Magnetic components

Abstract

A magnetic component with adjustable leakage inductance is provided. [Solution] The magnetic component includes a primary winding, a secondary winding, and at least one tertiary winding stacked on top of each other, forming a symmetric or asymmetric inductance structure. In a symmetric inductance structure, the relationship between the distances of the primary winding, the secondary winding, and the at least one tertiary winding allows for balancing the leakage inductance, stabilizing tolerances, suppressing reverse current, reducing AC losses in the tertiary winding, and / or reducing total losses. In an asymmetric inductance structure, the relationship between the distances of the primary winding, the secondary winding, and at least one tertiary winding allows for more flexible adjustment of the leakage inductance, stabilizing tolerances, and reducing coupling energy.

Description

Technical Field

[0001] The present invention relates to magnetic components, and more specifically, to magnetic components with adjustable leakage inductance.

Background Art

[0002] A transformer is an important magnetic component used to raise or lower voltage. Almost every circuit incorporates a transformer. In a multi-port charger, the electromagnetic coupling and voltage stability between the ports of the multi-port charger are closely related to the leakage inductance of the transformer. The leakage inductance determines the quality of energy coupling and the degree of interference between the ports of the multi-port charger. Thus, how to adjust the leakage inductance of the transformer for a multi-port charger has become an important design issue.

Summary of the Invention

Problems to be Solved by the Invention

[0003] The present invention solves the above problems by providing a magnetic component with adjustable leakage inductance.

Means for Solving the Problems

[0004] According to an embodiment of the present invention, the magnetic component includes a core, a primary winding, a secondary winding, a magnetic member, a first tertiary winding, and a second tertiary winding. The primary winding is disposed within the core. The secondary winding is disposed within the core. The magnetic member is disposed between the primary winding and the secondary winding. The first tertiary winding is disposed outside the primary winding. The second tertiary winding is disposed outside the secondary winding. The secondary winding is separated from the second tertiary winding by a first distance d1, the secondary winding is separated from the first tertiary winding by a second distance d2, the primary winding is separated from the first tertiary winding by a third distance d3, and the primary winding is separated from the second tertiary winding by a fourth distance d4. The first distance d1, the second distance d2, the third distance d3, and the fourth distance d4 satisfy 0.8 < (d1 + d2) / (d3 + d4) < 1.2 It satisfies the relationship.

[0005] In one embodiment, the core has an inner leg. The primary winding, secondary winding, first tertiary winding, and second tertiary winding are arranged at different positions along the longitudinal direction of the inner leg without overlapping.

[0006] In one embodiment, the number of turns of the first tertiary winding and the second tertiary winding are less than the number of turns of the primary winding and the secondary winding.

[0007] In one embodiment, the number of turns of the first tertiary winding and the second tertiary winding are less than half the number of turns of the primary winding and the secondary winding, respectively.

[0008] In one embodiment, at least one of the primary winding, secondary winding, first tertiary winding, and second tertiary winding is wound with multi-stranded insulated wire.

[0009] In one embodiment, a multi-stranded insulated wire includes a plurality of stranded wire layers, each of which is covered by a first insulating layer, and the first stranded wire layer includes a plurality of strands, each of which is covered by a second insulating layer.

[0010] In one embodiment, the primary winding, secondary winding, first tertiary winding, and second tertiary winding are either Litz wire or copper sheet.

[0011] In one embodiment, the core includes an I-shaped core, a first U-shaped core, and a second U-shaped core, the first U-shaped core and the second U-shaped core being arranged side by side to form inner legs, with a heat dissipation material filling the gaps in the inner legs, and the I-shaped core being positioned on top of the first U-shaped core and the second U-shaped core.

[0012] In one embodiment, the core has an inner leg and at least two outer legs, and a primary winding, a secondary winding, a first tertiary winding, and a second tertiary winding are wound around the inner leg.

[0013] In one embodiment, the magnetic component further includes a case, a thermally conductive filler, and a conductive member. The core is placed inside the case. The thermally conductive filler is filled inside the case. The thermally conductive filler covers at least a portion of the inner legs of the core and at least a portion of the primary winding, secondary winding, first tertiary winding, and second tertiary winding. The conductive member is placed above the core and the openings of the case. The conductive member includes two conductive metals covered with an insulating material. The first tertiary winding and the second tertiary winding are connected to the conductive member, and a portion of the conductive member is bent into the thermally conductive filler.

[0014] In one embodiment, two conductive metals are positioned opposite each other on either side of the core and do not contact the core or the case. Two bent structures of the two conductive metals located outside the core extend to a thermally conductive filler, and the two bent structures do not contact the core and do not extend to the bottom of the case.

[0015] In one embodiment, the magnetic component further includes a case, a thermally conductive filler, and a conductive member. The core is placed inside the case. The thermally conductive filler is filled inside the case. The thermally conductive filler covers at least a portion of the inner legs of the core and at least a portion of the primary winding, secondary winding, first tertiary winding, and second tertiary winding. The conductive member is placed next to the core. The conductive member includes two conductive metals covered with an insulating material. The first tertiary winding and the second tertiary winding are connected to the conductive member, and a portion of the conductive member is covered with the thermally conductive filler.

[0016] In one embodiment, two conductive metals are arranged side by side on the sides of the core and do not contact the core. Two bent structures of the two conductive metals located outside the core extend to a thermally conductive filler and do not contact the core. The first and second tertiary windings extend to the bottom of the case and are connected to a plurality of engagement holes in the two conductive metals, thereby connecting the first and second tertiary windings in parallel. Two horizontal structures of the two conductive metals protrude from the insulating material to form two electrodes for the first and second tertiary windings. An insulating member is located at the bottom of the case, and the plurality of engagement holes in the two conductive metals are located within the housing space of the insulating member.

[0017] According to another embodiment of the present invention, the magnetic component includes a core, a primary winding, a secondary winding, and a tertiary winding. The primary winding is located within the core. The secondary winding is located within the core. The tertiary winding is located between the primary and secondary windings. The secondary winding is located at a first distance d1 from the tertiary winding, and the primary winding is located at a second distance d2 from the tertiary winding. The first distance d1 and the second distance d2 are 0.8 <d2 / d1<1.2 It satisfies the relationship.

[0018] In one embodiment, the core has an inner leg. The primary winding, secondary winding, and tertiary winding are positioned at different locations along the length of the inner leg without overlapping.

[0019] In one embodiment, the number of turns of the tertiary winding is less than the number of turns of the primary winding and the secondary winding, respectively.

[0020] In one embodiment, the number of turns of the tertiary winding is less than half the number of turns of the primary and secondary windings, respectively.

[0021] In one embodiment, at least one of the primary winding, secondary winding, and tertiary winding is wound with a multi-strand insulated wire.

[0022] In one embodiment, the multi-twisted insulated wire includes a plurality of twisted wire layers, each of the plurality of twisted wire layers is covered by a first insulating layer, the first twisted wire layer of the plurality of twisted wire layers includes a plurality of twisted strands, and each of the plurality of twisted strands is covered by a second insulating layer.

[0023] In one embodiment, any one of the primary winding, the secondary winding, and the tertiary winding is a Litz wire or a copper plate.

[0024] In one embodiment, the core includes a type-I core, a first U-shaped core, and a second U-shaped core. The first U-shaped core and the second U-shaped core are arranged side by side so as to form inner legs, a heat dissipation material is filled in the gap between the inner legs, and the type-I core is arranged on the first U-shaped core and the second U-shaped core.

[0025] In one embodiment, the core has inner legs and at least two outer legs. The primary winding, the secondary winding, and the tertiary winding are wound around the inner legs.

[0026] In one embodiment, the magnetic component further includes a case, a thermally conductive filler, and a conductive member. The core is arranged in the case. The thermally conductive filler is filled in the case. The conductive member is arranged above the opening of the core and the case. The tertiary winding is connected to the conductive member, and a part of the conductive member is bent into the thermally conductive filler.

[0027] In one embodiment, the magnetic component further includes a case, a thermally conductive filler, and a conductive member. The core is arranged in the case. The thermally conductive filler is filled in the case. The conductive member is arranged beside the core. The tertiary winding is connected to the conductive member, and a part of the conductive member is covered by the thermally conductive filler.

[0028] According to another embodiment of the present invention, the magnetic component includes a core, a primary winding, a tertiary winding, a secondary winding, and a magnetic member. The primary winding is located within the core. The tertiary winding is located within the core. The secondary winding is located between the primary and tertiary windings. The magnetic member is located between the secondary and tertiary windings. The secondary winding is located at a first distance d1 from the tertiary winding, and the primary winding is located at a second distance d2 from the tertiary winding. The first distance d1 and the second distance d2 are 0 <d1 / d2<1.2 It satisfies the relationship.

[0029] In one embodiment, the core has an inner leg. The primary winding, secondary winding, and tertiary winding are positioned at different locations along the longitudinal direction of the inner leg without overlapping.

[0030] In one embodiment, the number of turns of the tertiary winding is less than the number of turns of the primary winding and the secondary winding, respectively.

[0031] As described above, in one embodiment, the magnetic member may be placed between the primary winding and the secondary winding, and the first tertiary winding and the second tertiary winding may be placed outside the primary and secondary windings to form a symmetrical inductance structure. The relationship of the distances between the primary winding, the secondary winding, the first tertiary winding, and the second tertiary winding (i.e., 0.8 < (d1 + d2) / (d3 + d4) < 1.2 ) allows for balancing the leakage inductance, stabilizing the tolerance, and reducing the total loss. In another embodiment, the tertiary winding can be positioned between the primary and secondary windings to form a symmetrical inductance structure. The relationship of the distances between the primary, secondary, and tertiary windings (i.e., 0.8 <d2 / d1<1.2 ) allows for the suppression of reverse current, the reduction of AC losses in the tertiary winding, and the reduction of total losses. In another embodiment, the secondary winding is placed between the primary and tertiary windings, and the magnetic member is placed between the secondary and tertiary windings to form an asymmetric inductance structure. The relationship of the distances between the primary, secondary, and tertiary windings (i.e., 0 <d1 / d2<1.2 This allows for more flexible adjustment of leakage inductance, stabilizes tolerances, and reduces coupling energy.

[0032] These and other objectives of the present invention will become apparent to those skilled in the art from the detailed description of preferred embodiments shown in the following various figures and drawings. [Brief explanation of the drawing]

[0033] [Figure 1] This is a perspective view showing a magnetic component according to one embodiment of the present invention. [Figure 2] Figure 1 is an exploded view showing the magnetic components. [Figure 3] This is a cross-sectional view showing the magnetic component shown in Figure 1. [Figure 4] This is a schematic diagram of a multi-strand insulated wire according to one embodiment of the present invention. [Figure 5] This is a perspective view showing a magnetic component according to another embodiment of the present invention. [Figure 6] Figure 5 is an exploded view showing the magnetic components. [Figure 7] Figure 5 is a cross-sectional view showing the magnetic component. [Figure 8] This is a perspective view showing a magnetic component according to another embodiment of the present invention. [Figure 9] Figure 8 is an exploded view showing the magnetic components. [Figure 10] Figure 9 is a perspective view of the component shown from a different angle. [Figure 11] Figure 8 is a cross-sectional view showing the magnetic component. [Figure 12] This is a perspective view showing a magnetic component according to another embodiment of the present invention. [Figure 13] Figure 12 is an exploded view showing the magnetic components. [Figure 14] Figure 12 is a cross-sectional view showing the magnetic component. [Figure 15] This is a perspective view showing a magnetic component according to another embodiment of the present invention. [Figure 16] Figure 15 is an exploded view showing the magnetic components. [Figure 17] Figure 15 is a cross-sectional view showing the magnetic component. [Modes for carrying out the invention]

[0034] Referring to Figures 1 to 3, Figure 1 is a perspective view showing a magnetic component 1 according to one embodiment of the present invention, Figure 2 is an exploded view showing the magnetic component 1 shown in Figure 1, and Figure 3 is a cross-sectional view showing the magnetic component 1 shown in Figure 1.

[0035] The magnetic component 1 of the present invention may be a transformer or other magnetic component. As shown in Figures 1 to 3, the magnetic component 1 includes a core 10, a primary winding 12, a secondary winding 14, a magnetic member 16, a first tertiary winding 18, a second tertiary winding 20, two insulating sheets 22a, 22b, and two bobbins 24a, 24b. The primary winding 12, secondary winding 14, magnetic member 16, first tertiary winding 18, second tertiary winding 20, two insulating sheets 22a, 22b, and two bobbins 24a, 24b are arranged within the core 10. In this embodiment, the core 10 may have an inner leg 100 and at least two outer legs 102. The primary winding 12, secondary winding 14, first tertiary winding 18, and second tertiary winding 20 are wound around the inner leg 100.

[0036] The magnetic member 16 is positioned between the primary winding 12 and the secondary winding 14, the insulating sheet 22a is positioned between the primary winding 12 and the magnetic member 16, and the insulating sheet 22b is positioned between the secondary winding 14 and the magnetic member 16. In this embodiment, the magnetic member 16 may be, but is not limited to, a magnetic shunt. The first tertiary winding 18 is positioned outside the primary winding 12, and the bobbin 24a is positioned between the primary winding 12 and the first tertiary winding 18. The second tertiary winding 20 is positioned outside the secondary winding 14, and the bobbin 24b is positioned between the secondary winding 14 and the second tertiary winding 20. The magnetic component 1 is assembled by sequentially arranging the first tertiary winding 18, bobbin 24a, primary winding 12, insulating sheet 22a, magnetic member 16, insulating sheet 22b, secondary winding 14, bobbin 24b, and second tertiary winding 20 around the inner legs 100 of the core 10, forming a symmetrical inductance structure. Furthermore, the first tertiary winding 18 and the second tertiary winding 20 are electrically connected in parallel.

[0037] As shown in Figure 3, the primary winding 12, secondary winding 14, first tertiary winding 18, and second tertiary winding 20 can be positioned at different locations along the length direction D of the inner leg 100 without overlapping with each other, thereby allowing each of the primary winding 12, secondary winding 14, first tertiary winding 18, and second tertiary winding 20 to have a large leakage inductance.

[0038] In this embodiment, the secondary winding 14 is located a distance of a first distance d1 from the second tertiary winding 20, the secondary winding 14 is located a distance of a second distance d2 from the first tertiary winding 18, the primary winding 12 is located a distance of a third distance d3 from the first tertiary winding 18, and the primary winding 12 is located a distance of a fourth distance d4 from the second tertiary winding 20. The first distance d1, the second distance d2, the third distance d3, and the fourth distance d4 are 0.8 < (d1 + d2) / (d3 + d4) < 1.2 The relationship satisfies the following: the relationship between the distances d1 to d4 between the primary winding 12, the secondary winding 14, the first tertiary winding 18, and the second tertiary winding 20 (i.e., 0.8 < (d1 + d2) / (d3 + d4) < 1.2 This allows for balancing the leakage inductance and stabilizing the tolerance. Furthermore, the error in the leakage inductance is less than 15%, i.e. (L1-L2) / L1*100%<15% This is the result. Here, L1 represents the leakage inductance of the primary winding 12, and L2 represents the leakage inductance of the secondary winding 14. When the magnetic component 1 is applied to a multi-port charger, the magnetic component 1 can achieve zero-voltage switching (ZVS) in both the charging mode and the discharging mode of the multi-port charger, thereby reducing the total loss.

[0039] In this embodiment, the number of turns of the first tertiary winding 18 and the second tertiary winding 20 may be less than the number of turns of the primary winding 12 and the secondary winding 14. Preferably, the number of turns of the first tertiary winding 18 and the second tertiary winding 20 may be less than half the number of turns of the primary winding 12 and the secondary winding 14.

[0040] In this embodiment, any of the primary winding 12, secondary winding 14, first tertiary winding 18, and second tertiary winding 20 may be Litz wire or copper plate. For example, as shown in Figure 2, the primary winding 12 and secondary winding 14 may be Litz wire, and the first tertiary winding 18 and second tertiary winding 20 may be copper plate, but the present invention is not limited thereto. Generally, copper plate has low DC loss and high AC loss, so a magnetic component 1 using a copper plate is prone to overheating due to high AC loss. Thus, in order to reduce AC loss, the first tertiary winding 18 and second tertiary winding 20 can be made of Litz wire.

[0041] In this embodiment, as shown in Figure 3, the core 10 can consist of an I-shaped core 10a, a first U-shaped core 10b, and a second U-shaped core 10c. The first U-shaped core 10b and the second U-shaped core 10c are arranged side by side to form an inner leg 100, which has a gap G. In addition, two outer legs 102 are provided by the first U-shaped core 10b and the second U-shaped core 10c respectively, and are located on opposite sides of each other. The I-shaped core 10a is placed on the first U-shaped core 10b and the second U-shaped core 10c. A heat dissipation material 104 is filled into the gap G of the inner leg 100 to improve heat dissipation. The core 10, consisting of the I-shaped core 10a, the first U-shaped core 10b, and the second U-shaped core 10c, can realize a high power density component by promoting heat dissipation and reducing core stress.

[0042] Refer to Figure 4. Figure 4 is a schematic diagram of a multi-strand insulated wire W according to one embodiment of the present invention.

[0043] In this embodiment, as shown in Figure 4, at least one of the primary winding 12, secondary winding 14, first tertiary winding 18, and second tertiary winding 20 may be wound around a multi-strand insulated wire W. The multi-strand insulated wire W may include a plurality of stranded wire layers W1, W2, W3, each of which may be covered by a first insulating layer I1. As shown in Figure 4, the multi-strand insulated wire W may include three stranded wire layers W1, W2, W3. The first stranded wire layer W1 may include a plurality of stranded wires S covered by the first insulating layer I1, the plurality of stranded wires S being twisted together to form the first stranded wire layer W1. The second stranded wire layer W2 may include multiple strands of the first stranded wire layer W1 covered by the first insulating layer I1, and the multiple strands of the first stranded wire layer W1 are twisted together to form the second stranded wire layer W2. The third stranded wire layer W3 may include multiple strands of the second stranded wire layer W2 covered by the first insulating layer I1, and the multiple strands of the second stranded wire layer W2 are twisted together to form the third stranded wire layer W3. Thus, the stranded wire layers W1, W2, and W3 are electrically insulated from each other via the first insulating layer I1. Furthermore, in the first stranded wire layer W1, each stranded wire S is covered by the second insulating layer I2, thereby electrically insulating each stranded wire S from each other via the second insulating layer I2. Note that a nylon wire may be placed in the center of the multi-stranded insulating wire W.

[0044] Referring to Figures 5 to 7, Figure 5 is a perspective view showing a magnetic component 1 according to another embodiment of the present invention, Figure 6 is an exploded view showing the magnetic component 1 shown in Figure 5, and Figure 7 is a cross-sectional view showing the magnetic component 1 shown in Figure 5.

[0045] As shown in Figures 5 to 7, the magnetic component 1 may further include a case 26, a thermally conductive filler 28, and a conductive member 30 in addition to the aforementioned components. The core 10 is placed inside the case 26. In this embodiment, the core 10 may be an EE core, but is not limited thereto. The core 10 may also be a UUI core or another type of core, depending on the actual application. The thermally conductive filler 28 is filled inside the case 26, thereby expanding the heat dissipation path by covering at least a portion of the inner legs 100 of the core 10 and at least a portion of the primary winding 12, secondary winding 14, first tertiary winding 18, and second tertiary winding 20. Examples of materials for the thermally conductive filler 28 include epoxy resin, silicone resin, polyurethane (PU), phenolic resin, thermoplastic polyethylene terephthalate (PET), polyamide (PA), polyphenylene sulfide (PPS), polyether ether ketone (PEEK), etc.

[0046] As shown in Figure 6, the primary winding 12, secondary winding 14, first tertiary winding 18, and second tertiary winding 20 can first be wound around bobbins 24a and 24b and then assembled onto the core 10. Here, the first distance d1, second distance d2, third distance d3, and fourth distance d4 (see Figure 3) between the primary winding 12, secondary winding 14, first tertiary winding 18, and second tertiary winding 20 can be adjusted by the thickness of the bobbins 24a and 24b.

[0047] The conductive member 30 is positioned above the core 10 and the opening 32 of the case 26. In this embodiment, the conductive member 30 may consist of two conductive metals 300 covered with an insulating material 302. The first tertiary winding 18 and the second tertiary winding 20 are connected to the conductive member 30, and a portion of the conductive member 30 is bent into the thermal conductive filler 28 for heat dissipation. In this embodiment, as shown in Figure 7, the two conductive metals 300 are positioned opposite each other on both sides of the core 10 and are not in contact with the core 10 or the case 26. Furthermore, the two bent structures 3000 of the two conductive metals 300 located outside the core 10 extend to the thermal conductive filler 28, and the two bent structures 3000 are not in contact with the core 10 and do not extend to the bottom of the case 26. The ends of the first tertiary winding 18 and the second tertiary winding 20 extend to the core 10 and the opening 32 of the case 26 and are connected to a plurality of engagement holes 3002 of the two conductive metals 300, thereby connecting the first tertiary winding 18 and the second tertiary winding 20 in parallel. Furthermore, two horizontal structures 3004 of the two conductive metals 300 extend from the insulating material 302 and form two electrodes 3006 for the first tertiary winding 18 and the second tertiary winding 20. The two electrodes 3006 can be screwed to a system board (not shown), thereby electrically connecting the first tertiary winding 18 and the second tertiary winding 20 to the system board.

[0048] Referring to Figures 8 to 11, Figure 8 is a perspective view showing a magnetic component 1 according to another embodiment of the present invention, Figure 9 is an exploded view showing the magnetic component 1 shown in Figure 8, Figure 10 is a perspective view showing the partial components shown in Figure 9 from a different viewpoint, and Figure 11 is a cross-sectional view showing the magnetic component 1 shown in Figure 8.

[0049] The main difference between the magnetic component 1 shown in Figures 8 to 11 and the magnetic component 1 shown in Figures 5 to 7 is the arrangement of the conductive member 30. As shown in Figures 8 to 11, the conductive member 30 is positioned to the side of the core 10, rather than above the core 10 and the opening 32 of the case 26. In this embodiment, a thermal conductive filler 28 is also filled into the case 26, and the thermal conductive filler 28 expands the heat dissipation path by covering at least a portion of the inner legs 100 of the core 10 and at least a portion of the primary winding 12, secondary winding 14, first tertiary winding 18, and second tertiary winding 20.

[0050] In this embodiment, the conductive member 30 may consist of two conductive metals 300 covered with an insulating material 302. The first tertiary winding 18 and the second tertiary winding 20 are connected to the conductive member 30, and a portion of the conductive member 30 is covered with a thermally conductive filler 28 for heat dissipation. In this embodiment, as shown in Figure 9, the two conductive metals 300 are arranged side by side on the sides of the core 10 and are not in contact with the core 10. Furthermore, the two bent structures 3000 of the two conductive metals 300 located outside the core 10 extend to the thermally conductive filler 28 and are not in contact with the core 10. The ends of the first tertiary winding 18 and the second tertiary winding 20 extend to the bottom of the case 26 and are connected to a plurality of engagement holes 3002 in the two conductive metals 300, thereby connecting the first tertiary winding 18 and the second tertiary winding 20 in parallel. Furthermore, two horizontal structures 3004 of the two conductive metals 300 protrude from the insulating material 302 to form two electrodes 3006 for the first tertiary winding 18 and the second tertiary winding 20. The two electrodes 3006 are screwed to a system board (not shown) to electrically connect the first tertiary winding 18 and the second tertiary winding 20 to the system board. In this embodiment, the insulating member 34 may be provided at the bottom of the case 26, and the multiple engagement holes 3002 of the two conductive metals 300 are arranged within the housing space 340 of the insulating member 34 to enhance electrical insulation between the conductive member 30 and the case 26. Because the conductive member 30 is positioned laterally to the core 10, the height of the magnetic component 1 can be effectively reduced.

[0051] Furthermore, bobbins 24a and 24b can function as spacers, and the first distance d1, second distance d2, third distance d3, and fourth distance d4 (see Figure 3) between the primary winding 12, secondary winding 14, first tertiary winding 18, and second tertiary winding 20 can be adjusted by the thickness of bobbins 24a and 24b. In addition, at least one opening can be formed in bobbins 24a and 24b between two windings, and the thermally conductive filler 28 can be filled into the opening to improve heat dissipation.

[0052] Referring to Figures 12 to 14, Figure 12 is a perspective view showing a magnetic component 1' according to another embodiment of the present invention, Figure 13 is an exploded view showing the magnetic component 1' shown in Figure 12, and Figure 14 is a cross-sectional view showing the magnetic component 1' shown in Figure 12.

[0053] The magnetic component 1' of the present invention may be a transformer or other magnetic component. As shown in Figures 12 to 14, the magnetic component 1' includes a core 10, a primary winding 12, a secondary winding 14, a tertiary winding 17, and two bobbins 24a, 24b. The primary winding 12, secondary winding 14, tertiary winding 17, and the two bobbins 24a, 24b are arranged within the core 10. In this embodiment, the core 10 may have an inner leg 100 and at least two outer legs 102. The primary winding 12, secondary winding 14, and tertiary winding 17 are wound around the inner leg 100.

[0054] The tertiary winding 17 is positioned between the primary winding 12 and the secondary winding 14, the bobbin 24a is positioned between the primary winding 12 and the tertiary winding 17, and the bobbin 24b is positioned between the secondary winding 14 and the tertiary winding 17. The magnetic component 1' is assembled by sequentially arranging the primary winding 12, bobbin 24a, tertiary winding 17, bobbin 24b, and secondary winding 14 around the inner legs 100 of the core 10, forming a symmetrical inductance structure.

[0055] As shown in Figure 14, the primary winding 12, secondary winding 14, and tertiary winding 17 can be positioned at different locations along the length direction D of the inner leg 100 without overlapping with each other, thereby allowing each of the primary winding 12, secondary winding 14, and tertiary winding 17 to have a large leakage inductance.

[0056] In this embodiment, the secondary winding 14 is located a first distance d1 away from the tertiary winding 17, and the primary winding 12 is located a second distance d2 away from the tertiary winding 17. The first distance d1 and the second distance d2 are 0.8 <d2 / d1<1.2 The relationship satisfies the following: the relationship d1-d2 between the primary winding 12, the secondary winding 14, and the tertiary winding 17 (i.e., 0.8 <d2 / d1<1.2 This allows for the suppression of reverse current and reduces the AC loss of the tertiary winding 17. Furthermore, the leakage inductance error is less than 15%, i.e. (L1-L2) / L1*100%<15% This is the result. Here, L1 represents the leakage inductance of the primary winding 12, and L2 represents the leakage inductance of the secondary winding 14. When magnetic component 1' is applied to a multiport charger, magnetic component 1' can achieve zero-voltage switching (ZVS) in both the charging and discharging modes of the multiport charger, thereby reducing total losses.

[0057] In this embodiment, the number of turns of the tertiary winding 17 may be less than the number of turns of the primary winding 12 and the secondary winding 14, respectively. Preferably, the number of turns of the tertiary winding 17 may be less than half the number of turns of the primary winding 12 and the secondary winding 14, respectively.

[0058] In this embodiment, the primary winding 12, secondary winding 14, and tertiary winding 17 may all be Litz wire or copper plate. For example, as shown in Figure 13, the primary winding 12, secondary winding 14, and tertiary winding 17 may all be Litz wire, but the present invention is not limited thereto. Generally, copper plate has low DC loss and high AC loss, so magnetic components 1' using copper plate tend to generate heat due to high AC loss. Thus, the tertiary winding 17 can be made of Litz wire to reduce AC loss.

[0059] In this embodiment, as shown in Figure 14, the core 10 may include an I-shaped core 10a, a first U-shaped core 10b, and a second U-shaped core 10c. The first U-shaped core 10b and the second U-shaped core 10c are arranged side by side to form an inner leg 100, which has a gap G. Furthermore, two outer legs 102 are formed by the first U-shaped core 10b and the second U-shaped core 10c, respectively, and these two outer legs 102 are located on opposite sides of each other. The I-shaped core 10a is placed on the first U-shaped core 10b and the second U-shaped core 10c. A heat dissipation material 104 is filled into the gap G of the inner leg 100 to improve heat dissipation. The core 10, composed of the I-shaped core 10a, the first U-shaped core 10b, and the second U-shaped core 10c, can realize a high power density component by improving heat dissipation and reducing core stress.

[0060] Since the embodiments shown in Figures 4 to 11 are also applicable to magnetic component 1', redundant explanations are omitted here.

[0061] Referring to Figures 15 to 17, Figure 15 is a perspective view showing a magnetic component 1'' according to another embodiment of the present invention, Figure 16 is an exploded view showing the magnetic component 1'' shown in Figure 15, and Figure 17 is a cross-sectional view showing the magnetic component 1'' shown in Figure 15.

[0062] The magnetic component 1'' of the present invention may be a transformer or other magnetic component. As shown in Figures 15 to 17, the magnetic component 1'' includes a core 10, a primary winding 12, a secondary winding 14, a magnetic member 16, a tertiary winding 17, two insulating sheets 22a, 22b, and two bobbins 24a, 24b. The primary winding 12, secondary winding 14, magnetic member 16, tertiary winding 17, two insulating sheets 22a, 22b, and two bobbins 24a, 24b are arranged within the core 10. In this embodiment, the core 10 may have an inner leg 100 and at least two outer legs 102. The primary winding 12, secondary winding 14, and tertiary winding 17 are wound around the inner leg 100.

[0063] The secondary winding 14 is positioned between the primary winding 12 and the tertiary winding 17, the bobbin 24a is positioned between the primary winding 12 and the tertiary winding 17, and the insulating sheet 22a is positioned below the primary winding 12. The magnetic member 16 is positioned between the secondary winding 14 and the tertiary winding 17, the bobbin 24b is positioned between the magnetic member 16 and the tertiary winding 17, and the insulating sheet 22b is positioned between the secondary winding 14 and the magnetic member 16. The magnetic component 1'' is assembled by sequentially arranging the insulating sheet 22a, primary winding 12, bobbin 24a, secondary winding 14, insulating sheet 22b, magnetic member 16, bobbin 24b, and tertiary winding 17 around the inner leg 100 to form an asymmetric inductance structure.

[0064] As shown in Figure 17, the primary winding 12, secondary winding 14, and tertiary winding 17 can be positioned at different locations along the length direction D of the inner leg 100 without overlapping, thereby allowing each of the primary winding 12, secondary winding 14, and tertiary winding 17 to have a large leakage inductance.

[0065] In this embodiment, the secondary winding 14 is located a first distance d1 away from the tertiary winding 17, and the primary winding 12 is located a second distance d2 away from the tertiary winding 17. The first distance d1 and the second distance d2 are 0 <d1 / d2<1.2 The following relationship is satisfied. Preferably, the first distance d1 and the second distance d2 are 0 <d1 / d2<0.9 The relationship satisfies the following: the relationship d1-d2 between the primary winding 12, the secondary winding 14, and the tertiary winding 17 (i.e., 0 <d1 / d2<1.2 , or preferably 0 <d1 / d2<0.9 This allows for more flexible adjustment of the leakage inductance and stabilizes the tolerance. When magnetic component 1'' is applied to a multi-port charger, the coupling energy between the high-voltage port and the low-voltage port can be reduced to, for example, 0.15 kW (i.e., coupling energy < 0.15 kW) in both the charging and discharging modes of the multi-port charger.

[0066] In this embodiment, the number of turns of the tertiary winding 17 may be smaller than the number of turns of the primary winding 12 and the secondary winding 14, respectively. Preferably, the number of turns of the tertiary winding 17 may be less than half the number of turns of the primary winding 12 and the secondary winding 14, respectively.

[0067] In this embodiment, the primary winding 12, secondary winding 14, and tertiary winding 17 may be Litz wire or copper plate. For example, as shown in Figure 16, the primary winding 12 and secondary winding 14 may be Litz wire, and the tertiary winding 17 may be a copper plate, but the present invention is not limited thereto. Generally, copper plates have low DC loss and high AC loss, so magnetic components 1'' using copper plates may be prone to overheating due to high AC loss. Thus, the tertiary winding 17 may be formed of Litz wire to reduce AC loss.

[0068] In this embodiment, as shown in Figure 17, the core 10 can consist of an I-shaped core 10a, a first U-shaped core 10b, and a second U-shaped core 10c. The first U-shaped core 10b and the second U-shaped core 10c are arranged side by side to form an inner leg 100, which has a gap G. In addition, two outer legs 102 are provided by the first U-shaped core 10b and the second U-shaped core 10c, respectively, and these two outer legs 102 are located on opposite sides of each other. The I-shaped core 10a is placed on the first U-shaped core 10b and the second U-shaped core 10c. A heat dissipation material 104 is filled into the gap G of the inner leg 100 to improve heat dissipation. The core 10, consisting of the I-shaped core 10a, the first U-shaped core 10b, and the second U-shaped core 10c, helps to dissipate heat and reduce core stress, enabling the realization of a high power density component.

[0069] Since the embodiments shown in Figures 4 to 11 are also applicable to magnetic component 1'', redundant explanations are omitted here.

[0070] As described above, in one embodiment, the magnetic member may be placed between the primary winding and the secondary winding, and the first tertiary winding and the second tertiary winding may be placed outside the primary and secondary windings, thereby forming a symmetrical inductance structure. The relationship of the distances between the primary winding, the secondary winding, the first tertiary winding, and the second tertiary winding (i.e., 0.8 < (d1 + d2) / (d3 + d4) < 1.2 ) allows for balancing the leakage inductance, stabilizing tolerances, and reducing total losses. In another embodiment, the tertiary winding can be positioned between the primary and secondary windings to form a symmetrical inductance structure. The relationship between the distances between the primary, secondary, and tertiary windings (i.e., 0.8 <d2 / d1<1.2 ) can suppress reverse current, reduce AC losses in the tertiary winding, and reduce total losses. In another embodiment, the secondary winding may be placed between the primary and tertiary windings, and the magnetic member may be placed between the secondary and tertiary windings, forming an asymmetric inductance structure. The relationship of the distances between the primary, secondary, and tertiary windings (i.e., 0 <d1 / d2<1.2 , or preferably 0 <d1 / d2<0.9 This allows for more flexible adjustment of leakage inductance, stabilizes tolerances, and reduces coupling energy.

[0071] Those skilled in the art will readily understand that numerous modifications and changes can be made to the apparatus and method while maintaining the teachings of the present invention. Accordingly, the above disclosure should be construed as being limited only by the boundaries and scope of the appended claims.

Claims

1. A magnetic component, said magnetic component is The core and The primary winding arranged within the core, A secondary winding arranged within the core, A magnetic member disposed between the primary winding and the secondary winding, A first tertiary winding is positioned outside the primary winding, It includes a second tertiary winding arranged outside the secondary winding, The secondary winding is located at a first distance d1 from the second tertiary winding, the secondary winding is located at a second distance d2 from the first tertiary winding, the primary winding is located at a third distance d3 from the first tertiary winding, and the primary winding is located at a fourth distance d4 from the second tertiary winding. The first distance d1, the second distance d2, the third distance d3, and the fourth distance d4 are, 0.8<(d1+d2) / (d3+d4)<1.2 Satisfying the relationship, Magnetic components.

2. The magnetic component according to claim 1, wherein the core has inner legs, and the primary winding, the secondary winding, the first tertiary winding, and the second tertiary winding are arranged at different positions along the longitudinal direction of the inner legs without overlapping.

3. The magnetic component according to claim 1, wherein the number of turns of the first tertiary winding and the second tertiary winding are less than the number of turns of the primary winding and the secondary winding.

4. The magnetic component according to claim 3, wherein the number of turns of the first tertiary winding and the second tertiary winding is less than half the number of turns of the primary winding and the secondary winding, respectively.

5. The magnetic component according to claim 1, wherein at least one of the primary winding, the secondary winding, the first tertiary winding, and the second tertiary winding is wound with a multi-strand insulated wire.

6. The magnetic component according to claim 5, wherein the multi-strand insulated wire includes a plurality of stranded wire layers, each of the plurality of stranded wire layers is covered by a first insulating layer, the first stranded wire layer of the plurality of stranded wire layers includes a plurality of stranded wires, and each of the plurality of stranded wires is covered by a second insulating layer.

7. The magnetic component according to claim 1, wherein any of the primary winding, the secondary winding, the first tertiary winding, and the second tertiary winding is a Litz wire or a copper plate.

8. The magnetic component according to claim 1, wherein the core comprises an I-shaped core, a first U-shaped core, and a second U-shaped core, the first U-shaped core and the second U-shaped core being arranged side by side to form inner legs, a heat dissipation material being filled into the gaps of the inner legs, and the I-shaped core being positioned on the first U-shaped core and the second U-shaped core.

9. The magnetic component according to claim 1, wherein the core has an inner leg and at least two outer legs, and the primary winding, the secondary winding, the first tertiary winding, and the second tertiary winding are wound around the inner leg.

10. It further includes a case, a thermally conductive filler, and a conductive member. The core is placed inside the case. The thermal conductive filler is filled into the case, and the thermal conductive filler covers at least a portion of the inner legs of the core and at least a portion of the primary winding, the secondary winding, the first tertiary winding, and the second tertiary winding. The conductive member is positioned above the core and the opening of the case, and the conductive member includes two conductive metals covered with an insulating material. The magnetic component according to claim 1, wherein the first tertiary winding and the second tertiary winding are connected to the conductive member, and a portion of the conductive member is bent into the thermally conductive filler.

11. The magnetic component according to claim 10, wherein the two conductive metals are arranged opposite each other on both sides of the core and are not in contact with the core or the case, and two bent structures of the two conductive metals located outside the core extend to the thermally conductive filler, the two bent structures are not in contact with the core and do not extend to the bottom of the case.

12. It further includes a case, a thermally conductive filler, and a conductive member. The core is placed inside the case. The thermal conductive filler is filled into the case, and the thermal conductive filler covers at least a portion of the inner legs of the core and at least a portion of the primary winding, the secondary winding, the first tertiary winding, and the second tertiary winding. The conductive member is positioned next to the core, and the conductive member includes two conductive metals covered with an insulating material. The magnetic component according to claim 1, wherein the first tertiary winding and the second tertiary winding are connected to the conductive member, and a portion of the conductive member is covered with the thermally conductive filler.

13. The two conductive metals are arranged side by side on the side of the core and are not in contact with the core. The two bent structures of the two conductive metals located outside the core extend to the thermally conductive filler and are not in contact with the core. The first tertiary winding and the second tertiary winding extend to the bottom of the case and are connected to a plurality of engagement holes in the two conductive metals, thereby connecting the first tertiary winding and the second tertiary winding in parallel. The two horizontal structures of the two conductive metals protrude from the insulating material to form two electrodes for the first tertiary winding and the second tertiary winding. The magnetic component according to claim 12, wherein an insulating member is disposed at the bottom of the case, and the plurality of engagement holes of the two conductive metals are arranged within the housing space of the insulating member.

14. A magnetic component, said magnetic component is The core and The primary winding arranged within the core, A secondary winding arranged within the core, A tertiary winding is positioned between the primary winding and the secondary winding, The secondary winding is located a first distance d1 away from the tertiary winding, and the primary winding is located a second distance d2 away from the tertiary winding. The first distance d1 and the second distance d2 are, 0.8<d2 / d1<1.2 Satisfying the relationship, Magnetic components.

15. The magnetic component according to claim 14, wherein the core has inner legs, and the primary winding, the secondary winding, and the tertiary winding are arranged at different positions along the longitudinal direction of the inner legs without overlapping.

16. The magnetic component according to claim 14, wherein the number of turns of the tertiary winding is less than the number of turns of the primary winding and the secondary winding, respectively.

17. The magnetic component according to claim 16, wherein the number of turns of the tertiary winding is less than half the number of turns of the primary winding and the secondary winding, respectively.

18. The magnetic component according to claim 14, wherein at least one of the primary winding, the secondary winding, and the tertiary winding is wound with a multi-strand insulated wire.

19. The magnetic component according to claim 18, wherein the multi-strand insulated wire includes a plurality of stranded wire layers, each of the plurality of stranded wire layers is covered by a first insulating layer, the first stranded wire layer of the plurality of stranded wire layers includes a plurality of stranded wires, and each of the plurality of stranded wires is covered by a second insulating layer.

20. The magnetic component according to claim 14, wherein any of the primary winding, the secondary winding, and the tertiary winding is a Litz wire or a copper plate.

21. The magnetic component according to claim 14, wherein the core comprises an I-shaped core, a first U-shaped core, and a second U-shaped core, the first U-shaped core and the second U-shaped core being arranged side by side to form inner legs, a heat dissipation material being filled into the gaps of the inner legs, and the I-shaped core being positioned on the first U-shaped core and the second U-shaped core.

22. The magnetic component according to claim 14, wherein the core has an inner leg and at least two outer legs, and the primary winding, the secondary winding, and the tertiary winding are wound around the inner leg.

23. It further includes a case, a thermally conductive filler, and a conductive member. The core is placed inside the case. The thermally conductive filler is filled into the case. The conductive member is positioned above the core and the opening of the case, The magnetic component according to claim 14, wherein the tertiary winding is connected to the conductive member, and a portion of the conductive member is bent into the thermally conductive filler.

24. It further includes a case, a thermally conductive filler, and a conductive member. The core is placed inside the case. The thermally conductive filler is filled into the case. The conductive member is positioned next to the core, The magnetic component according to claim 14, wherein the tertiary winding is connected to the conductive member, and a portion of the conductive member is covered with the thermally conductive filler.

25. A magnetic component, said magnetic component is The core and The primary winding arranged within the core, A tertiary winding arranged within the core, A secondary winding is positioned between the primary winding and the tertiary winding, A magnetic member disposed between the secondary winding and the tertiary winding is included, The secondary winding is located a first distance d1 away from the tertiary winding, and the primary winding is located a second distance d2 away from the tertiary winding. The first distance d1 and the second distance d2 are, 0<d1 / d2<1.2 Satisfying the relationship, Magnetic components.

26. The magnetic component according to claim 25, wherein the core has inner legs, and the primary winding, the secondary winding, and the tertiary winding are arranged at different positions along the longitudinal direction of the inner legs without overlapping.

27. The magnetic component according to claim 25, wherein the number of turns of the tertiary winding is less than the number of turns of the primary winding and the secondary winding, respectively.

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