Fractional turn structure magnetic integrated transformer device

Abstract

The utility model discloses a fractional turn structure magnetic integrated transformer device, transformer magnetic core, leakage inductance magnetic core, primary winding and secondary winding, wherein: transformer magnetic core includes first magnetic column, second magnetic column, third magnetic column, leakage inductance magnetic core includes fourth magnetic column, fifth magnetic column, the primary winding is wound in first magnetic column surface, and two coil terminals of primary winding are in transformer primary side, and secondary winding contains four half fractional turn coils, transformer and leakage inductance magnetic core set space air gap, under satisfying the maximum magnetic induction intensity of the set magnetic core, adjust the excitation inductance value and leakage value device of transformer and set adjustable air gap in the key position of magnetic core, can accurate control excitation inductance and leakage value, ensure that magnetic core works in the best state.

Description

Technical Field

[0001] This utility model relates to the field of transformer technology, specifically to a fractional-turn structure magnetic integrated transformer device. Background Technology

[0002] With the rapid development of power electronics technology, switching power supplies are constantly evolving towards higher frequencies, higher power densities, and higher efficiency. Especially in fields such as data centers, artificial intelligence computing clusters, and 5G communication base stations, the demand for high-current, low-voltage power supplies is becoming increasingly urgent. In these applications, the secondary windings of transformers often need to carry hundreds of amperes or even higher currents. Traditional multi-turn winding structures, due to skin effect and proximity effect, lead to severe copper losses and thermal management problems, becoming a major bottleneck in improving power supply efficiency and power density.

[0003] Currently, mainstream high-current solutions mainly employ two approaches: one is the traditional multi-turn winding transformer paired with an external discrete resonant inductor, but this approach suffers from inherent drawbacks such as large size, numerous parasitic parameters, and low production efficiency; the other is a fractional-turn winding transformer, which effectively reduces winding losses but still requires an external resonant inductor, preventing true high-density integration. Existing magnetic integration technologies mostly focus on integrating multiple magnetic components onto a single magnetic core, but there remains a technological gap regarding the integration of fractional-turn winding resonant inductors. In practical applications, while fractional-turn transformers significantly improve current carrying capacity, their unique magnetic circuit structure presents major challenges for the integration of resonant inductors. Traditional integration methods often lead to problems such as uncontrollable leakage inductance, uneven magnetic flux distribution, and complex winding processes, severely impacting the stability and reliability of the power supply. Furthermore, existing designs struggle to simultaneously meet the application requirements of different topologies, such as full-wave rectification and full-bridge rectification, lacking sufficient flexibility and adaptability.

[0004] Therefore, there is an urgent need for an innovative magnetic integration solution that can achieve efficient integration of resonant inductors while maintaining the high-current advantages of fractional-turn windings, and simultaneously ensuring parameter controllability and manufacturing feasibility. Such a solution will significantly improve the power density and conversion efficiency of high-current power supplies, meeting the higher requirements of next-generation electronic devices for power systems. Utility Model Content

[0005] The purpose of this invention is to provide a fractional-turn magnetic integrated transformer device, which aims to solve the technical problems of low power density and large size caused by the discrete structure of transformers and resonant inductors in existing high-current power supplies, using a fractional-turn winding structure. This device successfully integrates the functions of resonant inductance and transformer into a single magnetic element through an innovative core structure and winding design. Specifically, the device adopts a composite core design, including a symmetrically distributed three-pillar transformer core and a vertically symmetrically distributed leakage inductance core. The primary winding is wound on the central pillar, and its lead-out method can be flexibly configured according to leakage inductance requirements: leading from one side of the leakage inductance core yields a smaller leakage inductance, while leading from both sides symmetrically significantly increases the leakage inductance value. The secondary winding uses a parallel structure of four fractional-turn coils, which can be configured as a center-tapped mode suitable for full-wave rectifier circuits or a non-center-tapped mode suitable for full-bridge rectifier circuits, greatly improving current carrying capacity and meeting the needs of low-voltage, high-current applications.

[0006] The device includes a transformer assembly that integrates a resonant inductor and a transformer. The primary winding of the transformer employs a multi-turn structure, while the secondary winding employs a fractional-turn structure. A fractional-turn structure magnetically integrated transformer assembly includes: Transformer core, leakage inductance core, primary winding, and secondary winding; The transformer core includes a first magnetic column, a second magnetic column, and a third magnetic column, wherein the second and third magnetic columns are symmetrically distributed with respect to the first magnetic column, and the first magnetic column is located in the middle; The leakage inductance core includes a fourth magnetic post and a fifth magnetic post, which are spatially symmetrically distributed with respect to the first magnetic post, and the distribution direction is perpendicular to the distribution direction of the second and third magnetic posts. The primary winding is wound on the surface of the first magnetic post. The two coil terminals of the primary winding should be located on the primary side of the transformer. It can be wound from one side of the leakage inductance magnetic post (including the fourth and fifth magnetic posts) or from both sides. The winding method is as follows: if it is necessary to increase the leakage inductance, choose to wind from both sides; otherwise, wind from one side.

[0007] The secondary winding consists of four half-turn coils, or other fractional-turn structures (such as one-third, one-quarter, etc.). If the secondary winding is considered as a center-tapped transformer, then every two half-turn coils form a magnetic loop. These two half-turn coils need to be distributed on both sides of the first magnetic post, which is a parallel output in the circuit. When two half-turn coils have output current, the other two half-turn coils have no current. If the secondary winding is considered as a non-center-tapped transformer, then the four half-turn coils form a magnetic loop, which is a parallel output in the circuit to increase the output current.

[0008] The air gap in the magnetic core can be set to a certain value for the transformer and the leakage inductance core. Under the condition of satisfying the maximum magnetic induction intensity of the set magnetic core, the excitation inductance and leakage inductance values ​​of the transformer can be adjusted.

[0009] The transformer can meet the requirements of flat design and low-voltage, high-current switching power supply design.

[0010] Compared to existing technologies, the advantages of this invention are as follows: The fractional-turn magnetic integrated transformer device proposed in this invention employs a fractional-turn winding structure on the secondary side to increase the secondary-side output current. Simultaneously, a leakage inductance core is integrated within the device, thus enabling the design of both the transformer and resonant inductor within a single transformer unit. This device is suitable for high-current applications, increases the power density of the power supply, and is more conducive to the miniaturization and flattening of the power supply design. This device can simultaneously accommodate full-wave rectification and full-bridge rectification circuits, meeting diverse power supply requirements. Attached Figure Description

[0011] Figure 1 This is a schematic diagram of the exploded structure of this utility model; Figure 2 This is a front view of the fractional-turn magnetic integrated transformer device of this utility model; Figure 3 This is a side view of the fractional-turn magnetic integrated transformer device of this utility model; Figure 4 This is one of the fractional-turn coil connection methods for the fractional-turn structure magnetic integrated transformer of this utility model; Figure 5 This is the second connection method for the fractional-turn coils of the fractional-turn structure magnetic integrated transformer of this utility model.

[0012] List of labels in the attached diagram: 1-First magnetic post, 2-Second magnetic post, 3-Third magnetic post, 4-Fourth magnetic post, 5-Fifth magnetic post, 6-Primary winding, 7-Secondary winding, 8-Magnetic core beam. Detailed Implementation

[0013] The present invention will be further explained below with reference to the accompanying drawings and specific embodiments. It should be understood that the following specific embodiments are only used to illustrate the present invention and are not intended to limit the scope of the present invention. Example

[0014] Implementation plan as follows Figure 1-3 As shown, the core of the device adopts a composite magnetic core structure, which consists of two parts: a transformer core and a leakage inductance core.

[0015] The transformer core adopts a standard three-pillar structure. The first pillar 1 is located at the absolute center of the structure and serves as the main energy transmission channel. The second pillar 2 and the third pillar 3 are strictly symmetrically distributed with respect to the first pillar 1, forming a closed magnetic circuit together with the first pillar 1, ensuring the symmetry and balance of the magnetic flux.

[0016] The leakage inductance core consists of a fourth magnetic post 4 and a fifth magnetic post 5. These two magnetic posts are also spatially symmetrical with respect to the first magnetic post 1, but their distribution direction is perpendicular to the distribution direction of the second magnetic post 2 and the third magnetic post 3. This perpendicular arrangement is a key design feature, as it provides an additional magnetic path for the primary winding and is the basis for generating and controlling the required leakage inductance (i.e., resonant inductance).

[0017] The primary winding 6 is tightly wound on the surface of the central first magnetic post 1. Its lead-out method is a key design parameter that allows for flexible adjustment of the leakage inductance value. The two coil terminals of the primary winding 6 can be led out from the same side of the leakage inductance magnetic posts (the fifth and sixth magnetic posts), resulting in a smaller leakage inductance. If a larger leakage inductance value is required, the terminals can be led out symmetrically from both sides of the fifth and sixth magnetic posts, thereby utilizing this path to create a larger leakage flux.

[0018] The core innovation of this device lies in the secondary winding 7, which employs a four-parallel fractional-turn coil structure and integrates a transformer and a resonant inductor. The specific connection method depends on the rectification requirements. Center-tapped mode (suitable for full-wave rectifier circuits): Two fractional-turn coils located symmetrically on opposite sides of the first magnetic pillar 1 are grouped together, forming a magnetic circuit. During any half-cycle of switching, only one group of coils has current output, while the other group has no current. Full-wave rectification is achieved through the center tap, as shown below. Figure 4 and Figure 5 As shown. It should be noted that a single fractional-turn coil cannot work; multiple fractional-turn coils are needed to form a magnetic circuit, creating a closed magnetic loop, for the output to function properly.

[0019] Non-center tapped mode (suitable for full-bridge rectifier circuits): Four fractional-turn coils together form a complete magnetic loop, which appears as a direct parallel output in the circuit. This mode maximizes the total cross-sectional area of ​​the conductors, thereby significantly reducing conduction losses and meeting the output requirements of extremely high currents.

[0020] To precisely control magnetic parameters and prevent core saturation, controllable air gaps are placed at key locations in the transformer core and leakage inductance core. By precisely adjusting the dimensions of these air gaps, the excitation inductance and leakage inductance (used as a resonant inductor) of the transformer can be adjusted independently or in conjunction, while ensuring that the core operates within a safe range of maximum magnetic flux density, thereby achieving optimal circuit performance.

[0021] The entire device adopts a flat design concept. The magnetic core primarily uses a combination of low-profile E-type, I-type, or planar magnetic cores, while the windings are made of copper foil or flat copper wire. This design greatly reduces the vertical height of the device, reduces its size, increases power density, and facilitates heat dissipation, perfectly meeting the stringent requirements of modern switching power supplies for miniaturization, flatness, and high power density.

[0022] In summary, this fractional-turn magnetic integrated transformer device, through its unique core layout, innovative fractional-turn secondary winding, and adjustable leakage inductance design, successfully integrates a transformer with a resonant inductor, providing a high-performance, highly integrated solution for high-efficiency, low-voltage, high-current power supply applications.

[0023] It should be noted that the above content merely illustrates the technical concept of this utility model and cannot be used to limit the scope of protection of this utility model. For those skilled in the art, several improvements and modifications can be made without departing from the principle of this utility model, and all such improvements and modifications fall within the scope of protection of the claims of this utility model.

Claims

1. A fractional-turn magnetic integrated transformer device, characterized in that, The device includes: Transformer core, leakage inductance core, primary winding, and secondary winding, wherein: The transformer core includes a first magnetic column, a second magnetic column, and a third magnetic column; The leakage inductance core includes a fourth magnetic column and a fifth magnetic column; The primary winding is wound on the surface of the first magnetic post, and the two coil terminals of the primary winding are located on the primary side of the transformer; The secondary winding contains four half-turn coils; The transformer and leakage inductance core are configured with a space air gap. Under the condition of satisfying the maximum magnetic induction intensity of the core, the excitation inductance and leakage inductance of the transformer are adjusted.

2. The fractional-turn magnetic integrated transformer device according to claim 1, characterized in that, The second and third magnetic pillars are symmetrically distributed relative to the first magnetic pillar, with the first magnetic pillar located in the exact center.

3. The fractional-turn magnetic integrated transformer device according to claim 1, characterized in that, The fourth and fifth magnetic pillars are spatially symmetrically distributed relative to the first magnetic pillar, and their distribution direction is perpendicular to the distribution direction of the second and third magnetic pillars.

4. The fractional-turn magnetic integrated transformer device according to claim 1, characterized in that, The two coil terminals of the primary winding are located on the primary side of the transformer, and are wound out from one side of the fourth and fifth magnetic posts, or from both sides.

5. The fractional-turn magnetic integrated transformer device according to claim 1, characterized in that, The secondary winding coil uses one-third or one-quarter of the turns.

6. The fractional-turn magnetic integrated transformer device according to claim 1, characterized in that, If the secondary winding is considered as a center-tapped transformer, then every two half-turn coils form a magnetic circuit. These two half-turn coils need to be distributed on both sides of the first magnetic post, which is a parallel output in the circuit. When two half-turns have output current, the other two half-turns have no current.

7. The fractional-turn structure magnetic integrated transformer device according to claim 1, characterized in that, If the secondary winding is considered as a non-center-tapped transformer, then the four fractional-turn coils form a magnetic loop, which is represented as a parallel output in the circuit to increase the output current.

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