Modular stacked magnetic component

Abstract

To provide a modular stacked magnetic component capable of reducing the volume and loss of magnetic cores and achieving better flux distribution.SOLUTION: A modular stacked magnetic component 100 is for a DC-DC converter with N phases, and N is an odd number greater than 1. In the N phases, an nth phase is 360 / N degrees leading an (n+1)th phase; n is a positive integer less than N; and an Nth phase is 360 / N degrees leading a first phase. For example, the modular stacked magnetic component includes a plurality of magnetic cores 11, 12, 13, a magnetic cover 10 and a plurality of windings 21, 22, 23. The magnetic cores are stacked vertically in sequence. The magnetic cover is stacked on the top of the magnetic cores. The windings are connected to the phases of the DC-DC converter, respectively, and each winding is wound on winding columns of a corresponding magnetic core to form an integrated transformer and inductor. Any two adjacent windings have opposite current directions.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE This disclosure relates to magnetic components, and more particularly to modular stacked magnetic components. [Background technology]

[0002] With the rapid development of information technology (IT), especially cloud computing, big data, and artificial intelligence (AI), data center power consumption is increasing significantly. The power level of each power supply unit needs to be significantly increased without increasing its footprint. As a result, multiphase LLCs have become one of the leading candidates for data center applications due to their low root mean square (RMS) and peak current (PMS) requirements, low current ripple in DC capacitors, and better magnetic integration and power density. However, the integration of multiphase transformers and inductors in high-power applications remains a challenge due to magnetic flux concentration, eddy current losses, dimensional resonance, and physical size limitations.

[0003] Therefore, there is a need to provide a modular laminated magnetic component to overcome the shortcomings of the prior art. Summary of the Invention Problem to be solved

[0004] The present disclosure provides a modular laminated magnetic component that can reduce the volume and losses of the magnetic core and achieve better magnetic flux distribution. [Means for solving the problem]

[0005] According to one aspect of the present disclosure, a modular laminated magnetic component is provided. The modular laminated magnetic component is for use in an N-phase DC-DC converter, where N is an odd number greater than 1. Among the N phases, the nth phase leads the (n+1)th phase by 360 / N degrees, where n is a positive integer less than N, and the Nth phase leads the first phase by 360 / N degrees. The modular laminated magnetic component includes N magnetic cores, a magnetic cover, and N windings. The N magnetic cores are stacked vertically in order, each magnetic core including a plate and multiple winding columns, with the multiple winding columns disposed on the plate. The magnetic cover is stacked on top of the N magnetic cores. The N windings are respectively connected to the N phases of the DC-DC converter, and each of the N windings is wound around the multiple winding columns of the corresponding N magnetic cores to form an integrated transformer and inductor. Any two adjacent windings among the N windings have opposite current directions.

[0006] According to another aspect of the present disclosure, a modular laminated magnetic component is provided. The modular laminated magnetic component is for use in a single-phase DC-DC converter. The modular laminated magnetic component includes multiple magnetic cores, a magnetic cover, and multiple windings. The multiple magnetic cores are vertically stacked in order, each magnetic core including a plate and at least one winding column, with the at least one winding column disposed on the plate. The magnetic cover is stacked on top of the multiple magnetic cores. Each winding is wound around at least one winding column of a corresponding one of the multiple magnetic cores to form an integrated transformer and inductor, or a transformer or inductor. The multiple windings have the same current direction.

[0007] The above disclosure will become more readily apparent to those skilled in the art from the following detailed description and accompanying drawings. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a schematic diagram illustrating a modular stacked magnetic component according to one embodiment of the present disclosure. [Figure 2A]FIG. 1 is a schematic diagram showing a modular multilayer magnetic component applied to a single-phase DC-DC converter. [Figure 2B] 2B shows a schematic diagram of the magnetic flux relationships in FIG. 2A. [Figure 3A] FIG. 1 is a schematic diagram showing a modular multilayer magnetic component applied to a three-phase DC-DC converter. [Figure 3B] 3B shows a schematic diagram of the magnetic flux relationships in FIG. 3A. [Figure 4] FIG. 1 is a circuit schematic diagram illustrating a three-phase DC-DC converter with an integrated transformer and inductor formed with modular stacked magnetic components of the present disclosure. [Figure 5A] FIG. 5 is a schematic diagram illustrating a modular stacked magnetic component applied in the three-phase DC-DC converter of FIG. 4 operating under light load conditions. [Figure 5B] 5B shows a schematic diagram of the magnetic flux relationships in FIG. 5A. [Figure 6] FIG. 1 is a circuit schematic diagram illustrating another three-phase DC-DC converter with an integrated transformer and inductor formed with modular stacked magnetic components of the present disclosure. [Figure 7A] 1 illustrates different types of magnetic cores and winding methods. [Figure 7B] 1 illustrates different types of magnetic cores and winding methods. [Figure 7C] Illustrates different types of magnetic cores and winding methods. [Figure 8] FIG. 7D is a schematic perspective view showing an example of the modular stacked magnetic component of FIG. 7C. [Figure 9] FIG. 1 is a schematic perspective view illustrating a modular laminated magnetic component including a magnetic core without side columns according to one embodiment of the present disclosure. [Figure 10A] FIG. 1 is a schematic diagram illustrating a modular stacked magnetic component applied to a five-phase DC-DC converter according to an embodiment of the present disclosure. [Figure 10B] 10B shows a schematic diagram of the magnetic flux relationships in FIG. 10A. [Figure 11A]FIG. 10 is a schematic diagram illustrating a modular stacked magnetic component applied to a five-phase DC-DC converter according to another embodiment of the present disclosure. [Figure 11B] 11B shows a schematic diagram of the magnetic flux relationships in FIG. 11A. [Figure 12A] 10A and 10B show schematic diagrams of two possible implementations of the inductor-forming portion of the integrated transformer and inductor of FIG. 9; [Figure 12B] 10A and 10B show schematic diagrams of two possible implementations of the inductor-forming portion of the integrated transformer and inductor of FIG. 9; DETAILED DESCRIPTION OF THE INVENTION

[0009]

[0033] Hereinafter, embodiments of the present disclosure will be described in more detail. However, it should be noted that the following description of preferred embodiments of the present disclosure is presented for purposes of illustration and description only and is not intended to be exhaustive or limited to the precise forms disclosed.

[0010] Planar transformers with PCB windings have proven effective in enabling reliable automated manufacturing processes. However, integrating them into the Open Rack V3 (ORV3) standard presents challenges, especially for power supply units (PSUs) above 5kW. The main issues include the large footprint, compromised z-axis optimization, and underutilized height in one-rack-unit (1U) designs where the z-axis is perpendicular to the plane of the PCB.

[0011] The inventors have found that a limitation of conventional planar structures is that they do not fully utilize the degrees of freedom provided by the separated electrical and magnetic paths of a symmetrical multiphase system. Furthermore, planar transformers sacrifice the degree of freedom for z-axis optimization.

[0012] FIG. 1 is a schematic diagram illustrating a modular laminated magnetic component according to one embodiment of the present disclosure. As shown in FIG. 1, the modular laminated magnetic component 100 is applicable to a DC-DC converter and includes multiple magnetic cores (e.g., three magnetic cores 11, 12, and 13 shown in the figure), a magnetic cover 10, and multiple windings (e.g., three windings 21, 22, and 23 shown in the figure). The multiple magnetic cores are stacked vertically in order, and each magnetic core includes a plate (e.g., three plates 110, 120, and 130 shown in the figure) and one or more winding columns (e.g., side columns 111, 121, and 131 shown in the figure) disposed on the plate. In one embodiment, between any two adjacent magnetic cores, there is an air gap between the winding column of one magnetic core and the plate of the other magnetic core. The magnetic cover 10 is stacked on top of the multiple magnetic cores. A plurality of windings are connected to the phases of the DC-DC converter, and each winding is wound on one or more winding columns of a corresponding magnetic core to form an integrated transformer and inductor, a transformer, or an inductor. In some embodiments, the windings are implemented by PCB (printed circuit board) windings or wire windings. And, when the windings are implemented by PCB windings, the windings and the corresponding magnetic core form an integrated planar transformer and inductor, a planar transformer, or a planar inductor, respectively.

[0013] In this embodiment, the modular stacked magnetic component 100 includes a magnetic cover 10 disposed on a plurality of magnetic cores, i.e., magnetic core 11. Conventionally, multiple magnetic covers are disposed on a plurality of magnetic cores, respectively, but in this disclosure, the magnetic cover 10 is disposed only on the topmost magnetic core. Therefore, the overall volume of the magnetic component is reduced. In one embodiment, there are air gaps between adjacent magnetic cores (e.g., between magnetic cores 11 and 12, and between magnetic cores 12 and 13) and between magnetic core 11 and its adjacent magnetic cover 10.

[0014] Furthermore, the modular stacked magnetic component 100 is applicable to DC-DC converters with an odd number of phases, and the number of magnetic cores and the directional relationship between the currents flowing through the windings are related to the number of phases of the DC-DC converter. For example, the number of phases of the DC-DC converter may be any odd number. If the DC-DC converter has only one phase (i.e., a single phase), the number of magnetic cores may be any integer greater than 1, and all windings have the same current direction. Alternatively, if the number of phases of the DC-DC converter is an odd number greater than 1, the number of magnetic cores may be an integer multiple of the number of phases of the DC-DC converter, and any two adjacent windings have opposite current directions. FIG. 2A is a schematic diagram showing a modular multilayer magnetic component applied to a single-phase DC-DC converter. In FIG. 2A, components and elements corresponding to those in FIG. 1 are designated by the same reference numerals, and detailed descriptions thereof are omitted here. As shown in FIG. 2A, a modular multilayer magnetic component 100a is applied to a single-phase DC-DC converter and includes two magnetic cores 11 and 12 and two windings 21 and 22. The two windings 21 and 22 are wound on the two magnetic cores 11 and 12, respectively. In a single-phase DC-DC converter, the modular multilayer magnetic component may include three or more magnetic cores. The currents flowing through the windings 21 and 22 are from the same phase of the DC-DC converter and have the same direction. A magnetic flux Φ1 caused by a current flowing through the winding 21 flows through the magnetic cover 10 and the magnetic core 11. A magnetic flux Φ2 caused by a current flowing through the winding 22 flows through the magnetic cores 11 and 12. In this embodiment, because the currents have the same direction, the magnetic fluxes Φ1 and Φ2 in the magnetic core 11 are opposite in direction and cancel each other out. The relationship between the magnetic fluxes Φ1 and Φ2 is shown in FIG. 2B. Furthermore, because the magnetic fluxes in the magnetic core 11 cancel each other out, reducing the thickness of the plates in the magnetic core 11 reduces the volume and loss of the modular stacked magnetic component 100a and achieves better magnetic flux distribution. Generally, when the modular stacked magnetic component is applied to a single-phase DC-DC converter, due to the magnetic flux cancellation, the thickness of the plates in the middle magnetic core (e.g., magnetic core 11 in FIG. 2A) can be varied from a predetermined minimum thickness with acceptable mechanical strength to the thickness of the plates in the magnetic cover 10 (or the top magnetic core) or the bottom magnetic core (e.g., magnetic core 12 in FIG. 2A). Furthermore, in one embodiment, the air gaps between the magnetic cores 11 and 12 and between the magnetic core 11 and the adjacent magnetic cover 10 have the same size.

[0015] Please refer to FIG. 3A. FIG. 3A is a schematic diagram showing a modular stacked magnetic component applied to a three-phase DC-DC converter. In the present disclosure, a three-phase DC-DC converter can be expanded to an N-phase DC-DC converter, where N is an odd number greater than 1. In FIG. 3A, components and elements corresponding to those in FIG. 1 are designated by the same reference numerals, and detailed descriptions thereof will be omitted here. For an N-phase DC-DC converter, the nth phase leads the (n+1)th phase by 360 / N degrees, and the Nth phase leads the first phase by 360 / N degrees, where n is a positive integer less than N. Correspondingly, a modular stacked magnetic component may include one or more sets of magnetic cores and windings, each set including N magnetic cores and N windings. Note that the N windings are respectively connected to the N phases of the DC-DC converter and wound around the N magnetic cores. Furthermore, when a modular stacked magnetic component includes multiple sets, the multiple sets may be stacked in order in the lamination direction of the magnetic cores. Here, the stacking direction of the magnetic cores is set from top to bottom, for example, from the first magnetic core to the Nth magnetic core.

[0016] As shown in FIG. 3A, the modular stacked magnetic component 100b is applied to a three-phase DC-DC converter (i.e., N=3) and includes three magnetic cores 11, 12, and 13 and three windings 21, 22, and 23, respectively. The three windings 21, 22, and 23 are wound on the three magnetic cores 11, 12, and 13, respectively. The three windings 21, 22, and 23 are connected to the first to third phases of the DC-DC converter, respectively. That is, the currents flowing through the three windings 21, 22, and 23 are from the first, second, and third phases of the DC-DC converter. Furthermore, the direction of the current flowing through the winding 22 is opposite to the direction of the currents flowing through the windings 21 and 23. A magnetic flux Φ1 induced by the current flowing through the winding 21 flows through the magnetic cover 10 and the magnetic core 11. A magnetic flux Φ2 induced by the current flowing through the winding 22 flows through the magnetic cores 11 and 12. A magnetic flux Φ3 caused by the current flowing through winding 23 flows through magnetic cores 12 and 13. The relationship between magnetic fluxes Φ1, Φ2, and Φ3 is shown in Figure 3B. In this embodiment, because the currents flowing through windings 21 and 22 have opposite directions, the magnetic fluxes Φ1 and Φ2 in magnetic core 11 have the same direction, and therefore the total magnetic flux in magnetic core 11 is equal to the sum of magnetic fluxes Φ1 and Φ2. Similarly, because the currents flowing through windings 22 and 23 have opposite directions, the magnetic fluxes Φ2 and Φ3 in magnetic core 12 have the same direction, and therefore the total magnetic flux in magnetic core 12 is equal to the sum of magnetic fluxes Φ2 and Φ3.

[0017] FIG. 4 is a schematic circuit diagram illustrating a three-phase DC-DC converter with an integrated transformer and inductor formed using modular stacked magnetic components according to the present disclosure. Please refer to FIG. 4 in conjunction with FIG. 3A. The inductor L1 and transformer TR1 of the first phase of the DC-DC converter are an integrated transformer and inductor formed by a magnetic core 11 and a winding 21. The inductor L2 and transformer TR2 of the second phase of the DC-DC converter are an integrated transformer and inductor formed by a magnetic core 12 and a winding 22. The inductor L3 and transformer TR3 of the third phase of the DC-DC converter are an integrated transformer and inductor formed by a magnetic core 13 and a winding 23. In some embodiments of the present disclosure, the three transformers and three inductors in the three-phase DC-DC converter may be configured using three integrated transformers and inductors. Furthermore, in other embodiments of the present disclosure, the three transformers and inductors may be integrated into a single integrated transformer and inductor.

[0018] Furthermore, in one embodiment, when the DC-DC converter operates under light load conditions, only two of the three phases (the second phase and either the first or third phase) continue to operate to improve efficiency. FIG. 5A is a schematic diagram showing a modular stacked magnetic component 100b applied to the three-phase DC-DC converter of FIG. 4 operating under light load conditions. In this embodiment, only the first and second phases of the three-phase DC-DC converter operate to improve efficiency under light load conditions. Correspondingly, as shown in FIG. 5A, magnetic fluxes Φ1 and Φ2 are generated only in the magnetic cover 10 and the magnetic cores 11 and 12. The relationship between the magnetic fluxes Φ1 and Φ2 is shown in FIG. 5B. Under light load conditions, because only two phases operate, the phase difference between the magnetic fluxes Φ1 and Φ2 is 180 degrees. Therefore, the total magnetic flux in the magnetic core 11, which is equal to the sum of the magnetic fluxes Φ1 and Φ2, is zero or close to zero.

[0019] Furthermore, although the three-phase DC-DC converter shown in Figure 4 includes a coupled three-phase interleaved LLC circuit, DC-DC converters that can employ the modular stacked magnetic components of the present disclosure are not limited to this. For example, as shown in Figure 6, a three-phase DC-DC converter that uses the modular stacked magnetic components of the present disclosure to form inductors L1, L2, and L3 and transformers TR1, TR2, and TR3 includes a separated three-phase interleaved LLC circuit. It should be noted that possible implementations of DC-DC converters are not limited to the illustrated topology.

[0020] Please refer again to Figure 1. In the embodiment of Figure 1, the magnetic cores 11, 12, and 13 of the modular stacked magnetic component 100 are C-shaped cores, and the windings 21, 22, and 23 are wound on the side columns of the magnetic cores 11, 12, and 13 (i.e., the side columns of the magnetic cores 11, 12, and 13 function as winding columns). In particular, the magnetic core 11 includes a plate 110 and two side columns 111, which are disposed on the plate 110 and located on both sides of the plate 110, and the windings 21 are wound on the side columns 111. The magnetic core 12 includes a plate 120 and two side columns 121, which are disposed on the plate 120 and located on both sides of the plate 120, and the windings 22 are wound on the side columns 121. The magnetic core 13 includes a plate 130 and two side columns 131, which are disposed on the plate 130 and located on both sides of the plate 130, and the winding 23 is wound around the side columns 131.

[0021] It should be noted that the shape and winding method of the magnetic core are not limited thereto. For example, the magnetic core may be an E-core, a U-core, a T-core, or any other suitable planar core. Meanwhile, the windings may be wound around the central column or any other suitable portion of the magnetic core. Figures 7A, 7B, and 7C illustrate different types of magnetic cores and winding methods.

[0022] In the embodiment shown in FIG. 7A , the magnetic cores 11a, 12a, and 13a of the modular laminated magnetic component 100c are E-shaped cores, and the windings 21, 22, and 23 are wound around the center and side columns of the magnetic cores 11a, 12a, and 13a (i.e., the center and side columns of the magnetic cores 11a, 12a, and 13a function as winding columns). In particular, in the modular laminated magnetic component 100c, the magnetic core 11a includes a plate 110, two side columns 111, and a center column 112. The two side columns 111 and the center column 112 are disposed on the plate 110, with the two side columns 111 located on either side of the plate 110 and the center column 112 located between the two side columns 111. The winding 21 is wound around the two side columns 111 and the center column 112 of the magnetic core 11a. The magnetic core 12a includes a plate 120, two side columns 121, and a center column 122. The two side columns 121 and the center column 122 are arranged on the plate 120, with the two side columns 121 located on either side of the plate 120 and the center column 122 located between the two side columns 121. The windings 22 are wound around the two side columns 121 and the center column 122 of the magnetic core 12a. The magnetic core 13a includes a plate 130, two side columns 131, and the center column 132. The two side columns 131 and the center column 132 are arranged on the plate 130, with the two side columns 131 located on either side of the plate 130 and the center column 132 located between the two side columns 131. The windings 23 are wound around the two side columns 131 and the center column 132 of the magnetic core 13a.

[0023] In the embodiment shown in Figure 7B, the structure of the modular stacked magnetic component 100c is the same as that shown in Figure 7A. The difference between the embodiments of Figures 7A and 7B is that in Figure 7B, the windings 21, 22, and 23 are wound around the central columns 112, 122, and 132 of the magnetic cores 11a, 12a, and 13a, respectively (i.e., the central columns 112, 122, and 132 of the magnetic cores 11a, 12a, and 13a function as winding columns).

[0024] In the embodiment shown in FIG. 7C , each of the magnetic cores 11b, 12b, and 13b of the modular laminated magnetic component 100d includes two intermediate columns and one central column as winding columns and two side columns as non-winding columns, and windings 21, 22, and 23 are wound around the central and intermediate columns of the magnetic cores 11b, 12b, and 13b. Components and elements corresponding to those in FIG. 7A are designated by the same reference numerals and will not be described in detail here. In particular, in the modular laminated magnetic component 100d, the magnetic core 11b further includes two intermediate intermediate columns 113 disposed on the plate 110. One intermediate column 113 is located between the central column 112 and one of the side columns 111, and the other intermediate intermediate column 113 is located between the central column 112 and the other side column 111. The winding 21 is wound around the central column 112 and the two intermediate columns 113 of the magnetic core 11b. The magnetic core 12b further includes two intermediate columns 123 arranged on the plate 120. One intermediate column 123 is located between the center column 122 and one of the side columns 121, and the other intermediate column 123 is located between the center column 122 and the other side column 121. The winding 22 is wound around the center column 122 and the two intermediate columns 123 of the magnetic core 12b. The magnetic core 13b further includes two intermediate columns 133 arranged on the plate 130. One intermediate column 133 is located between the center column 132 and one of the side columns 131, and the other intermediate column 133 is located between the center column 132 and the other side column 131. The winding 23 is wound around the center column 132 and the two intermediate columns 133 of the magnetic core 13b. For ease of understanding, a schematic perspective view illustrating an example of the modular stacked magnetic component of FIG. 7C is shown in FIG. 8.

[0025] In the above-described embodiments, the magnetic core always includes side columns. However, the present disclosure is not limited thereto. See FIG. 9. FIG. 9 is a schematic perspective view illustrating a modular laminated magnetic component including a magnetic core without side columns according to one embodiment of the present disclosure. Components and elements corresponding to those in FIG. 8 are designated by the same reference numerals and will not be described in detail here. As shown in FIG. 9, each of the magnetic cores 11c, 12c, and 13c of the modular laminated magnetic component 100e includes plates (110, 120, and 130) and multiple winding columns, with each winding wound around the multiple winding columns of the corresponding magnetic core. For example, the magnetic core 11c includes two inductor winding columns 114 and two transformer winding columns 115, and the winding 21 is wound around the two inductor winding columns 114 and the two transformer winding columns 115 to form an integrated transformer and inductor. Specifically, the winding 21 includes an inductor winding and a transformer winding, the inductor winding of the winding 21 being wound around two inductor winding columns 114 to form an inductor portion of an integrated transformer and inductor, and the transformer winding of the winding 21 being wound around two transformer winding columns 115 to form a transformer portion of an integrated transformer and inductor. Furthermore, each magnetic core may have an inductor air gap and a transformer air gap between its winding column and the magnetic cover 10 or another magnetic core disposed thereon. For example, the magnetic core 11c has an inductor air gap formed between the inductor winding column 114 and the magnetic cover 10, and a transformer air gap formed between the transformer winding column 115 and the magnetic cover 10. Furthermore, the inductor air gaps of the magnetic cores may be the same (within a tolerance range), and the transformer air gaps of the magnetic cores may be the same (within a tolerance range). The inductor air gaps and the transformer air gaps may be the same or different.

[0026] FIG. 10A is a schematic diagram showing a modular stacked magnetic component applied to a five-phase DC-DC converter according to one embodiment of the present disclosure. In FIG. 10A, components and elements corresponding to those in FIG. 1 are designated by the same reference numerals, and detailed descriptions thereof are omitted. Among the five phases of the DC-DC converter, the nth phase leads the (n+1)th phase by 72 degrees, and the fifth phase leads the first phase by 72 degrees. As shown in FIG. 10A, the modular stacked magnetic component 100f includes five magnetic cores 11, 12, 13, 14, and 15 and five windings 21, 22, 23, 24, and 25 wound around the five magnetic cores 11, 12, 13, 14, and 15, respectively. Among the five windings 21, 22, 23, 24, and 25, any two adjacent windings have opposite current directions. The phases of the DC-DC converter connected to the five windings 21, 22, 23, 24, and 25 may be determined based on the phase difference of the magnetic flux generated in each magnetic core. For example, in each magnetic core, the phase difference of the magnetic flux generated by the current flowing through adjacent windings must be greater than 90 degrees and less than 270 degrees. This reduces the total magnitude of the magnetic flux. In other words, any two adjacent windings can be connected to two phases with a phase difference greater than 90 degrees and less than 270 degrees.

[0027] In the embodiment of Figure 10A, windings 21, 22, 23, 24, and 25 are connected to the first, third, fifth, second, and fourth phases of the DC-DC converter, respectively. A magnetic flux Φ1 caused by a current flowing through winding 21 flows through magnetic cover 10 and magnetic core 11. A magnetic flux Φ3 caused by a current flowing through winding 22 flows through magnetic cores 11 and 12. A magnetic flux Φ5 caused by a current flowing through winding 23 flows through magnetic cores 12 and 13. A magnetic flux Φ2 caused by a current flowing through winding 24 flows through magnetic cores 13 and 14. A magnetic flux Φ4 caused by a current flowing through winding 25 flows through magnetic cores 14 and 15. Therefore, the total magnetic flux in magnetic core 11 is equal to the sum of magnetic fluxes Φ1 and Φ3, the total magnetic flux in magnetic core 12 is equal to the sum of magnetic fluxes Φ3 and Φ5, the total magnetic flux in magnetic core 13 is equal to the sum of magnetic fluxes Φ5 and Φ2, and the total magnetic flux in magnetic core 14 is equal to the sum of magnetic fluxes Φ2 and Φ4. The relationship between magnetic fluxes Φ1, Φ2, Φ3, Φ4, Φ5 and the total magnetic fluxes is shown in Figure 10B.

[0028] FIG. 11A is a schematic diagram illustrating a modular stacked magnetic component applied to a five-phase DC-DC converter according to another embodiment of the present disclosure. In FIG. 11A, components and elements corresponding to those in FIG. 10A are designated by the same reference numerals, and detailed descriptions thereof are omitted here. The difference between the embodiments of FIG. 10A and FIG. 11A is the phases of the DC-DC converter connected to five windings 21, 22, 23, 24, and 25. In particular, in the embodiment of FIG. 11A, windings 21, 22, 23, 24, and 25 are connected to the first, fourth, second, fifth, and third phases of the DC-DC converter, respectively. A magnetic flux Φ1 caused by a current flowing through winding 21 flows through magnetic cover 10 and magnetic core 11. A magnetic flux Φ4 caused by a current flowing through winding 22 flows through magnetic cores 11 and 12. A magnetic flux Φ2 caused by a current flowing through winding 23 flows through magnetic cores 12 and 13. A magnetic flux Φ5 caused by current flowing through winding 24 flows through magnetic cores 13 and 14. A magnetic flux Φ3 caused by current flowing through winding 25 flows through magnetic cores 14 and 15. Thus, the total magnetic flux in magnetic core 11 is equal to the sum of magnetic fluxes Φ1 and Φ4, the total magnetic flux in magnetic core 12 is equal to the sum of magnetic fluxes Φ4 and Φ2, the total magnetic flux in magnetic core 13 is equal to the sum of magnetic fluxes Φ2 and Φ5, and the total magnetic flux in magnetic core 14 is equal to the sum of magnetic fluxes Φ5 and Φ3. The relationship between magnetic fluxes Φ1, Φ2, Φ3, Φ4, and Φ5 and the above total magnetic fluxes is shown in Figure 11B.

[0029] Based on the illustrated applications of modular stacked magnetic components in single-phase, three-phase, and five-phase DC-DC converters, the application of the modular stacked magnetic components of the present disclosure can be extended and implemented in a similar manner to DC-DC converters having more phases.

[0030] Furthermore, in the modular laminated magnetic components of the present disclosure, the layers of windings that, together with the corresponding magnetic core, form an inductor or the inductor portion of an integrated transformer and inductor may be arranged in a specific manner to reduce footprint and loss. Figures 12A and 12B schematically illustrate two possible implementations of the portion forming the inductor portion of the integrated transformer and inductor of Figure 9. Specifically, Figures 12A and 12B show the magnetic cover 10, the winding 21, and the inductor winding column 114 and plate 110 of the magnetic core 11c, with the winding 21 wound around the inductor winding column 114 to form the inductor portion of the integrated transformer and inductor. As shown in Figures 12A and 12B, the magnetic core 11c has an air gap g between the inductor winding column 114 and the magnetic cover 10, and the winding 21 wound around the inductor winding column 114 includes M layers, where M is an integer greater than 2. For example, among the M layers of the winding 21, the layer closest to the air gap g is the first layer LY1, and the layer farthest from the air gap g is the Mth layer LYM, with the first through Mth layers LY1-LYM stacked vertically in order. In one embodiment, if M is an even number, the mth closest layer to the air gap g is electrically connected in parallel with the mth farthest layer from the air gap g to form the mth layer set, where m is a positive integer less than or equal to M / 2, and all layer sets are electrically connected in series. Alternatively, if M is an odd number, the mth closest layer to the air gap g is electrically connected in parallel with the mth farthest layer from the air gap g to form the mth layer set, where m is a positive integer less than or equal to (M-1) / 2, and all layer sets are electrically connected in series with the middle layer (i.e., the ((M+1) / 2)th layer). The above method of connecting winding layers can reduce footprint and winding losses.

[0031] The difference between the implementations shown in Figures 12A and 12B is the number of layers of the winding 21. In Figure 12A, M is an even number, 6. The first layer LY1, closest to the air gap g, is electrically connected in parallel with the sixth layer LY6, farthest from the air gap g, to form the first layer set. The second layer LY2, second closest to the air gap g, is electrically connected in parallel with the fifth layer LY5, second farthest from the air gap g, to form the second layer set. The third layer LY3, third closest to the air gap g, is electrically connected in parallel with the fourth layer LY4, third farthest from the air gap g, to form the third layer set. The first through third layer sets are electrically connected in series.

[0032] In Figure 12B, M is an odd number, 5. The first layer LY1, closest to the air gap g, is electrically connected in parallel with the fifth layer LY5, farthest from the air gap g, to form the first layer set. The second layer LY2, second closest to the air gap g, is electrically connected in parallel with the fourth layer LY4, second farthest from the air gap g, to form the second layer set. The middle third layer LY3 and the first and second layer sets are electrically connected in series.

Claims

1. A modular laminated magnetic component for an N-phase DC-DC converter, comprising: N is an odd number greater than 1, and in the N phases, the nth phase leads the (n+1)th phase by 360 / N degrees, and n is a positive integer less than N, and the Nth phase leads the first phase by 360 / N degrees; The modular stacked magnetic component comprises: N magnetic cores stacked vertically in order, each of the N magnetic cores including a plate and a plurality of winding columns, the plurality of winding columns being disposed on the plate; a magnetic cover laminated on the N magnetic cores; N windings respectively connected to the N phases of the DC-DC converter, each of the N windings being wound around the plurality of winding columns of a corresponding one of the N magnetic cores to form an integrated transformer and inductor; A modular laminated magnetic component, wherein any two adjacent windings among the N windings have current directions opposite to each other.

2. 2. The modular laminated magnetic component of claim 1, wherein two magnetic fluxes generated by any two adjacent windings among the N windings at least partially cancel each other out on a plate between the two adjacent windings.

3. 3. The modular laminated magnetic component of claim 2, wherein the phase difference between the two magnetic fluxes is greater than 90 degrees and less than 270 degrees.

4. 4. The modular stacked magnetic component of claim 3, wherein a thickness of a plate between two adjacent windings is less than or equal to a thickness of the magnetic cover or a thickness of a plate of an Nth magnetic core among the N magnetic cores.

5. 2. The modular laminated magnetic component of claim 1, wherein in any two adjacent magnetic cores among the N magnetic cores, there is an air gap between the plurality of winding columns of one magnetic core and the plate of the other magnetic core.

6. 6. The modular laminated magnetic component of claim 5, wherein each of the N windings includes M layers stacked vertically in sequence, where M is an even number greater than 2, and wherein the mth layer closest to the air gap is electrically connected in parallel with the mth layer farthest from the air gap to form a layer set, where m is a positive integer less than or equal to M / 2, and all of the layer sets are electrically connected in series.

7. Each of the N windings includes M layers stacked vertically in sequence; M is an odd number greater than 2, Among the M layers, the layer closest to the gap is electrically connected in parallel with the layer farthest from the gap to form a layer set; m is a positive integer equal to or less than (M-1) / 2, 6. The modular laminated magnetic component of claim 5, wherein the ((M+1) / 2)th layer and all said layer sets are electrically connected in series.

8. the plurality of winding columns include an inductor winding column and a transformer winding column; each of the N windings includes an inductor winding and a transformer winding; the inductor winding is wound on the inductor winding column; 6. The modular laminated magnetic component of claim 5, wherein the transformer winding is wound on the transformer winding column.

9. In any two adjacent magnetic cores of the N magnetic cores, the air gaps between the inductor winding column of one magnetic core and the plate of the other magnetic core have the same size; 9. The modular laminated magnetic component of claim 8, wherein the air gaps between the transformer winding column of one magnetic core and the plate of the other magnetic core have the same size.

10. 10. The modular stacked magnetic component of claim 1, wherein the DC-DC converter includes an N-phase interleaved LLC circuit.

11. 10. The modular laminated magnetic component of claim 1, wherein said N windings comprise N printed circuit board windings.

12. A modular stacked magnetic component for a single-phase DC-DC converter, comprising: a plurality of magnetic cores stacked vertically in succession, each of the plurality of magnetic cores including a plate and at least one winding column, the at least one winding column disposed on the plate; a magnetic cover laminated on the plurality of magnetic cores; a plurality of windings, each wound on at least one of the winding columns of a corresponding one of the plurality of magnetic cores to form an integrated transformer and inductor, or a transformer or an inductor; The plurality of windings have the same current direction.

13. 13. The modular laminated magnetic component of claim 12, wherein two magnetic fluxes generated by any two adjacent windings among the plurality of windings at least partially cancel each other out on a plate between the two adjacent windings.

14. 14. The modular stacked magnetic component of claim 13, wherein a thickness of a plate between two adjacent windings is equal to or less than a thickness of the magnetic cover or a thickness of a plate of a bottommost magnetic core of the plurality of magnetic cores.

15. 13. The modular stacked magnetic component of claim 12, wherein for any two adjacent magnetic cores of the plurality of magnetic cores, there is an air gap between the at least one winding column of one magnetic core and the plate of the other magnetic core.

16. Each of the plurality of windings includes M layers stacked in a vertical direction; M is an even number greater than 2, Among the M layers, the layer closest to the gap is electrically connected in parallel with the layer farthest from the gap to form a layer set; m is a positive integer equal to or less than M / 2, 16. The modular laminated magnetic component of claim 15, wherein all of the layer sets are electrically connected in series.

17. Each of the plurality of windings includes M layers stacked in a vertical direction; M is an odd number greater than 2, Among the M layers, the layer closest to the gap is electrically connected in parallel with the layer farthest from the gap to form a layer set; m is a positive integer equal to or less than (M-1) / 2, 16. The modular laminated magnetic component of claim 15, wherein the ((M+1) / 2)th layer and all layer sets are electrically connected in series.

18. the at least one winding column includes an inductor winding column and a transformer winding column; each of the plurality of windings includes an inductor winding and a transformer winding; the inductor winding is wound on the inductor winding column; 16. The modular laminated magnetic component of claim 15, wherein the transformer winding is wound on the transformer winding column.

19. 19. The modular stacked magnetic component of claim 18, wherein, between any two adjacent magnetic cores of the plurality of magnetic cores, the air gaps between the inductor winding column of one magnetic core and the plate of the other magnetic core have the same size, and the air gaps between the transformer winding column of one magnetic core and the plate of the other magnetic core have the same size.

20. The modular laminated magnetic component of claim 12 , wherein the plurality of windings comprises a plurality of printed circuit board windings.

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