Magnetic element with magnetic flux compensation structure and manufacture method thereof

Abstract

This invention provides a method for manufacturing a magnetic element with a magnetic flux compensation structure, comprising the following steps: providing an iron core of a magnetic element, wherein the iron core includes a plurality of central pillars and a frame, each of the central pillars being disposed adjacently in an accommodating space of the frame; and winding a coil on each of the central pillars, such that when the magnetic element receives a current in each coil, each central pillar and the frame respectively form a magnetic flux path, and a corresponding magnetic flux is generated on each magnetic flux path; wherein the structure of the iron core is configured such that the magnetic flux paths formed by each central pillar and the frame pass through at least a portion of the frame, and the cross-sectional area of ​​the frame is configured such that the magnetic flux passing through the at least a portion of the frame cross-sectional area cancels each other out, such that the maximum value of the magnetic flux on the frame is less than the maximum value of the magnetic flux on each central pillar.

Claims

1. A magnetic element with a flux compensation structure, comprising: An iron core, the iron core comprising a plurality of central posts and a frame, wherein each central post is disposed adjacently in an accommodating space of the frame; The magnetic element comprises multiple coils wound around the central pillars, such that when each coil receives a current, each central pillar and the frame form a magnetic flux path, and a corresponding magnetic flux is generated on each magnetic flux path. The core structure ensures that the magnetic flux paths formed by the central pillars and the frame pass through at least a portion of the frame, and the cross-sectional area of ​​the frame causes the magnetic flux passing through the at least a portion to cancel each other out, resulting in a maximum value of the magnetic flux on the frame being less than a maximum value of the magnetic flux on each central pillar. The multiple central pillars include a first central pillar and a second central pillar, and the multiple coils include a first coil and a second coil. The first central pillar and the second central pillar are arranged adjacent to each other in the accommodating space of the frame, and the first coil and the second coil are wound around the first central pillar and the second central pillar, respectively. The current includes a first coil current and a second coil current, and the magnetic flux includes a first magnetic flux and a second magnetic flux. The first coil current is received through the first coil, and the second coil current is received through the second coil. The first magnetic flux and the second magnetic flux are generated based on the first coil current. The first current phase of the first coil current leads the second current phase of the second coil current, such that the first magnetic flux phase of the first magnetic flux leads the second magnetic flux phase of the second magnetic flux, and the first magnetic flux and the second magnetic flux passing through the cross-sectional area of ​​the frame cancel each other out.

2. The magnetic element with a flux compensation structure as described in claim 1, wherein the first central column and the second central column are respectively provided with a first air gap and a second air gap between them and the frame, and the first air gap and the second air gap are connected to the accommodating space.

3. A magnetic element with a flux compensation structure as described in claim 2, wherein the plurality of central pillars further includes a third central pillar, the coil further includes a third coil, the current further includes a third coil current, and the magnetic flux further includes a third magnetic flux. The third central pillar is disposed adjacent to the second central pillar in the accommodating space of the frame. The third coil is wound around the third central pillar and receives the third coil current through the third coil, and generates the third magnetic flux according to the third coil current. The first coil current, the second coil current, and the third coil current are a three-phase current, and the second current phase of the second coil current leads the third current phase of the third coil current, such that the second magnetic flux phase of the second magnetic flux leads the third magnetic flux phase of the third magnetic flux, and such that the first magnetic flux, the second magnetic flux, and the third magnetic flux passing through the cross-sectional area of ​​the frame cancel each other out. A third air gap is provided between the third central pillar and the frame, and the third air gap communicates with the accommodating space.

4. The magnetic element with a flux compensation structure as described in claim 1, wherein the accommodating space of the frame is a single accommodating space.

5. A magnetic element having a flux compensation structure as described in claim 1, wherein the frame system of the iron core is a closed frame.

6. A magnetic element with a flux compensation structure as described in claim 3, wherein the frame has a cross-sectional area through which the first magnetic flux, the second magnetic flux, and the third magnetic flux pass, the cross-sectional area being calculated based on a magnetic flux saturation density of a material of the core, the magnitude of the first magnetic flux, the second magnetic flux, and the third magnetic flux, and a volume of the core being calculated based on the cross-sectional area of ​​the frame.

7. A magnetic element with a flux compensation structure as described in claim 3, wherein the frame includes an upper cover and a lower frame, the lower frame includes two side posts and a lower cover, and the height of one of the first central post, the second central post and the third central post is lower than the height of one of the two side posts, such that the upper cover covers the two side posts of the lower frame, and the first air gap, the second air gap and the third air gap are respectively formed between the upper cover and the first central post, the second central post and the third central post, and together with the lower frame, form the receiving space.

8. A magnetic element with a flux compensation structure as described in claim 3, wherein the first central column comprises a plurality of first flux columns, and a plurality of first air gaps are formed between the plurality of first flux columns and between the plurality of first flux columns and the frame; the second central column comprises a plurality of second flux columns, and a plurality of second air gaps are formed between the plurality of second flux columns and between the plurality of second flux columns and the frame; the third central column comprises a plurality of third flux columns, and a plurality of third air gaps are formed between the plurality of third flux columns and between the plurality of third flux columns and the frame.

9. A magnetic element having a flux compensation structure as described in claim 8, wherein a plurality of the first air gaps, a plurality of the second air gaps and a plurality of the third air gaps are each filled with a non-magnetic material.

10. A magnetic element with a flux compensation structure as described in claim 3, wherein the first coil includes a first primary coil and a first secondary coil, the first primary coil receiving a first coil current such that the first secondary coil generates the first magnetic flux according to the first coil current; and the second coil includes a second primary coil and a second secondary coil, the second primary coil receiving a second coil current such that the second secondary coil generates the second magnetic flux according to the second coil current.

11. A magnetic element having a flux compensation structure as described in claim 10, wherein the third coil comprises a third primary side coil and a third secondary side coil, the third primary side coil receiving the third coil current such that the third secondary side coil generates the third magnetic flux according to the third coil current.

12. A magnetic element having a flux compensation structure as described in claim 11, wherein the magnetic element comprises a transformer and an inductor.

13. A method for manufacturing a magnetic element with a flux compensation structure, comprising: A magnetic element is provided, wherein the core includes a plurality of central posts and a frame, and each of the central posts is disposed adjacently in an accommodating space of the frame; A coil is wound around each of the central pillars, so that when the magnetic element receives a current in each coil, each central pillar and the frame form a magnetic flux path, and a corresponding magnetic flux is generated in each magnetic flux path; wherein, the structure of the iron core is configured such that the magnetic flux paths formed by each central pillar and the frame pass through at least a portion of the frame, and a cross-sectional area of ​​the frame is configured such that the magnetic flux passing through the at least a portion of the cross-sectional area cancels each other out, so that the maximum value of the magnetic flux on the frame is less than the maximum value of the magnetic flux of each central pillar; wherein, the plurality of central pillars include a first central pillar and a second central pillar, each coil includes a first coil and a second coil, the first central pillar and the second central pillar are arranged adjacently in the accommodating space of the frame, and the first coil and the second coil are wound around the first central pillar and the second central pillar respectively; The current includes a first coil current and a second coil current, and the magnetic flux includes a first magnetic flux and a second magnetic flux. The first coil current is received through the first coil, and the second coil current is received through the second coil. The first magnetic flux and the second magnetic flux are generated based on the first coil current. The first current phase of the first coil current leads the second current phase of the second coil current, such that the first magnetic flux phase of the first magnetic flux leads the second magnetic flux phase of the second magnetic flux, and the first magnetic flux and the second magnetic flux passing through the cross-sectional area of ​​the frame cancel each other out.

14. A magnetic element with a flux compensation structure, comprising: An iron core, comprising a first central post, a second central post, a third central post, and a frame, wherein the first central post, the second central post, and the third central post are arranged adjacently in an accommodating space of the frame; a first coil wound on the first central post, such that when the magnetic element receives a first coil current in the first coil, the first central post and the frame form a first magnetic flux path, and a corresponding first magnetic flux is generated on the first magnetic flux path according to the first coil current; a second coil wound on the second central post, such that when the magnetic element receives a second coil current in the second coil, the second central post and the frame form a second magnetic flux path, and a corresponding second magnetic flux is generated on the second magnetic flux path according to the second coil current; A third coil is wound around the third central post, such that when the magnetic element receives a third coil current, the third central post and the frame form a third magnetic flux path, and a corresponding third magnetic flux is generated on the third magnetic flux path according to the third coil current; wherein, the structure of the iron core is such that the first magnetic flux path, the second magnetic flux path, and the third magnetic flux path formed by the first central post, the second central post, and the third central post and the frame all pass through at least a portion of the frame, and the cross-sectional area of ​​the frame is such that the first magnetic flux, the second magnetic flux, and the third magnetic flux passing through the at least a portion cancel each other out, so that the maximum value of the sum of the first magnetic flux, the second magnetic flux, and the third magnetic flux on the frame is less than the maximum value of the first magnetic flux, the maximum value of the second magnetic flux, and the maximum value of the third magnetic flux; The first central column, the second central column, and the third central column are respectively connected to the frame by a first air gap, a second air gap, and a third air gap, and the first air gap, the second air gap, and the third air gap are connected to the accommodating space; the first coil current, the second coil current, and the third coil current are three-phase currents, and the second current phase of one of the second coil currents leads the third current phase of one of the third coil currents, such that the second magnetic flux phase of one of the second magnetic fluxes leads the third magnetic flux phase of one of the third magnetic fluxes, and the first magnetic flux, the second magnetic flux, and the third magnetic flux passing through the cross-sectional area of ​​the frame cancel each other out.

Images