Magnetic integrated element

Abstract

A magnetic integrated component includes a transformer magnetic core unit, a first winding, a second winding, a resonant inductor magnetic core, and a resonant inductor coil. The first winding is disposed on the transformer magnetic core unit. The second winding is disposed on the transformer magnetic core unit. The transformer magnetic core unit is connected to the resonant inductor magnetic core. The resonant inductor coil is disposed on the resonant inductor magnetic core, wherein at least a portion of the resonant inductor coil and at least a portion of the first winding are wound by the same wire.

Description

Technical Field

[0001] This utility model relates to a magnetic integrated element, and more particularly to a magnetic integrated element suitable for transformers. Background Technology

[0002] In traditional transformer manufacturing, a common practice is to stack and combine pre-wound coil modules with copper sheets to form the desired winding structure. This method has several advantages over traditional manual winding, such as simplifying the process, shortening assembly time, and improving product consistency and production yield. Because the structure of coils and copper sheets is relatively stable and can be mass-produced using standardized molds, effectively reducing manufacturing difficulty and labor costs, it is widely used in the mass production of small and medium-sized transformers.

[0003] However, existing single-layer coil structures still have some technical bottlenecks. For example, it is difficult to completely avoid conductor crossings (i.e., conductors need to cross other coil layers during winding) in the coil design. This crossing phenomenon occupies part of the winding slot space, resulting in poor space utilization efficiency. In addition, the uneven stacking caused by crossings may also affect the compactness of the conductor arrangement and heat dissipation, further limiting the power density and performance of the transformer. In other words, although traditional coil stacking technology can effectively improve production efficiency, there is still room for further improvement under the application requirements of high power density, high consistency, and miniaturization. Utility Model Content

[0004] The present invention provides a magnetic integrated element to address the problems of the prior art, comprising a transformer core unit, a first winding, a second winding, a resonant inductor core, and a resonant inductor coil. The first winding is disposed in the transformer core unit. The second winding is disposed in the transformer core unit. The transformer core unit is connected to the resonant inductor core. The resonant inductor coil is disposed in the resonant inductor core, wherein at least a portion of the resonant inductor coil and at least a portion of the first winding are wound with the same conductor.

[0005] In one embodiment, the transformer core unit includes a first core component and a second core component, the first winding and the second winding are sandwiched between the first core component and the second core component, the first core component is located between the second core component and the resonant inductor core, and the conductor extends through the first core component.

[0006] In one embodiment, the first magnetic core component includes a first base and a first core post, the first core post being disposed on the first base, and a magnetic core notch being formed on the first base, through which the wire extends.

[0007] In one embodiment, the magnetic integrated element further includes a current transformer connected to the transformer core unit.

[0008] In one embodiment, the current transformer is disposed in the magnetic core notch.

[0009] In one embodiment, the resonant inductor coil and the first winding are made entirely of the same conductor.

[0010] In one embodiment, the first winding includes a first primary coil and a second primary coil, and the second winding includes a first metal sheet and a second metal sheet. The first metal sheet is disposed between the resonant inductor coil and the first primary coil, and the second metal sheet is disposed between the first primary coil and the second primary coil.

[0011] In one embodiment, the first metal sheet is U-shaped and has a first notch through which the wire extends.

[0012] In one embodiment, the second metal sheet is U-shaped and has a second notch. The first notch faces a first direction, and the second notch faces a second direction opposite to the first direction. The wire does not pass through the second notch.

[0013] In one embodiment, the second metal sheet is U-shaped and has a second notch. The first notch faces a first direction, and the second notch also faces the first direction. The wire extends through the second notch.

[0014] In this embodiment of the invention, at least a portion of the resonant inductor coil and at least a portion of the first winding are continuously wound from the same conductor. This continuous winding design not only reduces the number of coil contacts and the risk of contact defects, but also effectively reduces the differences between coils and improves the consistency of coil performance. Furthermore, in this invention, the conductor design extends through the core gap of the first magnetic core component, thereby effectively optimizing the space waste caused by the traditional cross-wire structure and improving the utilization rate of the winding slots. In another embodiment, the conductor can also extend through the first gap of the first metal sheet, further reducing the space occupied by cross-wires and significantly improving the power density and structural compactness of the transformer. In summary, this invention successfully overcomes the space waste problem caused by single-layer coil cross-wires in the prior art, and improves the transformer manufacturing efficiency and performance through continuous winding and gap optimization design. Attached Figure Description

[0015] Figure 1 This is a diagram showing the main component assembly of the magnetic integrated element according to an embodiment of the present invention;

[0016] Figure 2This is an exploded view showing the main components of the magnetic integrated element according to an embodiment of the present invention;

[0017] Figure 3 This is a magnetic integrated element illustrating another embodiment of the present invention;

[0018] Figure 4 This shows the complete structure of the magnetic integrated element in an embodiment of the present invention;

[0019] Figure 5 This shows the complete structure of the magnetic integrated element according to an embodiment of the present invention, wherein the current transformer is shown in dashed lines;

[0020] Figure 6 This is a magnetic integrated element that shows another embodiment of the present invention.

[0021] [Symbol Explanation]

[0022] T: Magnetic integrated components

[0023] T1: Magnetic integrated component

[0024] T2: Magnetic integrated component

[0025] 1: First winding

[0026] 11: First primary coil

[0027] 12: Second primary coil

[0028] 2: Second winding

[0029] 21: First metal sheet

[0030] 211: First Gap

[0031] 22: Second metal sheet

[0032] 221: Second Gap

[0033] 3: Transformer core unit

[0034] 31: First magnetic core component

[0035] 311: The First Body

[0036] 312: First Core Pillar

[0037] 313: Core notch

[0038] 32: Second magnetic core component

[0039] 4: Resonant inductor core

[0040] 5: Resonant inductor coil

[0041] 6: Wire

[0042] 7: Current transformer

[0043] Z1: First Direction

[0044] Z2: Second Direction Detailed Implementation

[0045] Figure 1 This is a diagram showing the main component assembly of the magnetic integrated element according to an embodiment of the present invention. Figure 2 This is an exploded view showing the main components of the magnetic integrated element according to an embodiment of this utility model. See also: Figure 1 , 2 The present invention provides a magnetic integrated element T to address the problems of the prior art, comprising a transformer core unit 3, a first winding 1, a second winding 2, a resonant inductor core 4, and a resonant inductor coil 5. The first winding 1 is disposed on the transformer core unit 3. The second winding 2 is disposed on the transformer core unit 3. The transformer core unit 3 is connected to the resonant inductor core 4. The resonant inductor coil 5 is disposed on the resonant inductor core 4.

[0046] Matching reference Figure 1 , 2 In one embodiment, the transformer core unit 3 includes a first core component 31 and a second core component 32, the first winding 1 and the second winding 2 are sandwiched between the first core component 31 and the second core component 32, and the first core component 31 is located between the second core component 32 and the resonant inductor core 4.

[0047] Figure 3 This is a magnetic integrated element illustrating another embodiment of the present invention. (See reference...) Figure 3 In this embodiment, at least a portion of the resonant inductor coil 5 of the magnetic integrated element T1 and at least a portion of the first winding 1 are wound with the same conductor 6. The conductor 6 extends through the first magnetic core component 31.

[0048] exist Figure 3 In the diagram, the routing of conductor 6 is for illustrative purposes only. In reality, to save space, the actual length of conductor 6 in the crossing section is longer than that of conductor 6. Figure 3 The length should be short. The above disclosure does not limit the scope of this utility model.

[0049] Reference Figure 3 In one embodiment, the first magnetic core component 31 includes a first base 311 and a first core post 312. The first core post 312 is disposed on the first base 311. A magnetic core notch 313 is formed on the first base 311, and the wire 6 extends through the magnetic core notch 313.

[0050] Figure 4 This shows the complete structure of the magnetic integrated element in an embodiment of the present invention. Figure 5 This diagram shows the complete structure of the magnetic integrated element according to an embodiment of the present invention, wherein the current transformer is represented by dashed lines. (See accompanying reference.) Figure 4 , 5 In one embodiment, the magnetic integrated element T further includes a current transformer 7, which is connected to the transformer core unit 3.

[0051] Matching reference Figure 4 , 5 In one embodiment, the current transformer 7 is disposed in the magnetic core notch 313. This further saves installation space.

[0052] Refer to Figure 3 In one embodiment, the resonant inductor 5 and the first winding 1 are made entirely of the same conductor 6.

[0053] Reference Figure 3 In one embodiment, the first winding 1 includes a first primary coil 11 and a second primary coil 12, and the second winding 2 includes a first metal sheet 21 and a second metal sheet 22. The first metal sheet 21 is disposed between the resonant inductor coil 5 and the first primary coil 11, and the second metal sheet 22 is disposed between the first primary coil 11 and the second primary coil 12.

[0054] Reference Figure 3 In one embodiment, the first metal sheet 21 is U-shaped and has a first notch 211 through which the wire 6 extends.

[0055] Reference Figure 3 In one embodiment, the second metal sheet 22 is U-shaped and has a second notch 221. The first notch 211 faces a first direction Z1, and the second notch 221 faces a second direction Z2, which is opposite to the first direction Z1. The wire 6 does not pass through the second notch 221 and crosses over the outer edge of the second metal sheet 22.

[0056] Figure 6 This is a magnetic integrated element illustrating yet another embodiment of the present invention. (See reference...) Figure 6 In this embodiment, the magnetic integrated element T2 has a second metal sheet 22 in the shape of a U-shape. The second metal sheet 22 has a second notch 221. The first notch 211 faces a first direction Z1, and the second notch 221 also faces the first direction Z1. The wire 6 extends through the second notch 221. This further saves space across the wire.

[0057] In this embodiment of the invention, at least a portion of the resonant inductor coil and at least a portion of the first winding are continuously wound from the same conductor. This continuous winding design not only reduces the number of coil contacts and the risk of contact defects, but also effectively reduces the differences between coils and improves the consistency of coil performance. Furthermore, in this invention, the conductor design extends through the core gap of the first magnetic core component, thereby effectively optimizing the space waste caused by the traditional cross-wire structure and improving the utilization rate of the winding slots. In another embodiment, the conductor can also extend through the first gap of the first metal sheet, further reducing the space occupied by cross-wires and significantly improving the power density and structural compactness of the transformer. In summary, this invention successfully overcomes the space waste problem caused by single-layer coil cross-wires in the prior art, and improves the transformer manufacturing efficiency and performance through continuous winding and gap optimization design.

[0058] Although the present invention has been disclosed above with reference to specific preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art may make some modifications and refinements without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be determined by the scope defined in the appended claims.

Claims

1. A magnetic integrated element, characterized in that, include: A transformer core unit; A first winding is located in the core unit of the transformer; A second winding is provided in the transformer core unit; A resonant inductor core, wherein the transformer core unit is connected to the resonant inductor core; and A resonant inductor coil is disposed on the resonant inductor core, wherein at least a portion of the resonant inductor coil and at least a portion of the first winding are wound with the same conductor.

2. The magnetic integrated element as described in claim 1, characterized in that, The transformer core unit includes a first core component and a second core component. The first winding and the second winding are sandwiched between the first core component and the second core component. The first core component is located between the second core component and the resonant inductor core. The conductor extends through the first core component.

3. The magnetic integrated element as described in claim 2, characterized in that, The first magnetic core component includes a first base and a first core post. The first core post is disposed on the first base, and a magnetic core notch is formed on the first base. The wire extends through the magnetic core notch.

4. The magnetic integrated element as described in claim 3, characterized in that, It also includes a current transformer connected to the transformer core unit.

5. The magnetic integrated element as described in claim 4, characterized in that, The current transformer is located at the notch in the magnetic core.

6. The magnetic integrated element as described in claim 2, characterized in that, The resonant inductor coil and the first winding are made entirely of the same conductor.

7. The magnetic integrated element according to any one of claims 1 to 6, characterized in that, The first winding includes a first primary coil and a second primary coil, and the second winding includes a first metal sheet and a second metal sheet. The first metal sheet is disposed between the resonant inductor coil and the first primary coil, and the second metal sheet is disposed between the first primary coil and the second primary coil.

8. The magnetic integrated element as described in claim 7, characterized in that, The first metal sheet is U-shaped and has a first notch through which the wire extends.

9. The magnetic integrated element as described in claim 8, characterized in that, The second metal sheet is U-shaped and has a second notch. The first notch faces a first direction, and the second notch faces a second direction opposite to the first direction. The wire does not pass through the second notch.

10. The magnetic integrated element as claimed in claim 8, characterized in that, The second metal sheet is U-shaped and has a second notch. The first notch faces a first direction, and the second notch also faces the first direction. The wire extends through the second notch.

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