integrated structure 10 results in a large local magnetic flux density, which easily leads to high losses in the magnetic core 11. Furthermore, because the local magnetic flux is relatively large at the top and bottom of the magnetic integrated structure 10, the thickness of the top and bottom of the magnetic integrated structure 10 needs to be increased to reduce the risk of local saturation, which would increase the size of the magnetic integrated structure 10 and hinder the trend of device miniaturization.
[0037] To address the aforementioned technical problems, this application proposes a magnetically integrated structure. Please refer to... Figure 3 , Figure 3 This is a schematic diagram of a magnetic integrated structure according to an embodiment of the present application. In a specific embodiment, the magnetic integrated structure 20 includes a top magnetic post 21, a bottom magnetic post 22, at least one set of wound magnetic post groups 210, and two side magnetic posts 25.
[0038] The top magnetic post 21 and the bottom magnetic post 22 are spaced apart relative to each other along a first direction m. At least one set of wound magnetic post groups 210 is disposed between the top magnetic post 21 and the bottom magnetic post 22, and one set of wound magnetic post groups 210 includes two wound magnetic post groups 210. The two wound magnetic post groups 210 are spaced apart along a second direction n; each side magnetic post 25 includes an upper magnetic post 211 disposed at the end of the top magnetic post 21 and a lower magnetic post 212 disposed at the end of the bottom magnetic post 22, and a first air gap 220 is provided between the upper magnetic post 211 and the lower magnetic post 212 of the same side magnetic post 25; the top magnetic post 21 and / or the bottom magnetic post 22 are provided with a second air gap 230, and the second air gap 230 is located in the region between the two wound magnetic post groups 210.
[0039] In this embodiment, the magnetic integrated structure 20 includes a first magnetic core 23 and a second magnetic core 24. To clearly describe the structural positional relationship, the direction of the line connecting the center point of the top magnetic column 21 and the center point of the bottom magnetic column 22 is defined as the first direction m. The first magnetic core 23 and the second magnetic core 24 are arranged opposite each other along the first direction m. The first magnetic core 23 and the second magnetic core 24 act as conductors of magnetic flux, helping to guide and limit the magnetic flux, forming a magnetic flux loop. The two winding magnetic column groups 210 are the first excitation coil magnetic column group 260 and the second excitation coil magnetic column group 270, respectively. The first excitation coil magnetic column group 260 includes a first coil winding magnetic column 261 located on the first magnetic core 23 and a second coil winding magnetic column 262 located on the second magnetic core 24. The first coil winding magnetic column 261 and the second coil winding magnetic column 262 are spaced apart along the first direction m. The first coil winding magnetic column 261 and the second coil winding magnetic column 262 are used to wind the first excitation coil. The second excitation coil magnetic post group 270 includes a third coil winding magnetic post 271 located on the second magnetic core 24 and a fourth coil winding magnetic post 272 located on the first magnetic core 23. The third coil winding magnetic post 271 and the fourth coil winding magnetic post 272 are used to wind the second excitation coil. The first excitation coil and the second excitation coil form magnetic fluxes in opposite directions on the first excitation coil magnetic post group 260 and the second excitation coil magnetic post group 270, respectively. The two winding magnetic post groups 210 are spaced apart along the second direction n. The first magnetic core 23 is composed of a top magnetic post 21, upper magnetic posts 211 located on both sides of the top magnetic post 21, and the first coil winding magnetic post 261 and the fourth coil winding magnetic post 272 on the top magnetic post 21. The second magnetic core 24 is composed of a bottom magnetic post 22, lower magnetic posts 212 located on both sides of the bottom magnetic post 22, and the second coil winding magnetic post and the third coil winding magnetic post 271 on the bottom magnetic post 22.
[0040] The first excitation coil magnetic post group 260 is used for winding the first excitation coil, and the second excitation coil magnetic post group 270 is used for winding the second excitation coil. Please refer to the following: Figure 4 , Figure 4 for Figure 3 A schematic diagram of the magnetic flux transmission path in the magnetic integrated structure 20. Among them, Figure 4 The solid line in the middle represents the magnetic flux transmission path generated by the first excitation coil on the first excitation coil magnetic column group 260 on the left. Figure 4The dashed line in the middle represents the magnetic flux transmission path generated by the second excitation coil coil on the second excitation coil magnetic column group 270 on the right. The magnetic flux transmission path in the magnetic integrated structure 20 is as follows: the first excitation coil generates magnetic flux, which is transmitted from the first excitation coil magnetic column group 260 to the top magnetic column 21. After the magnetic flux is transmitted to the top magnetic column 21, part of it is transmitted to the side magnetic column 25 in the direction away from the second excitation coil magnetic column group 270 and returns to the first excitation coil magnetic column group 260. Another part is transmitted on the top magnetic column 21 towards the second excitation coil magnetic column group 270, and part of it passes through the second excitation coil magnetic column group 270 and returns to the first excitation coil magnetic column group 260. Another part passes through the side magnetic column 25 on the side closer to the second excitation coil magnetic column group 270 and returns to the first excitation coil magnetic column group 260. The second excitation coil also generates magnetic flux, which is transmitted from the second excitation coil magnetic column group 270 to the bottom magnetic column 22. After the magnetic flux is transmitted to the bottom magnetic column 22, part of it is transmitted to the side magnetic column 25 in the direction away from the first excitation coil magnetic column group 260 and returns to the second excitation coil magnetic column group 270. Another part is transmitted on the bottom magnetic column 22 towards the first excitation coil magnetic column group 260. Part of it passes through the first excitation coil magnetic column group 260 and returns to the second excitation coil magnetic column group 270, while another part passes through the side magnetic column 25 on the side closer to the first excitation coil magnetic column group 260 and returns to the second excitation coil magnetic column group 270. As can be seen from the above magnetic flux transmission path, the magnetic flux in the region between the top magnetic post 21 and the bottom magnetic post 22 and the side magnetic post 25 and the wound magnetic post group 210 of the magnetic integrated structure 20 is relatively small, while the magnetic flux in the region between the top magnetic post 21 and the bottom magnetic post 22 and the two wound magnetic post groups 210 is relatively large. The magnetic integrated structure 20 suffers from magnetic flux unevenness. Furthermore, in the existing magnetic integrated structure 20, the side magnetic posts 25 are spliced together, and the air gap between the side magnetic posts 25 generates magnetic reluctance. Therefore, the magnetic flux at the two side magnetic posts 25 of the magnetic integrated structure 20 becomes even smaller. This magnetic flux unevenness easily leads to core loss in the magnetic integrated structure 20. In this embodiment, the top magnetic post 21 and / or the bottom magnetic post 22 are provided with a second air gap 230, and the second air gap 230 is located in the region between the two wound magnetic post groups 210. The second air gap 230 can generate magnetic resistance, thereby reducing the magnetic flux in the region between the two wound magnetic post groups 210 of the top magnetic post 21 and the bottom magnetic post 22, thereby reducing the magnetic flux difference of the magnetic integrated structure 20 and reducing the loss of the magnetic core of the magnetic integrated structure 20.
[0041] Unlike existing technologies, this application provides a magnetic integrated structure 20, a magnetic integrated device, and a power supply device. The top magnetic post 21 and / or bottom magnetic post 22 of the magnetic integrated structure 20 are provided with a second air gap 230, located in the region between two wound magnetic post groups 210. As mentioned above, the second air gap 230 reduces the magnetic flux in the region between the two wound magnetic post groups 210 on the top magnetic post 21 and bottom magnetic post 22, and increases the magnetic flux of the edge magnetic post 25 and other regions on the top magnetic post 21 and bottom magnetic post 22, thereby reducing the magnetic flux difference at various points in the magnetic integrated structure 20. On the other hand, the reduced magnetic flux in the region between the two wound magnetic post groups 210 on the top magnetic post 21 and bottom magnetic post 22 reduces the risk of magnetic flux saturation, allows for thinning of the top magnetic post 21 and bottom magnetic post 22, and reduces the size of the magnetic integrated device.
[0042] In some embodiments, the top magnetic pillar 21 and the bottom magnetic pillar 22 each include multiple sub-magnetic pillars, which are arranged along a second direction and spliced together, with a second air gap 230 between adjacent sub-magnetic pillars. Specifically, the second direction n is perpendicular to the first direction m. The second direction n on the top magnetic pillar 21 and the bottom magnetic pillar 22 is the direction of magnetic flux transmission on the top magnetic pillar 21 and the bottom magnetic pillar 22. The arrangement of multiple sub-magnetic pillars along the second direction n enables the second air gap 230 between the sub-magnetic pillars to block the transmission of magnetic flux on the top magnetic pillar 21 and the bottom magnetic pillar 22, thereby reducing the magnetic flux between the top magnetic pillar 21 and the bottom magnetic pillar 22 in the two wound magnetic pillar groups 210. In this embodiment, both the top magnetic pillar 21 and the bottom magnetic pillar 22 are composed of multiple sub-magnetic pillars spliced together. The top magnetic pillar 21 and the bottom magnetic pillar 22 can each be composed of two, three, or any other reasonable number of sub-magnetic pillars. In other embodiments, the top magnetic pillar 21 may be composed of multiple sub-magnetic pillars joined together, while the bottom magnetic pillar 22 may be a single complete magnetic pillar. Alternatively, the top magnetic pillar 21 may be a single complete magnetic pillar, while the bottom magnetic pillar 22 may be composed of multiple sub-magnetic pillars joined together.
[0043] In some embodiments, both the top magnetic post 21 and the bottom magnetic post 22 include two sub-magnetic posts. Specifically, both the top magnetic post 21 and the bottom magnetic post 22 are composed of two sub-magnetic posts, which can reduce the magnetic flux of the top magnetic post 21 and the bottom magnetic post 22 by generating magnetic resistance through the second air gap 230, and also minimize the second air gap 230 between the top magnetic post 21 and the bottom magnetic post 22, thereby improving the overall integrity of the magnetic integrated structure 20.
[0044] In some embodiments, the top magnetic pillar 21 and the bottom magnetic pillar 22 each include an integrally formed sub-magnetic pillar, which has a notch to form a second air gap 230. Specifically, in this embodiment, neither the top magnetic pillar 21 nor the bottom magnetic pillar 22 is formed by splicing sub-magnetic pillars; both are integrally formed structures. Forming the second air gap 230 by forming a notch improves the overall integrity of the magnetic integrated structure 20. In other embodiments, one of the top magnetic pillar 21 and the bottom magnetic pillar 22 may form the second air gap 230 by providing a notch, while the other of the top magnetic pillar 21 and the bottom magnetic pillar 22 may form the second air gap 230 by splicing sub-magnetic pillars.
[0045] In some embodiments, the top magnetic post 21, the bottom magnetic post 22, and the side magnetic post 25 are all made of magnetic material. The first air gap 220 on the side magnetic post 25 and the second air gap 230 on the top magnetic post 21 and the bottom magnetic post 22 are all filled with an adhesive (not shown). The permeability of the adhesive is less than the permeability of the magnetic material. Specifically, the materials used to manufacture the first magnetic core 23 and the second magnetic core 24 may include ferrite, metal magnetic powder, amorphous alloy, and other magnetic materials. The adhesive may be glass bead adhesive, magnetic powder adhesive, resin adhesive, or low-permeability magnetic material adhesive, etc.
[0046] In some embodiments, the sum of the magnetic reluctance of one side magnetic post 25, the magnetic reluctance of the region from the side magnetic post 25 to the wound magnetic post group 210 on the top magnetic post 21 on one side of the side magnetic post 25, and the magnetic reluctance of the region from the side magnetic post 25 to the wound magnetic post group 210 on the bottom magnetic post 22 on the other side of the side magnetic post 25 constitutes the first magnetic reluctance; the sum of the magnetic reluctance of the region between the two wound magnetic post groups 210 on the top magnetic post 21 and the magnetic reluctance of the region between the two wound magnetic post groups 210 on the bottom magnetic post 22 constitutes the second magnetic reluctance, which is greater than the first magnetic reluctance. Specifically, the magnetic reluctance of the side magnetic post 25 specifically includes the magnetic reluctance of the upper magnetic post 211 of the side magnetic post 25, the magnetic reluctance of the lower magnetic post 212 of the side magnetic post 25, and the sum of the magnetic reluctance generated by the first air gap 220 between the upper magnetic post 211 and the lower magnetic post 212. Two first magnetic reluctances are generated on both sides of the magnetic integrated structure 20 in the second direction. The sum of the magnetic reluctance of the region between the two wound magnetic column groups 210 on the top magnetic column 21 and the region between the two wound magnetic column groups 210 on the bottom magnetic column 22 includes the magnetic reluctance generated by the second air gap 230. The transmission path of magnetic flux in the magnetic integrated structure 20 is as follows: the first excitation coil generates magnetic flux, which is transmitted from the first excitation coil magnetic column group 260 to the top magnetic column 21. After the magnetic flux is transmitted to the top magnetic column 21, part of it is transmitted to the side magnetic column 25 in the direction away from the second excitation coil magnetic column group 270 and returns to the first excitation coil magnetic column group 260. Another part is transmitted on the top magnetic column 21 towards the second excitation coil magnetic column group 270, and part of it passes through the second excitation coil magnetic column group 270 and returns to the first excitation coil magnetic column group 260. Another part passes through the side magnetic column 25 on the side closer to the second excitation coil magnetic column group 270 and returns to the first excitation coil magnetic column group 260. The second excitation coil also generates magnetic flux, which is transmitted from the second excitation coil magnetic column group 270 to the bottom magnetic column 22. After the magnetic flux is transmitted to the bottom magnetic column 22, part of it is transmitted to the side magnetic column 25 in the direction away from the first excitation coil magnetic column group 260 and returns to the second excitation coil magnetic column group 270. Another part is transmitted on the bottom magnetic column 22 towards the first excitation coil magnetic column group 260. Part of it passes through the first excitation coil magnetic column group 260 and returns to the second excitation coil magnetic column group 270, while another part passes through the side magnetic column 25 on the side closer to the first excitation coil magnetic column group 260 and returns to the second excitation coil magnetic column group 270. As can be seen from the transmission path of the magnetic flux, when the first magnetic reluctance and the second magnetic reluctance exist and the first magnetic reluctance and the second magnetic reluctance are the same, although the magnetic flux in the region between the two wound magnetic column groups 210 on the top magnetic column 21 and the bottom magnetic column 22 is reduced due to the second air gap 230, the magnetic flux in the region between the two wound magnetic column groups 210 on the top magnetic column 21 and the bottom magnetic column 22 is still greater than the magnetic flux in the region of the upper edge magnetic column 25 on the top magnetic column 21 and the bottom magnetic column 22.Only when the second magnetic reluctance is greater than the first magnetic reluctance can the magnetic flux in the region between the two wound magnetic column groups 210 on the top magnetic column 21 and the bottom magnetic column 22 be equal to the magnetic flux in the region of the upper edge magnetic column 25 on the top magnetic column 21 and the bottom magnetic column 22.
[0047] Furthermore, in a preferred embodiment, the magnetic integrated structure 20 is a four-column magnetic integrated structure 20, and the second magnetic reluctance is twice that of the first magnetic reluctance. Please refer to [reference needed]. Figure 6 , Figure 6 for Figure 3 A schematic diagram of the magnetic reluctance and magnetic flux distribution on the magnetic integrated structure. In this embodiment, the first magnetic core 23 and the second magnetic core 24 have the same shape and size, and the first excitation coil magnetic column group 260 and the second excitation coil magnetic column group 270 have the same number of coil turns. The magnetic flux transmission path of the magnetic integrated structure 20 can be simplified as follows: Figure 6As shown. Since the first magnetic core 23 and the second magnetic core 24 have the same shape and size, and the first excitation coil magnetic column group 260 and the second excitation coil magnetic column group 270 have the same number of coil turns, the magnetic flux and magnetic reluctance at corresponding positions on the top magnetic column 21 and the bottom magnetic column 22 are the same. The magnetic reluctance of the top magnetic column 21 and the bottom magnetic column 22 in the area between the two side magnetic columns 25 and the winding magnetic column group 210 is defined as Rmd1, the magnetic reluctance of the top magnetic column 21 and the bottom magnetic column 22 in the area between the two winding magnetic column groups 210 is defined as Rmd2, and the magnetic reluctance of the two side magnetic columns 25 is defined as Rmb. The magnetic reluctance of the side magnetic column 25 includes the magnetic reluctance of the upper magnetic column 211, the magnetic reluctance of the lower magnetic column 212, and the sum of the magnetic reluctance generated by the first air gap 220 between the upper magnetic column 211 and the lower magnetic column 212. Then we have Rmc1 = Rmb + Rmd1 * 2; Rmc2 = Rmd2 * 2. In the above formula, Rmc1 is the first magnetic reluctance, which includes the magnetic reluctance of one side magnetic post 25, the magnetic reluctance of the area from the side magnetic post 25 to the wound magnetic post group 210 on the top magnetic post 21 on one side of the side magnetic post 25, and the magnetic reluctance of the area from the side magnetic post 25 to the wound magnetic post group 210 on the bottom magnetic post 22 on the other side of the side magnetic post 25. Specifically, the magnetic reluctance of the side magnetic post 25 includes the magnetic reluctance of the upper magnetic post 211, the magnetic reluctance of the lower magnetic post 212, and the magnetic reluctance generated by the first air gap 220 between the upper and lower magnetic posts 211 and 212. The magnetic integrated structure 20 has two Rmc1 locations on both sides in the n-direction. Rmc2 is the second magnetic reluctance, which includes the sum of the magnetic reluctance of the region between the two wound magnetic column groups 210 on the top magnetic column 21 and the region between the two wound magnetic column groups 210 on the bottom magnetic column 22. The sum of the magnetic reluctance of the region between the two wound magnetic column groups 210 on the top magnetic column 21 and the region between the two wound magnetic column groups 210 on the bottom magnetic column 22 also includes the magnetic reluctance generated by the second air gap 230. According to the expression for magnetomotive force, there exists the formula F = (N ÷ 2) * i; where F is the magnetomotive force of the magnetic integrated structure 20, N is the sum of the number of turns of the coil on the first excitation coil magnetic column group 260 and the coil on the second excitation coil magnetic column group 270, and i is the current through the coil. Figure 6 In the magnetic integrated structure 20, the formula for calculating the magnetic flux on the wound magnetic column assembly 210 is as follows: ; This refers to the total magnetic flux independently generated by the excitation coil on either of the two wound magnetic column groups 210. The formula for calculating the magnetic flux in the region between the upper edge magnetic column 25 of the top magnetic column 21 or the bottom magnetic column 22 and the wound magnetic column group 210 is as follows: ; This refers to the magnetic flux in the region between the upper edge of the top magnetic post 21 or the bottom magnetic post 22, the upper edge of the magnetic post 25, and the wound magnetic post group 210. The two wound magnetic post groups 210 on the top magnetic post 21 or the bottom magnetic post 22... ; This refers to the magnetic flux in the region between the two wound magnetic column groups 210 on the top magnetic column 21 or the bottom magnetic column 22. When the magnetic flux in the magnetic integrated structure 20 is uniform, there exists... Substituting into the above equation and simplifying, we get the following expression: ;Right now =0, then Rmc2=2Rmc1; that is, when the second magnetic reluctance is twice that of the first magnetic column, the magnetic flux in the region between the two wound magnetic column groups 210 on the top magnetic column 21 and the bottom magnetic column 22 is the same as the magnetic flux in other regions on the top magnetic column 21 and the bottom magnetic column 22, as well as the magnetic flux of the edge magnetic column 25. Please refer to the following: Figure 5 , Figure 5 for Figure 3 A schematic diagram of the magnetic flux of the top magnetic post 21 of the magnetic integrated structure 20. (See diagram below.) Figure 5 As shown in the figure, the magnetic flux in the region between the two wound magnetic column groups 210 on the top magnetic column 21 of the magnetic integrated structure 20 is approximately equal to the magnetic flux in other regions of the top magnetic column 21 and the magnetic flux of the edge magnetic column 25. In this embodiment, the second magnetic reluctance is twice the first magnetic reluctance. In other embodiments, the second magnetic reluctance is greater than the first magnetic reluctance. Specifically, the second magnetic reluctance can also be a reasonable multiple such as 1.5 times or 1.8 times the first magnetic reluctance. The aforementioned second magnetic reluctance can also reduce the magnetic flux difference of the magnetic integrated structure 20.
[0048] In this embodiment, a wound magnetic column group 210 includes a first wound magnetic column 201 and a second wound magnetic column 202; two adjacent first wound magnetic columns 201 are spaced apart on the top magnetic column 21 along a second direction; two adjacent second wound magnetic columns 202 are spaced apart on the bottom magnetic column 22 along a second direction; a first wound magnetic column 201 and a second wound magnetic column 202 are arranged opposite to each other to form a wound magnetic column group 210, and the air gap between the first wound magnetic column 201 and the second wound magnetic column 202 forms a third magnetic reluctance, which is used to adjust the main inductance of the magnetic integrated structure 20.
[0049] In this embodiment, the top magnetic post 21 and the bottom magnetic post 22 are provided with two side magnetic posts 25 and a set of wound magnetic post groups 210. The magnetic integrated structure 20 is a four-post magnetic integrated structure 20. In other embodiments, the magnetic integrated structure 20 may also be provided with two, three or other sets of wound magnetic post groups 210, wherein each set of wound magnetic post groups 210 includes two wound magnetic post groups 210, and each set of wound magnetic post groups 210 can be used to wind coils with different numbers of turns, so that the magnetic integrated structure 20 can generate magnetomotive forces of different magnitudes. In addition, when the magnetic integrated structure 20 is provided with multiple sets of wound magnetic post groups 210, the number of second air gaps 230 on the top magnetic post 21 and / or the bottom magnetic post 22 can be multiple, and a second air gap 230 can be provided in the area between any two wound magnetic post groups 210 on the top magnetic post 21 and / or the bottom magnetic post 22.
[0050] In some embodiments, the first magnetic core 23 and the second magnetic core 24 have the same shape and size. Specifically, in this embodiment, the top magnetic post 21 and the bottom magnetic post 22 are both rectangular, and the length of the top magnetic post 21 and the thickness of the bottom magnetic post 22 in the second direction n and the first direction m are the same. The side magnetic posts 25 on the top magnetic post 21 and the side magnetic posts 25 on the bottom magnetic post 22 are both rectangular, and the length and thickness of the side magnetic posts 25 are the same. The first wound magnetic post on the top magnetic post 21 and the second wound magnetic post on the bottom magnetic post 22 are also rectangular and have the same size. In other embodiments, the length and thickness of the top magnetic post 21 and the bottom magnetic post 22 may be different. In addition, the length and thickness of the side magnetic posts 25 on the top magnetic post 21 and the bottom magnetic post 22 may also be different, and the length and thickness of the first wound magnetic post and the second wound magnetic post may also be different.
[0051] In this embodiment, the second air gap 230 on the top magnetic post 21 and / or the bottom magnetic post 22 is centered between the two winding magnetic post groups 210. In other embodiments, the two second air gaps 230 may not be centered between the two winding magnetic post groups 210. That is, the second air gap 230 between the two winding magnetic post groups 210 may be closer to the left winding magnetic post group 210 or closer to the right winding magnetic post group 210.
[0052] In this embodiment, the side magnetic pillars 25 on both sides of the magnetic integrated structure 20 are perpendicular to the top magnetic pillar 21 and the bottom magnetic pillar 22, that is, the angles between the side magnetic pillars 25 and the top magnetic pillar 21, and between the side magnetic pillars 25 and the bottom magnetic pillar 22, are both 90 degrees. In other embodiments, the side magnetic pillars 25 may not be perpendicular to the top magnetic pillar 21 and the bottom magnetic pillar 22; the side magnetic pillars 25 may be rotated relative to the winding magnetic pillar group 210 and the top magnetic pillar 21 by a certain angle. For example, the angles between the side magnetic pillars 25 and the top magnetic pillar 21, and between the side magnetic pillars 25 and the bottom magnetic pillar 22, can also be reasonable angles such as 60 degrees, 80 degrees, 120 degrees, and 100 degrees.
[0053] In a specific application scenario, the magnetic integrated structure 20 has a length of 70 mm in the second direction n, a height of 30 mm in the first direction m, and a height of 25 mm in the third direction. The third direction is perpendicular to the first direction m and also perpendicular to the second direction n. This magnetic integrated structure 20 is the same as the magnetic integrated structure 20 described in any of the above embodiments. The excitation current frequency of this magnetic integrated structure 20 is 250 kHz. The magnetic material used to manufacture this magnetic integrated structure 20 is DMR96A, a manganese-zinc ferrite material characterized by high saturation magnetic induction and low core loss. The peak magnetic flux density of this magnetic integrated structure 20 is 0.15 Tesla. This magnetic integrated structure 20 is composed of multiple sub-magnetic pillars spliced together by a top magnetic pillar 21 and a bottom magnetic pillar 22. The thickness of the top magnetic pillar 21 and the thickness of the bottom magnetic pillar 22 can be reduced from 6.5 mm to 5 mm. The cross-sectional area of the magnetic integrated structure 20 in the first direction m can be reduced by about 23%, and the volume of the magnetic integrated structure 20 can be reduced by about 13.5%. Through the above, the core loss of the magnetic integrated structure 20 can be reduced by 40%.
[0054] Unlike existing technologies, this application provides a magnetic integrated structure 20, a magnetic integrated device, and a power supply device. The magnetic integrated structure 20 has a first air gap 220 on its edge magnetic pillars 25, and a second air gap 230 on its top magnetic pillar 21 and / or bottom magnetic pillar 22. The second air gap 230 is located in the region between two wound magnetic pillar groups 210. By introducing the second air gap 230 in the region between the two wound magnetic pillar groups 210 on the top magnetic pillar 21 and the bottom magnetic pillar 22, the second air gap 230 reduces the magnetic flux in the region between the two wound magnetic pillar groups 210 on the top magnetic pillar 21 and the bottom magnetic pillar 22, and increases the magnetic flux in the edge magnetic pillar 25 and other regions on the top magnetic pillar 21 and the bottom magnetic pillar 22, thereby reducing the magnetic flux difference of the magnetic integrated structure 20. On the other hand, the magnetic flux in the region between the two wound magnetic column groups 210 on the top magnetic column 21 and the bottom magnetic column 22 is reduced, which reduces the risk of magnetic flux saturation. This allows the thickness of the top magnetic column 21 and the bottom magnetic column 22 to be reduced, thus reducing the size of the magnetic integrated device.
[0055] Correspondingly, this application also proposes a magnetically integrated device, which includes a magnetically integrated structure, a first excitation coil, and a second excitation coil; wherein, the magnetically integrated structure is the magnetically integrated structure described above; the first excitation coil and the second excitation coil are respectively wound on two sets of winding magnetic columns. In this embodiment, the magnetically integrated device is a magnetically integrated transformer; in some other embodiments, the magnetically integrated structure can also be a magnetically integrated inductor, a magnetically integrated mutual inductor, a magnetically integrated magnetic amplifier, a magnetically integrated solenoid valve, or other devices.
[0056] In some embodiments, the magnetic integrated device includes a PCB disposed between a top magnetic post and a bottom magnetic post, with a winding magnetic post assembly passing through the PCB, and a first excitation coil and a second excitation coil integrated on the PCB. In this embodiment, there is one PCB, and both the first and second excitation coils are integrated on this PCB.
[0057] In other embodiments, please refer to Figure 7 , Figure 7 This is a schematic diagram of the structure of an embodiment of the magnetic integrated device of this application. In this embodiment, the PCB includes a first PCB 31 and a second PCB 32, wherein the first PCB 31 and the second PCB 32 are arranged opposite to each other, with the first PCB 31 near the top magnetic post and the second PCB 32 near the bottom magnetic post; a winding magnetic post group passes through the first PCB 31 and the second PCB 32. The first excitation coil and the second excitation coil are integrated on the first PCB 31 and the second PCB 32. Specifically, the first PCB 31 and the second PCB 32 each integrate a first excitation coil and a first primary coil on the side of the first excitation coil magnetic post group, and the first excitation coil magnetic post group is wound with the first excitation coil and the first primary coil. The first PCB 31 and the second PCB 32 each integrate a second excitation coil and a second primary coil on the side of the second excitation coil magnetic post group, and the second excitation coil magnetic post group is wound with the second excitation coil and the second primary coil. The two sets of first excitation coils on the first PCB 31 and the second PCB 32 are connected in parallel and have the same number of turns. The two sets of second excitation coils are connected in parallel and have the same number of turns. In some embodiments, the first excitation coil and the second excitation coil of the first PCB31 and the second PCB32 may also be connected in parallel or in series.
[0058] Correspondingly, this application also proposes a power supply device that includes the magnetic integrated device described in the above embodiments.
[0059] The above description is merely an embodiment of this application and does not limit the patent scope of this application. Any equivalent structural or procedural transformations made using the content of this application's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this application.
Claims
1. A magnetic integrated structure, characterized in that, The magnetic integrated structure includes: Top and bottom magnetic pillars are arranged at relative intervals along a first direction; At least one set of wound magnetic column groups, the set of wound magnetic column groups including two wound magnetic column groups, the wound magnetic column groups being disposed between the top magnetic column and the bottom magnetic column, and the two wound magnetic column groups being spaced apart along a second direction; The two side magnetic pillars, each of the side magnetic pillars includes an upper magnetic pillar disposed at the end of the top magnetic pillar and a lower magnetic pillar disposed at the end of the bottom magnetic pillar, and a first air gap is provided between the upper magnetic pillar and the lower magnetic pillar of the same side magnetic pillar; The top magnetic column and / or the bottom magnetic column are provided with a second air gap, which is located in the area between the two winding magnetic column groups.
2. The magnetic integrated structure according to claim 1, characterized in that, The top magnetic column and the bottom magnetic column each include multiple sub-magnetic columns, which are arranged along the second direction and spliced together, with a second air gap between two adjacent sub-magnetic columns.
3. The magnetic integrated structure according to claim 2, characterized in that, Both the top magnetic pillar and the bottom magnetic pillar include two sub-magnetic pillars.
4. The magnetic integrated structure according to claim 1, characterized in that, The top magnetic column and the bottom magnetic column include an integrally formed sub-magnetic column, which has a notch to form the second air gap.
5. The magnetic integrated structure according to claim 1, characterized in that, The top magnetic pillar, the bottom magnetic pillar, and the side magnetic pillar are all made of magnetic material; The first air gap on the edge magnetic column, the second air gap on the top magnetic column, and the second air gap on the bottom magnetic column are all filled with an adhesive, and the magnetic permeability of the adhesive is less than that of the magnetic material.
6. The magnetic integrated structure according to claim 5, characterized in that, The adhesive includes one or more of glass bead adhesive, magnetic powder adhesive, and resin adhesive.
7. The magnetic integrated structure according to claim 1, characterized in that, The magnetic integrated structure includes a first magnetic core and a second magnetic core; each of the wound magnetic column groups includes a first wound magnetic column and a second wound magnetic column; The first magnetic core includes: Top magnetic pillar; The two upper magnetic pillars are arranged on both sides of the top magnetic pillar; The first winding magnetic column, two adjacent first winding magnetic columns are spaced apart on the top magnetic column along the second direction; The second magnetic core includes: Bottom magnetic pillar; The two lower magnetic pillars are arranged on both sides of the bottom magnetic pillar; The second winding magnetic column, two adjacent second winding magnetic columns are spaced apart on the bottom magnetic column along the second direction; The first winding magnetic post and the second winding magnetic post are arranged opposite to each other to form the winding magnetic post group, and a third air gap is provided between the first winding magnetic post and the second winding magnetic post, the third air gap being filled with adhesive.
8. The magnetic integrated structure according to claim 7, characterized in that, The first magnetic core and the second magnetic core have the same shape and size; The magnetic reluctance of the edge magnetic post, together with the magnetic reluctance of the region from the edge magnetic post to the winding magnetic post group on the top magnetic post on one side of the edge magnetic post, and the magnetic reluctance of the region from the edge magnetic post to the winding magnetic post group on the bottom magnetic post on the other side of the edge magnetic post, constitutes a first magnetic reluctance; the magnetic reluctance of the region between the two winding magnetic post groups on the top magnetic post and the magnetic reluctance of the region between the two winding magnetic post groups on the bottom magnetic post constitutes a second magnetic reluctance, wherein the second magnetic reluctance is greater than the first magnetic reluctance.
9. The magnetic integrated structure according to claim 8, characterized in that, The second magnetoresistive force is twice that of the first magnetoresistive force.
10. A magnetic integrated device, characterized in that, The magnetic integrated device includes a magnetic integrated structure, a first excitation coil, and a second excitation coil; wherein the magnetic integrated structure is the magnetic integrated structure according to any one of claims 1 to 9; the first excitation coil and the second excitation coil are respectively wound on two winding magnetic column groups of the set of winding magnetic column groups.
11. The magnetic integrated device according to claim 10, characterized in that, The magnetic integrated device includes a PCB, which is disposed between the top magnetic post and the bottom magnetic post. The winding magnetic post group passes through the PCB, and the first excitation coil and the second excitation coil are integrated on the PCB.
12. The magnetic integrated device according to claim 11, characterized in that, The PCB includes a first PCB and a second PCB, wherein the first PCB and the second PCB are disposed opposite to each other, the first PCB is close to the top magnetic post, and the second PCB is close to the bottom magnetic post; the winding magnetic post group passes through the first PCB and the second PCB.
13. The magnetic integrated device according to claim 12, characterized in that, The first excitation coil and the second excitation coil are integrated on the first PCB and the second PCB.
14. A power supply device, characterized in that, The power supply device includes the magnetic integrated device as described in any one of claims 10-13.