Magnetic component and magnetic module

Abstract

The present disclosure addresses the problem of making it possible to reduce the maximum applied voltage of a secondary-side circuit in a power conversion circuit. A magnetic component (100) comprises a core block, a first conductor part (71), a second conductor part (72), and a third conductor part (73). The core block has a magnetic leg (601). The first conductor part (71) has a C-shaped first body portion (710). The first body portion (710) is disposed so as to surround the magnetic leg (601). The second conductor part (72) has a C-shaped second body portion (720) larger than the first body portion (710). The second body portion (720) is disposed so as to surround the magnetic leg (601) at a position outside the first body portion (710). The third conductor part (73) has a C-shaped third body portion (730) larger than the second body portion (720). The third body portion (730) is disposed around the magnetic leg (601) so as to be positioned outside the second body portion (720).

Description

Magnetic Components and Magnetic Modules

[0001] The present disclosure relates to magnetic components and magnetic modules, and more particularly to magnetic components including a plurality of conductor portions and magnetic modules including magnetic components.

[0002] Non-Patent Document 1 describes a TLVR (Trans-Inductor Voltage Regulator) circuit.

[0003] Conventional VRMs (Voltage Regulator Modules) are configured using multi-phase step-down DC-DC converters. Non-Patent Document 1 describes that in such a conventional multi-phase step-down DC-DC converter, a TLVR circuit is configured by adding an inner lead (secondary winding) for one turn to each inductor to form a 1:1 transformer (so-called "transformer inductor"). In the TLVR circuit described in Non-Patent Document 1, a series loop is formed by the plurality of newly added secondary windings and a further added compensation inductor.

[0004] The TLVR circuit has an advantage that its transient response is faster than that of a conventional multi-phase step-down DC-DC converter.

[0005] Shreyankh Krishnamurthy et al., Trans-Inductor Voltage Regulator(TLVR): Circuit Operation, Power Magnetic Construction, Efficiency and Cost Trad-Offs, PCIM Europe 2022, 10-12 May 2022

[0006] In the TLVR circuit described in Non-Patent Document 1, a plurality of secondary windings are connected in series (hereinafter, the series circuit of the plurality of secondary windings is also referred to as a "secondary circuit"). Therefore, if the high-side switches of a multi-phase step-down DC-DC converter are turned on simultaneously, voltages are induced in each of the plurality of secondary windings, and the sum of the induced voltages is applied between both ends of the secondary circuit.

[0007] The object of this disclosure is to provide magnetic components and magnetic modules that, when applied to power conversion circuits such as TLVR circuits, can reduce the maximum applied voltage of the secondary circuit in a power conversion circuit.

[0008] A magnetic component according to one aspect of the present disclosure comprises a core block, a first conductor portion, a second conductor portion, and a third conductor portion. The core block has magnetic legs. The first conductor portion has a C-shaped first body portion. The first body portion is arranged to surround the magnetic legs. The second conductor portion has a C-shaped second body portion that is larger than the first body portion. The second body portion is arranged to surround the magnetic legs at a position outside the first body portion. The third conductor portion has a C-shaped third body portion that is larger than the second body portion. The third body portion is arranged to surround the magnetic legs at a position outside the second body portion.

[0009] A magnetic module according to one aspect of the present disclosure functions as a transformer. The magnetic module comprises the magnetic component and a connecting member. The connecting member connects the end of the first main body and the end of the third main body. The primary winding of the transformer includes the first main body, the connecting member, and the third main body. The secondary winding of the transformer includes the second main body. The turns ratio of the primary winding to the secondary winding is n:m, where n > m, n is an integer of 2 or more, and m is an integer of 1 or more.

[0010] A magnetic module according to one aspect of the present disclosure functions as a transformer. The magnetic module comprises the magnetic component and a connecting member. The connecting member connects the end of the second body portion and the end of the third body portion. The primary winding of the transformer includes the second body portion, the connecting member, and the third body portion. The secondary winding of the transformer includes the first body portion. The turns ratio of the primary winding to the secondary winding is n:m, where n > m, n is an integer of 2 or more, and m is an integer of 1 or more.

[0011] A magnetic module according to one aspect of the present disclosure comprises a magnetic component and a mounting substrate. The magnetic component comprises a core block, a first conductor portion, and a second conductor portion. The core block has magnetic legs. The first conductor portion has a C-shaped first body portion. The first body portion is arranged to surround the magnetic legs. The second conductor portion has a C-shaped second body portion that is larger than the first body portion. The second body portion is arranged to surround the magnetic legs at an external position to the first body portion. The first and second ends of the first body portion and the first and second ends of the second body portion are arranged in the order of the first end of the second body portion, the first end of the first body portion, the second end of the first body portion, and the second end of the second body portion along a predetermined direction. The first end of the first body portion and the second end of the second body portion are connected by a pattern conductor of the mounting substrate.

[0012] Figure 1 is a perspective view of a magnetic module of an embodiment. Figure 2 is a cross-sectional view of the same magnetic module. Figure 3 is a cross-sectional view of the same magnetic module along line III-III in Figure 2. Figure 4 is a perspective view of the same magnetic module with the core block omitted. Figure 5 is a cross-sectional view of the same magnetic module along line V-V in Figure 2. Figure 6 is a bottom view of the same magnetic module. Figure 7 is a perspective view of multiple magnetic modules connected together. Figure 8 is a bottom view of multiple magnetic modules connected together. Figure 9 is a perspective view of the magnetic module of Modification 1 with the core block omitted. Figure 10 is a perspective view of a magnetic module of Modification 2. Figure 11 is a cross-sectional view of the same magnetic module. Figure 12 is a cross-sectional view of the same magnetic module along line XII-XII in Figure 11. Figure 13 is a bottom view of the same magnetic module. Figure 14 is a cross-sectional view of the same magnetic module along line XIV-XIV in Figure 11. Figure 15 is a cross-sectional view of a magnetic module of Modification 3. Figure 16 is a perspective view of the magnetic module shown above with the core block omitted. Figure 17 is a cross-sectional view of the magnetic module shown above along the line XVII-XVII in Figure 15. Figure 18 is a bottom view of the magnetic module shown above. Figure 19 is a cross-sectional view of the magnetic module of Modification 4. Figure 20 is a perspective view of the magnetic module shown above with the core block omitted. Figure 21 is a cross-sectional view of the magnetic module shown above with the core block omitted, along the line XXI-XXI in Figure 19. Figure 22 is a bottom view of the magnetic module shown above. Figure 23 is a cross-sectional view of the magnetic module of Modification 5. Figure 24 is a cross-sectional view of the magnetic module shown above with the core block omitted, along the line XXIV-XXIV in Figure 23. Figure 25 is a cross-sectional view of the magnetic module of Modification 6. Figure 26 is a cross-sectional view of the magnetic module shown above along the line XXVI-XXVI in Figure 25. Figure 27 is a circuit diagram of the power conversion circuit of the embodiment. Figure 28 shows the time variation of the voltage in the same power conversion circuit. Figure 29 is another figure showing the time variation of the voltage in the same power conversion circuit.

[0013] Magnetic components and magnetic modules of embodiments of this disclosure will be described with reference to the drawings. The figures described in the embodiments below are schematic diagrams, and the ratios of the size and thickness of each component shown in the figures do not necessarily reflect the actual dimensional ratios.

[0014] (1) Embodiment (1.1) Configuration of the power conversion circuit First, the power conversion circuit A1 (modified TLVR circuit) to which the magnetic component 100 and magnetic module 10 of this embodiment are applied will be described with reference to Figure 27.

[0015] As shown in Figure 27, the power conversion circuit A1 of this embodiment includes a pair of input terminals 1a and 1b, a first capacitor C1, a plurality (N; N is an integer of 1 or more) of switching circuits 1, a plurality (N; the same number as the switching circuits 1) of transformers 5, a first inductor L100 (compensation inductor), a second capacitor C2, a pair of output terminals 2a and 2b, and a control circuit 20. The power conversion circuit A1 is a multiphase (N-phase) step-down DC-DC converter.

[0016] A pair of input terminals 1a and 1b are electrically connected to both ends of a DC power supply V1. The DC power supply V1 is, for example, a power supply circuit that outputs a DC voltage. The voltage between the pair of input terminals 1a and 1b is the voltage from the DC power supply V1 (input voltage) Vi. The input voltage Vi is, for example, 12V. In this disclosure, "terminal" may refer to a component for connecting wires, etc., or it may refer to a lead of an electronic component or a part of a conductor included in a circuit board. Input terminal 1b is electrically connected to the ground of, for example, a power conversion circuit A1.

[0017] The pair of output terminals 2a and 2b are electrically connected to both ends of the load 40. The load 40 is, for example, a microprocessor such as a CPU or GPU. The voltage between the pair of output terminals 2a and 2b is the voltage across the second capacitor C2 (output voltage) Vo. The output voltage Vo is, for example, 1V. Note that the load 40 is not limited to a microprocessor, but may also be a control IC, another DC-DC converter, etc.

[0018] The first capacitor C1 is electrically connected between a pair of input terminals 1a and 1b. The high-potential terminal of the first capacitor C1 is electrically connected to input terminal 1a. The low-potential terminal of the first capacitor C1 is electrically connected to input terminal 1b.

[0019] The second capacitor C2 is electrically connected between the pair of output terminals 2a and 2b. The high-potential terminal of the second capacitor C2 is electrically connected to output terminal 2a. The low-potential terminal of the second capacitor C2 is electrically connected to output terminal 2b.

[0020] The multiple switching circuits 1 include the first switching circuit 11 to the Nth switching circuit 1N. For convenience, the third switching circuit 13 to the (N-1)th switching circuit 1(N-1) are omitted from Figure 27.

[0021] The k-th switching circuit 1k (where k is an integer from 1 to N) comprises a high-side switching element Qk1 and a low-side switching element Qk2 connected in series. Each switching element Qk1 and Qk2 has a first main terminal, a second main terminal, and a control terminal. Each switching element Qk1 and Qk2 is, for example, a MOSFET (Metal-Oxide-Semiconductor Field Effect Transistor). For convenience, the first main terminal will also be referred to as the drain terminal, the second main terminal as the source terminal, and the control terminal as the gate terminal.

[0022] The k-th switching circuit 1k is connected in parallel with the first capacitor C1. The drain terminal of the high-side switching element Qk1 is electrically connected to the high-potential side terminal of the first capacitor C1. The gate terminal of the switching element Qk1 is electrically connected to the control circuit 20. The source terminal of the switching element Qk1 is electrically connected to the drain terminal of the low-side switching element Qk2. The gate terminal of the switching element Qk2 is electrically connected to the control circuit 20. The source terminal of the switching element Qk2 is electrically connected to the low-potential side terminal of the first capacitor C1. In addition, the source terminal of the switching element Qk2 is electrically connected to the low-potential side terminal of the second capacitor C2.

[0023] Each switching element Qk1 and Qk2 is a Si-based MOSFET, but is not limited to Si-based MOSFETs; for example, a SiC-based MOSFET may also be used. Furthermore, each switching element Qk1 and Qk2 is not limited to MOSFETs; for example, an IGBT (Insulated Gate Bipolar Transistor) or a GaN-based GIT (Gate Injection Transistor) may also be used. In addition, each switching circuit 1k may include a diode connected in antiparallel to each switching element Qk1 and Qk2 (in the same orientation as the parasitic diode) in place of or in addition to the parasitic diode in the MOSFETs constituting each switching element Qk1 and Qk2.

[0024] The multiple transformers 5 include the first transformer Tr1 to the Nth transformer TrN. The first transformers Tr1 to the Nth transformer TrN correspond one-to-one with the first switching circuit 11 to the Nth switching circuit 1N. For convenience, the third transformer Tr3 to the (N-1)th transformer Tr(N-1) are omitted from the illustration in Figure 27.

[0025] The kth transformer Trk (where k is an integer from 1 to N) comprises a magnetically coupled primary winding Lk1 and a secondary winding Lk2.

[0026] The first end of the primary winding Lk1 of the k-th transformer Trk is electrically connected to the connection point 3k between switching elements Qk1 and Qk2 in the k-th switching circuit 1k. The second end of the primary winding Lk1 of the k-th transformer Trk is electrically connected to the high-potential terminal of the second capacitor C2.

[0027] In short, in power conversion circuit A1, a step-down DC-DC converter (for one phase) is configured with the k-th switching circuit 1k, the primary winding Lk1 of the k-th transformer Trk, (and the first capacitor C1 and the second capacitor C2). Hereafter, the number "N" of step-down DC-DC converters in power conversion circuit A1 may be referred to as the "number of phases".

[0028] The first terminal of the first inductor L100 is electrically connected to the ground of the power conversion circuit A1. The second terminal of the first inductor L100 is electrically connected to the first terminal of the secondary winding L12 of the first transformer Tr1. The second terminal of the secondary winding Li2 of the i-th transformer Tri (where i is an integer from 1 to N-1) is electrically connected to the first terminal of the secondary winding L(i+1)2 of the (i+1) transformer Tr(i+1). The second terminal of the secondary winding LN2 of the nth transformer TrN is electrically connected to the ground of the power conversion circuit A1.

[0029] In other words, in power conversion circuit A1, the secondary winding L12 of the first transformer Tr1 to the secondary winding LN2 of the nth transformer TrN are connected in series to form the secondary circuit 2. The ends of the series circuit between the first inductor L100 and the secondary circuit 2 are electrically connected to the ground of power conversion circuit A1.

[0030] The control circuit 20 is implemented, for example, by a computer system having one or more processors and one or more memories. In other words, the functions of the control circuit 20 are realized by one or more processors executing a program stored in memory. The program may be pre-stored in memory, provided via a telecommunication line such as the Internet, or provided on a non-temporary recording medium such as a memory card.

[0031] The control circuit 20 controls multiple switching circuits 1. The control circuit 20 controls the on / off state of switching elements Qk1 and Qk2 in each switching circuit 1k. For example, the control circuit 20 controls the on / off state of switching elements Qk1 and Qk2 based on the magnitude of the current flowing into the second capacitor C2. In the power conversion circuit A1, the control circuit 20 controls multiple switching circuits 1 to step down the input voltage Vi to the output voltage Vo. In the power conversion circuit A1, the control circuit 20 steps down the input voltage Vi to the output voltage Vo by performing synchronous rectification on each switching circuit 1k.

[0032] (1.2) Operation of the Power Conversion Circuit In the power conversion circuit A1, during the period when the high-side switching element Qk1 in the k-th switching circuit 1k is ON, the voltage VLk1 applied to the series circuit between the primary winding Lk1 of the k-th transformer Trk and the second capacitor C2 becomes the input voltage Vi. As a result, a current Itk flows through the primary winding Lk1 of the transformer Trk, and magnetic energy is stored in the primary winding Lk1. During the period when the switching element Qk1 is ON, the current Itk flowing through the primary winding Lk1 increases at a constant slope.

[0033] Subsequently, when the control circuit 20 turns off the high-side switching element Qk1 and turns on the low-side switching element Qk2, the voltage VLk1 becomes a negative output voltage -Vo, and the magnetic energy stored in the primary winding Lk1 is supplied to the load 40 as a current. During the period when the switching element Qk1 is off, the current Itk flowing through the primary winding Lk1 decreases at a constant slope.

[0034] In the power conversion circuit A1, the control circuit 20 basically controls the multiple switching circuits 1 such that the periods during which the high-side switching element Qk1 in different switching circuits 1 are turned on are staggered, or in other words, the high-side switching element Qk1 in different switching circuits 1 are not turned on simultaneously. That is, the control circuit 20 performs interleaving operation (phase shift) on the switching elements Q11 to QN1 in the first switching circuit 11 to the Nth switching circuit 1N.

[0035] The first to eighth stages of Figure 28 show the time variation of voltages VL11 to VL81 when the control circuit 20 is performing interleaved operation with a phase number N of "8". Each voltage VLk1 is equal to the input voltage Vi when the high-side switching element Qk1 is ON (and the low-side switching element Qk2 is OFF). Also, each voltage VLk1 is a negative output voltage -Vo when the high-side switching element Qk1 is OFF (and the low-side switching element Qk2 is ON).

[0036] The power conversion circuit A1 has the advantage of stabilizing the output voltage Vo and reducing ripple current compared to a single-phase step-down DC-DC converter by performing interleaving operation for the N-phase (e.g., 8-phase) step-down DC-DC converter.

[0037] Furthermore, in the power conversion circuit A1, the secondary winding Lk2 is magnetically coupled to the primary winding Lk1 in each transformer Trk. Therefore, a voltage is induced in the secondary winding Lk2 in accordance with the time change of the current flowing through the magnetically coupled primary winding Lk1. The bottom row of Figure 28 shows the time change of the voltage VLC (equal to the voltage across the secondary circuit 2) generated across the first inductor L100. As shown in Figure 28, a voltage is applied across the first inductor L100 during each period in which a voltage is applied to the primary windings L11 to L81.

[0038] Here, the power conversion circuit A1 has the advantage of having a fast transient response because it includes a series loop between the secondary circuit 2 (a series circuit of secondary windings L12 to LN2) and the first inductor L100.

[0039] For example, suppose the current demand of load 40 suddenly increases at a certain point in time. In this case, the control circuit 20 increases the output current by lengthening the on-time (increasing the duty cycle) of the switching element Qa1 (where a is an integer from 1 to N) that is ON at that time. In power conversion circuit A1, since multiple secondary windings L12 to LN2 are connected in series, the output current from the primary winding Lb1 connected to the OFF switching element Qb1 (where b is an integer from 1 to N other than a) also increases simultaneously. As a result, power conversion circuit A1 can respond to a sudden increase in current demand in a shorter time (faster transient response) compared to an N-phase step-down DC-DC converter that does not have a secondary circuit 2.

[0040] (1.3) Magnetic Module Next, the magnetic module 10 of this embodiment will be described with reference to Figures 1 to 5.

[0041] As shown in Figure 1, the magnetic module 10 comprises a magnetic component 100 and a mounting substrate 900.

[0042] For the sake of explanation, the magnetic module 10 will be described below by defining three axes (X-axis, Y-axis, and Z-axis) in a right-handed three-dimensional Cartesian coordinate system, as shown in Figure 1, etc. For convenience, the direction along the X-axis will be defined as the left-right direction, with the positive direction of the X-axis being "left" and the opposite direction being "right". The direction along the Y-axis will be defined as the front-back direction, with the positive direction of the Y-axis being "front" and the opposite direction being "back". The direction along the Z-axis will be defined as the up-down direction, with the positive direction of the Z-axis being "up" and the opposite direction being "down". However, the definitions of axes and directions in this disclosure merely indicate the relative positional relationships between the members of the magnetic module 10 and do not limit the orientation of the magnetic module 10 when it is in use.

[0043] As shown in Figures 1 to 3, the magnetic component 100 comprises a core block 60, a first conductor portion 71, a second conductor portion 72, and a third conductor portion 73.

[0044] As shown in FIGS. 1 to 3, the core block 60 includes a first core portion 61 and a second core portion 62.

[0045] The first core portion 61 is formed of a magnetic material. The first core portion 61 is a so-called E-core.

[0046] The first core portion 61 integrally has a first base portion 610, a first central leg portion 611, a first left leg portion 612, and a first right leg portion 613. The first base portion 610 is a plate-shaped rectangle in a rear view. The first central leg portion 611 is a plate-shaped rectangle in a rear view and protrudes rearward from the central portion of the rear surface of the first base portion 610. The first left leg portion 612 is a plate-shaped rectangle in a rear view and protrudes rearward from the left side portion of the rear surface of the first base portion 610. The first right leg portion 613 is a plate-shaped rectangle in a rear view and protrudes rearward from the right side portion of the rear surface of the first base portion 610.

[0047] The second core portion 62 is formed of a magnetic material. The second core portion 62 is a so-called E-core. Here, the second core portion 62 is formed in the same shape (symmetrical shape with respect to the XZ plane) as the first core portion 61.

[0048] The second core portion 62 integrally has a second base portion 620, a second central leg portion 621, a second left leg portion 622, and a second right leg portion 623. The second base portion 620 is a plate-shaped rectangle in a front view. The second central leg portion 621 is a plate-shaped rectangle in a front view and protrudes forward from the central portion of the front surface of the second base portion 620. The second left leg portion 622 is a plate-shaped rectangle in a front view and protrudes forward from the left side portion of the front surface of the second base portion 620. The second right leg portion 623 is a plate-shaped rectangle in a front view and protrudes forward from the right side portion of the front surface of the second base portion 620.

[0049] As shown in FIG. 3, the front end surface (rear surface) of the first central leg portion 611 and the front end surface (front surface) of the second central leg portion 621 face each other with a gap. The first central leg portion 611 and the second central leg portion 621 constitute the central magnetic leg 601 of the core block 60. The central magnetic leg 601 extends in the front-rear direction.

[0050] The front end (rear surface) of the first left leg portion 612 and the front end (front surface) of the second left leg portion 622 face each other with a gap between them. The first left leg portion 612 and the second left leg portion 622 constitute the left magnetic leg 602 of the core block 60. The left magnetic leg 602 extends in the front-rear direction.

[0051] The front end (rear surface) of the first right leg portion 613 and the front end (front surface) of the second right leg portion 623 face each other with a gap between them. The first right leg portion 613 and the second right leg portion 623 constitute the right magnetic leg 603 of the core block 60. The right magnetic leg 603 extends in the front-rear direction.

[0052] In the core block 6, spaces for arranging the first conductor section 71 to the third conductor section 73 are formed between the central magnetic leg 601 and the left magnetic leg 602, between the central magnetic leg 601 and the right magnetic leg 603, and above the central magnetic leg 601.

[0053] The first conductor portion 71 is formed from a conductive material such as copper. The first conductor portion 71 is, for example, a plate-like shape with a uniform thickness in parts other than the corners.

[0054] As shown in Figures 2 and 4, the first conductor portion 71 has a C-shaped first main body portion 710 (viewed along the axial direction of the magnetic leg 601).

[0055] The first main body portion 710 integrally includes a first central plate portion 711, a first left plate portion 712, and a first right plate portion 713. The first central plate portion 711 is rectangular in shape when viewed from above, has thickness in the vertical direction, and extends in the left-right direction. The first left plate portion 712 is rectangular in shape when viewed from the side, has thickness in the left-right direction, and extends downward from the left end of the first central plate portion 711. The first right plate portion 713 is rectangular in shape when viewed from the side, has thickness in the left-right direction, and extends downward from the right end of the first central plate portion 711.

[0056] In the following, for convenience, the lower end of the first left plate portion 712 of the first main body portion 710 may be referred to as the "first end of the first main body portion 710." Also, the lower end of the first right plate portion 713 of the first main body portion 710 may be referred to as the "second end of the first main body portion 710."

[0057] As shown in Figure 2, the first main body 710 is positioned to surround the central magnetic leg 601 of the core block 60. The first main body 710 surrounds the magnetic leg 601 from three sides: above, to the left, and to the right.

[0058] As shown in Figures 2, 4, and 5, the first conductor portion 71 further comprises a first left-side projection 718 and a first right-side projection 719. The first left-side projection 718 is a rectangular plate in top view, has thickness in the vertical direction, and extends in the left-right direction. The first left-side projection 718 extends to the right from the lower end of the first left-side plate portion 712 and faces the left-side portion of the lower surface of the magnetic leg 601. The first right-side projection 719 is a rectangular plate in top view, has thickness in the vertical direction, and extends in the left-right direction. The first right-side projection 719 extends to the left from the lower end of the first right-side plate portion 713 and faces the right-side portion of the lower surface of the magnetic leg 601. In Figure 5, for convenience, the boundary between the first left-side plate portion 712 and the first left-side projection 718, and the boundary between the first right-side plate portion 713 and the first right-side projection 719 are shown by dashed lines.

[0059] In the first conductor portion 71, the first end and the first left-side projection 718 of the first main body portion 710 are fixed to the pattern conductor 9 of the mounting substrate 900 (the first secondary conductor 921 in the example of Figure 5) by, for example, soldering. In addition, the second end and the first right-side projection 719 of the first main body portion 710 are fixed to the pattern conductor 9 of the mounting substrate 900 (the second secondary conductor 922 in the example of Figure 5) by, for example, soldering. The presence of the first left-side projection 718 and the first right-side projection 719 of the first conductor portion 71 facilitates mounting onto the mounting substrate 900.

[0060] The second conductor portion 72 is formed from a conductive material such as copper. The material of the second conductor portion 72 may be the same as the material of the first conductor portion 71. The second conductor portion 72 is, for example, a plate-like shape with a uniform thickness in parts other than the corners.

[0061] As shown in Figures 2 and 4, the second conductor portion 72 has a C-shaped second body portion 720 (viewed along the axial direction of the magnetic leg 601). The second body portion 720 is (slightly) larger than the first body portion 710.

[0062] The second main body portion 720 integrally includes a second central plate portion 721, a second left-side plate portion 722, and a second right-side plate portion 723. The second central plate portion 721 is a rectangular plate in top view, has thickness in the vertical direction, and extends in the left-right direction. The second left-side plate portion 722 is a rectangular plate in side view, has thickness in the left-right direction, and extends downward from the left end of the second central plate portion 721. The second right-side plate portion 723 is a rectangular plate in side view, has thickness in the left-right direction, and extends downward from the right end of the second central plate portion 721.

[0063] In the following, for convenience, the lower end of the second left plate portion 722 of the second main body portion 720 may be referred to as the "first end of the second main body portion 720." Also, the lower end of the second right plate portion 723 of the second main body portion 720 may be referred to as the "second end of the second main body portion 720."

[0064] As shown in Figure 2, the second main body portion 720 is positioned outside the first main body portion 710 and is arranged to surround the central magnetic leg 601 of the core block 60. The second main body portion 720 is arranged concentrically with the first main body portion 710. The width of the second main body portion 720 in the front-rear direction is the same as the width of the first main body portion 710 in the front-rear direction. In this disclosure, "two elements are the same" does not mean that the two elements are strictly identical, but rather that manufacturing tolerances for each element, assembly tolerances between elements, etc., are permissible.

[0065] The second main body portion 720 surrounds the outer surface of the first main body portion 710 from three sides: above, to the left, and to the right. Specifically, the second central plate portion 721 is positioned above the first central plate portion 711 with a gap in between, and covers the upper surface of the first central plate portion 711. The second left side plate portion 722 is positioned to the left of the first left side plate portion 712 with a gap in between, and covers the left side of the first left side plate portion 712. The second right side plate portion 723 is positioned to the right of the first right side plate portion 713 with a gap in between, and covers the right side of the first right side plate portion 713.

[0066] As shown in Figures 4 and 5, the second conductor portion 72 further comprises a second left-side projection 728 and a second right-side projection 729. The second left-side projection 728 is plate-shaped with a rectangular form in side view, has thickness in the left-right direction, and extends in the front-rear direction. The second left-side projection 728 extends rearward from the lower end of the second left-side plate portion 722. The second right-side projection 729 is plate-shaped with a rectangular form in side view, has thickness in the left-right direction, and extends in the front-rear direction. The second right-side projection 729 extends forward from the lower end of the second right-side plate portion 723. In Figure 5, for convenience, the boundary between the second left-side plate portion 722 and the second left-side projection 728, and the boundary between the second right-side plate portion 723 and the second right-side projection 729 are shown by dashed lines.

[0067] In the second conductor portion 72, the first end and the second left protrusion 728 of the second main body portion 720 are fixed to the pattern conductor 9 of the mounting substrate 900 (the third primary side conductor 913 in the example of Figure 5) by, for example, soldering. Also, the second end and the second right protrusion 729 of the second main body portion 720 are fixed to the pattern conductor 9 of the mounting substrate 900 (the second primary side conductor 912 in the example of Figure 5) by, for example, soldering. The presence of the second left protrusion 728 and the second right protrusion 729 of the second conductor portion 72 facilitates mounting onto the mounting substrate 900.

[0068] The third conductor portion 73 is formed from a conductive material such as copper. The material of the third conductor portion 73 may be the same as the material of the first conductor portion 71 and the second conductor portion 72. The third conductor portion 73 is, for example, a plate-like shape with a uniform thickness in all parts except the corners.

[0069] As shown in Figures 2 and 4, the third conductor portion 73 has a C-shaped third body portion 730 (when viewed along the axial direction of the magnetic leg 601). The third body portion 730 is (slightly) larger than the second body portion 720.

[0070] The third main body portion 730 integrally includes a third central plate portion 731, a third left-side plate portion 732, and a third right-side plate portion 733. The third central plate portion 731 is a rectangular plate in top view, has thickness in the vertical direction, and extends in the left-right direction. The third left-side plate portion 732 is a rectangular plate in side view, has thickness in the left-right direction, and extends downward from the left end of the third central plate portion 731. The third right-side plate portion 733 is a rectangular plate in side view, has thickness in the left-right direction, and extends downward from the right end of the third central plate portion 731.

[0071] In the following, for convenience, the lower end of the third left plate portion 732 of the third main body portion 730 may be referred to as the "first end of the third main body portion 730." Also, the lower end of the third right plate portion 733 of the third main body portion 730 may be referred to as the "second end of the third main body portion 730."

[0072] As shown in Figure 2, the third main body portion 730 is positioned outside the second main body portion 720 and is arranged to surround the central magnetic leg 601 of the core block 60. The third main body portion 730 is arranged concentrically with the first main body portion 710 and the second main body portion 720. The front-to-back width of the third main body portion 730 is the same as the front-to-back width of the first main body portion 710 and the second main body portion 720.

[0073] The third main body portion 730 surrounds the outer surface of the second main body portion 720 from three sides: above, to the left, and to the right. Specifically, the third central plate portion 731 is positioned above the second central plate portion 721 with a gap in between, and covers the upper surface of the second central plate portion 721. The third left side plate portion 732 is positioned to the left of the second left side plate portion 722 with a gap in between, and covers the left side of the second left side plate portion 722. The third right side plate portion 733 is positioned to the right of the second right side plate portion 723 with a gap in between, and covers the right side of the second right side plate portion 723.

[0074] As shown in Figures 2, 4, and 5, the third conductor portion 73 further comprises a third left-side projection 738 and a third right-side projection 739. The third left-side projection 738 is plate-shaped with a rectangular top view, has thickness in the vertical direction, and extends in the left-right direction. The third left-side projection 738 extends to the left from the lower end of the third left-side plate portion 732. The third right-side projection 739 is plate-shaped with a rectangular top view, has thickness in the vertical direction, and extends in the left-right direction. The third right-side projection 739 extends to the right from the lower end of the third right-side plate portion 733. In Figure 5, for convenience, the boundary between the third left-side plate portion 732 and the third left-side projection 738, and the boundary between the third right-side plate portion 733 and the third right-side projection 739 are shown by dashed lines.

[0075] In the third conductor portion 73, the first end and the third left protrusion 738 of the third main body portion 730 are fixed to the pattern conductor 9 of the mounting substrate 900 (the first primary side conductor 911 in the example of Figure 5) by, for example, soldering. In addition, the second end and the third right protrusion 739 of the third main body portion 730 are fixed to the pattern conductor 9 of the mounting substrate 900 (the third primary side conductor 913 in the example of Figure 5) by, for example, soldering. The presence of the third left protrusion 738 and the third right protrusion 739 of the third conductor portion 73 facilitates mounting onto the mounting substrate 900.

[0076] As shown in Figure 2, in the magnetic component 100 of this embodiment, the first end of the third main body 730, the first end of the second main body 720, the first end of the first main body 710, the second end of the first main body 710, the second end of the second main body 720, and the second end of the third main body 730 are arranged in a predetermined direction (left-right direction).

[0077] As shown in Figures 4 and 5, the projection direction (to the right) of the first left projection 718 is perpendicular to the projection direction (to the rear) of the second left projection 728. The projection direction (to the rear) of the second left projection 728 is perpendicular to the projection direction (to the left) of the third left projection 738.

[0078] Furthermore, the protruding direction (left) of the first right-side protrusion 719 is perpendicular to the protruding direction (forward) of the second right-side protrusion 729. The protruding direction (forward) of the second right-side protrusion 729 is perpendicular to the protruding direction (right) of the third right-side protrusion 739.

[0079] Thus, one of the first conductor portion 71, the second conductor portion 72, and the third conductor portion 73 has a projection that protrudes from the end of the corresponding main body portion, and another of the first conductor portion 71, the second conductor portion 72, and the third conductor portion 73 has another projection that protrudes from the end of the corresponding main body portion. Furthermore, the projection direction of the one projection is perpendicular to the projection direction of the other projection. This improves the ease of mounting the magnetic component 100 (for example, ease of soldering).

[0080] In this disclosure, "two elements are orthogonal" does not mean that the two elements are orthogonal in a strict sense, but rather that deviations due to manufacturing tolerances of the elements, assembly tolerances between the elements, etc., are acceptable.

[0081] As shown in Figure 2, the first left plate portion 712, the second left plate portion 722, and the third left plate portion 732 are located in the space between the central magnetic leg 601 and the left magnetic leg 602. The first right plate portion 713, the second right plate portion 723, and the third right plate portion 733 are located in the space between the central magnetic leg 601 and the right magnetic leg 603. The first central plate portion 711, the second central plate portion 721, and the third central plate portion 731 are located in the space above the central magnetic leg 601. As shown in Figures 1 and 2, the upper surface of the third central plate portion 731 is exposed above the core block 60.

[0082] Thus, the first conductor section 71 to the third conductor section 73 are arranged within the space of the core block 60. This improves magnetic shielding from the outside.

[0083] In the magnetic component 100, the gap between the magnetic leg 601 and the first conductor portion 71, the gap between the first conductor portion 71 and the third conductor portion 73, and the gap between the third conductor portion 73 and the core block 60 may be empty space or may be filled with resin (for example, epoxy resin). Furthermore, appropriate spacers may be provided in these gaps.

[0084] The mounting board 900 is a so-called printed circuit board (PCB). As shown in Figures 1, 2, 4 to 6, the mounting board 900 comprises a board body 90 and a plurality of pattern conductors 9.

[0085] The substrate body 90 is made of resin. The substrate body 90 is a rectangular plate. The substrate body 90 has a first surface 901 (top surface) and a second surface 902 (bottom surface).

[0086] The pattern conductor 9 is made of a conductive metal such as copper. The pattern conductor 9 is provided on the substrate body 90.

[0087] In this embodiment, the plurality of pattern conductors 9 include a first primary conductor 911, a second primary conductor 912, and a third primary conductor 913. The plurality of pattern conductors 9 also include a first secondary conductor 921 and a second secondary conductor 922.

[0088] As shown in Figures 4 and 5, the first primary conductor 911 is provided on the first surface 901 of the substrate body 90 so as to extend in the left-right direction. The first end (left end) of the first primary conductor 911 is located at the left end of the substrate body 90. The first end of the first primary conductor 911 functions as a connection terminal (first primary terminal) that is connected to an external member. The first end of the third main body portion 730 is connected to the second end (right end) of the first primary conductor 911.

[0089] The third primary conductor 913 is provided on the first surface 901 of the substrate body 90 in a C-shape when viewed from above. The first end (left end) of the third primary conductor 913 is connected to the first end of the second body portion 720. The second end (right end) of the third primary conductor 913 is connected to the second end of the third body portion 730.

[0090] The second primary conductor 912 is provided on the first surface 901 of the substrate body 90 so as to extend in the left-right direction. The second end of the second main body portion 720 is connected to the first end (left end) of the second primary conductor 912. The second end (right end) of the second primary conductor 912 is located at the right end of the substrate body 90. The second end of the second primary conductor 912 functions as a connection terminal (second primary terminal) that is connected to an external component.

[0091] In the magnetic module 10, the second end of the third main body 730 and the first end of the second main body 720 are connected by a third primary conductor 913. This results in a primary winding (two turns) being wound around the magnetic leg 601 between the first primary terminal and the second primary terminal of the magnetic module 10. In this embodiment, the primary winding includes the second main body 720, the third main body 730, and the third primary conductor 913. In this embodiment, the third primary conductor 913 functions as a connecting member 8 that connects the end of the second main body 720 and the end of the third main body 730. In other words, the connecting member 8 that connects the end of the second main body 720 and the end of the third main body 730 includes a pattern conductor 9 provided on the mounting substrate 900. In the magnetic module 10, the winding of the magnetic module 10 (e.g., a transformer) is constructed using the pattern conductor 9 provided on the mounting substrate 900.

[0092] The first secondary conductor 921 includes a first portion and a second portion.

[0093] As shown in Figure 2, the first portion of the first secondary conductor 921 penetrates the substrate body 90 vertically. The first portion of the first secondary conductor 921 is a so-called "via". In Figure 2, the first portion is shown as a filled via, but it may also be an unfilled through-hole conductor.

[0094] As shown in Figure 6, the second portion of the first secondary conductor 921 is provided on the second surface 902 of the substrate body 90. The second portion extends from the lower end of the first portion to the rear end of the substrate body 90.

[0095] The first end (upper end of the first portion) of the first secondary conductor 921 is connected to the first end of the first main body 710. The second end (rear end of the second portion) of the first secondary conductor 921 functions as a connection terminal (first secondary terminal) that is connected to an external member.

[0096] The second secondary conductor 922 includes a first portion and a second portion.

[0097] As shown in Figure 2, the first portion of the second secondary conductor 922 penetrates the substrate body 90 vertically. The first portion of the second secondary conductor 922 is a so-called "via".

[0098] As shown in Figure 6, the second portion of the second secondary conductor 922 is provided on the second surface 902 of the substrate body 90. The second portion extends from the lower end of the first portion to the front end of the substrate body 90.

[0099] The second end of the first main body 710 is connected to the first end (upper end of the first portion) of the second secondary conductor 922. The second end (front end of the second portion) of the second secondary conductor 922 functions as a connection terminal (second secondary terminal) that is connected to an external component.

[0100] In the magnetic module 10, a secondary winding (one turn) is formed between the first secondary terminal and the second secondary terminal, wound around the magnetic leg 601. In this embodiment, the secondary winding includes the first main body portion 710.

[0101] In short, the magnetic module 10 functions as a transformer having a primary winding and a secondary winding. In the magnetic module 10 (transformer) of this embodiment, the turns ratio of the primary winding to the secondary winding is 2:1.

[0102] The magnetic module 10 of this embodiment is used, for example, as the kth transformer Trk (where k is an integer from 1 to N) in the power conversion circuit A1 (see Figure 27). That is, the magnetic component 100 is used as a component that constitutes at least a part of the inductor in a multiphase step-down DC-DC converter. Here, each of the first transformer Tr1 to the Nth transformer TrN is composed of the magnetic module 10.

[0103] In this embodiment of the magnetic component 100, as shown in Figure 3, the width D10 (dimension in the front-to-back direction) of the first main body 710, the width D20 (dimension in the front-to-back direction) of the second main body 720, and the width D30 (dimension in the front-to-back direction) of the third main body 730 are the same.

[0104] Furthermore, the thickness D21 of the second main body portion 720 and the thickness D31 of the third main body portion 730 are the same. Therefore, the cross-sectional area of ​​the second main body portion 720 and the cross-sectional area of ​​the third main body portion 730 are the same. As a result, the resistance value per unit length of the second main body portion 720 and the resistance value per unit length of the third main body portion 730 are the same. Therefore, in the magnetic component 100, the resistance value per unit length of the members constituting the primary winding (second main body portion 720 and third main body portion 730) is constant.

[0105] On the other hand, as shown in Figure 3, the thickness D11 of the first main body portion 710 is smaller than the thickness D21 of the second main body portion 720 and smaller than the thickness D31 of the third main body portion 730. Therefore, the cross-sectional area of ​​the first main body portion 710 is smaller than the cross-sectional area of ​​the second main body portion 720 and smaller than the cross-sectional area of ​​the third main body portion 730. As a result, in the magnetic component 100, the resistance value per unit length of the members constituting the primary winding (second main body portion 720 and third main body portion 730) is smaller than the resistance value per unit length of the members constituting the secondary winding (first main body portion 710).

[0106] In this way, by making the resistance per unit length of the components constituting the primary winding smaller than the resistance per unit length of the components constituting the secondary winding, the series equivalent resistance of the primary winding can be kept low, and losses due to the primary winding can be reduced.

[0107] Furthermore, the cross-sectional area of ​​the first main body 710 may be smaller than half the cross-sectional area of ​​the second main body 720 and smaller than half the cross-sectional area of ​​the third main body 730. In this case, the resistance per unit length of the second main body 720 will be smaller than half the resistance per unit length of the first main body 710, and the resistance per unit length of the third main body 730 will be smaller than half the resistance per unit length of the first main body 710. Also, since the turns ratio of the primary winding to the secondary winding is 2:1, the series equivalent resistance of the primary winding will be smaller than the series equivalent resistance of the secondary winding. This makes it possible to further reduce losses due to the primary winding.

[0108] (1.4) Advantages Below, the advantages of the power conversion circuit A1 (modified TLVR circuit) equipped with the magnetic module 10 of this embodiment as the first transformer Tr1 to the Nth transformer TrN will be explained, along with a comparison with the power conversion circuit of the comparative example.

[0109] The comparative power conversion circuit has basically the same configuration as the power conversion circuit A1 of this embodiment (see Figure 27), but differs in that it is equipped with a transinductor instead of each of the first transformer Tr1 to the Nth transformer TrN. In this disclosure, "transinductor" means a magnetic component in which a primary winding and a secondary winding are each wound one turn around the magnetic legs of a core. In other words, the comparative power conversion circuit is a general TLVR circuit.

[0110] On the other hand, in the power conversion circuit A1 of this embodiment, the turns ratio between the primary winding Lk1 and the secondary winding Lk2 is 2:1 in each of the first transformer Tr1 to the Nth transformer TrN.

[0111] For the sake of explanation, the following description will use the case where the number of phases N of the power conversion circuit A1 is "8" as an example. Also, for the sake of explanation, elements of the power conversion circuit of the comparative example that correspond to elements of the power conversion circuit A1 of the embodiment may be denoted by the same reference numerals.

[0112] As described above, in the power conversion circuit A1 of the embodiment, the control circuit 20 basically performs interleaved operation. Similarly, in the power conversion circuit of the comparative example, the control circuit 20 also basically performs interleaved operation.

[0113] The first to eighth rows of Figure 28 show the time variation of the voltage VLk1 (where k is an integer from 1 to 8) when the control circuit 20 is performing interleaved operation. Note that the time variation of the voltage VLk1 (where k is an integer from 1 to 8) (see the first to eighth rows of Figure 28) is common to both the power conversion circuit A1 of the embodiment and the power conversion circuit of the comparative example.

[0114] Furthermore, the bottom row of Figure 28 shows the time variation of the voltage VLC across the first inductor L100 in the power conversion circuit A1 of the embodiment. For convenience, the bottom row of Figure 28 also shows the voltage VLCx across the first inductor L100 in the power conversion circuit of the comparative example as a dashed line.

[0115] As shown in the bottom row of Figure 28, the amplitude of the voltage VLC across the first inductor L100 in the power conversion circuit A1 of the embodiment is half the amplitude of the voltage VLCx across the first inductor L100 in the power conversion circuit of the comparative example. This is because, in the power conversion circuit of the comparative example, the turns ratio between the primary winding Lk1 and the secondary winding Lk2 is 1:1, whereas in the power conversion circuit A1 of the embodiment, the turns ratio between the primary winding Lk1 and the secondary winding Lk2 is 2:1.

[0116] By the way, in the power conversion circuit A1 of the embodiment and the power conversion circuit of the comparative example, depending on the control of the control circuit 20, the high-side switching elements Q11 to QN1 of the first switching circuit 11 to the nth switching circuit 1N may be turned on simultaneously. In that case, as shown in the first to eighth stages of Figure 29, voltages are applied simultaneously to the primary windings L11 to L81 of the first transformer Tr1 to the eighth transformer Tr8, and voltages are induced in the secondary windings L12 to L82 of the first transformer Tr1 to the eighth transformer Tr8, respectively. As a result, the sum of the voltages induced in the secondary windings L12 to L82 is applied across the first inductor L100. The bottom stage of Figure 29 shows the time change of the voltage VLC (equal to the voltage across the secondary circuit 2) generated across the first inductor L100. Furthermore, for convenience, the voltage VLCx across the first inductor L100 in the comparative example power conversion circuit is also shown as a dashed line at the bottom of Figure 29.

[0117] Here, as described above, in the comparative example power conversion circuit, the turns ratio between the primary winding Lk1 and the secondary winding Lk2 is 1:1, whereas in the embodiment power conversion circuit A1, the turns ratio between the primary winding Lk1 and the secondary winding Lk2 is 2:1. Therefore, even when voltages are induced simultaneously, similar to the case of interleaved operation, the amplitude of the voltage VLC across the first inductor L100 in the embodiment power conversion circuit A1 is half the amplitude of the voltage VLCx across the first inductor L100 in the comparative example power conversion circuit (see bottom row of Figure 29). In other words, the maximum applied voltage of the secondary circuit 2 in the embodiment power conversion circuit A1 is half the maximum applied voltage of the secondary circuit 2 in the comparative example power conversion circuit.

[0118] Thus, the power conversion circuit A1 of this embodiment (modified TLVR circuit) can reduce the maximum applied voltage of the secondary circuit 2 (by half in this embodiment) compared to the power conversion circuit of the comparative example (a general TLVR circuit). As a result, it is possible to reduce the occurrence of malfunctions in the power conversion circuit A1.

[0119] Furthermore, in the power conversion circuit A1 of this embodiment, the maximum applied voltage of the secondary circuit 2 is reduced, which in turn reduces the required dielectric strength of the transformer Trk (first transformer Tr1 in the example of Figure 27) having the secondary winding Lk2 with the highest potential in the secondary circuit 2. As a result, the gap between the winding and the core, which is provided in the transformer Trk to increase the dielectric strength, can be reduced, making it possible to miniaturize the transformer Trk.

[0120] (1.5) Connection of Multiple Magnetic Modules As described above, in the power conversion circuit A1 of this embodiment, each of the first transformer Tr1 to the Nth transformer TrN is composed of a magnetic module 10. In this case, as shown in Figures 7 to 8, by arranging N (eight in the illustrated example) magnetic modules 10 in a row and connecting the first secondary terminal (first secondary conductor 921) and the second secondary terminal (second secondary conductor 922) of adjacent magnetic modules 10, the secondary windings L12 to LN2 of the first transformer Tr1 to the Nth transformer TrN can be easily connected in series.

[0121] (2) Modifications The above embodiments are only one of many embodiments of the present disclosure. The above embodiments can be modified in various ways depending on the design, etc., as long as the objectives of the present disclosure are achieved. Modifications of the embodiments are listed below. The above embodiments and the modifications described below can be combined and applied as appropriate.

[0122] (2.1) Modification 1 The magnetic module 10 of this modification will be described with reference to Figure 9. Note that the core block 60 (see Figure 1) is not shown in Figure 9.

[0123] As shown in Figure 9, in this modified magnetic module 10, the second conductor portion 72 does not have a second left-side projection 728 and a second right-side projection 729 (see Figure 4). The other configurations of this modified magnetic module 10 are substantially the same as those of the embodiment, so a detailed explanation is omitted.

[0124] Similar to the magnetic module 10 of the embodiment, this modified version of the magnetic module 10 can be applied to the power conversion circuit A1 (modified TLVR circuit) to reduce the maximum applied voltage of the secondary circuit 2 in the power conversion circuit A1.

[0125] (2.2) Modification 2 The magnetic module 10 of this modification will be described with reference to Figures 10 to 14.

[0126] The modified magnetic module 10 differs from the embodiment's magnetic module 10 mainly in that the primary winding of the transformer includes the first main body portion 710 and the third main body portion 730 of the magnetic component 100, and the secondary winding includes the second main body portion 720. The configuration of the modified magnetic module 10 that is substantially the same as that of the embodiment's magnetic module 10 will be omitted from the explanation as appropriate.

[0127] As shown in Figures 10 to 14, the modified magnetic module 10 comprises a magnetic component 100 and a mounting substrate 900. The magnetic component 100 comprises a core block 60, a first conductor portion 71, a second conductor portion 72, and a third conductor portion 73. The mounting substrate 900 comprises a substrate body 90 and a plurality of pattern conductors 9.

[0128] In this modified magnetic module 10, as shown in Figure 12, the first end (left end) of the third primary conductor 913 is connected to the first end of the first main body 710. Also, the first end (left end) of the second primary conductor 912 is connected to the second end of the first main body 710.

[0129] Furthermore, the first end (left end) of the first primary conductor 911 functions as a connection terminal (first primary terminal) connected to an external member, the second end (right end) of the first primary conductor 911 is connected to the first end of the third main body 730, the second end (right end) of the third primary conductor 913 is connected to the second end of the third main body 730, and the second end (right end) of the second primary conductor 912 functions as a connection terminal (second primary terminal) connected to an external member, similar to the magnetic module 10 of the embodiment.

[0130] In this modified example of the magnetic module 10, the second end of the third main body 730 and the first end of the first main body 710 are connected by a third primary conductor 913. This forms a primary winding (two turns) wound around the magnetic leg 601 between the first primary terminal and the second primary terminal. In this modified example, the primary winding includes the first main body 710, the third main body 730, and the third primary conductor 913. In this modified example, the third primary conductor 913 functions as a connecting member 8 that connects the end of the first main body 710 and the end of the third main body 730. In other words, the connecting member 8 that connects the end of the first main body 710 and the end of the third main body 730 includes a pattern conductor 9 provided on the mounting substrate 900.

[0131] Furthermore, as shown in Figures 11 and 13, the first end (upper end of the first portion) of the first secondary conductor 921 is connected to the first end of the second main body 720. The first end (upper end of the first portion) of the second secondary conductor 922 is connected to the second end of the second main body 720.

[0132] Furthermore, the fact that the second end (rear end of the second portion) of the first secondary conductor 921 functions as a connection terminal (first secondary terminal) connected to an external member, and the second end (front end of the second portion) of the second secondary conductor 922 functions as a connection terminal (second secondary terminal) connected to an external member, is the same as in the magnetic module 10 of the embodiment.

[0133] In the magnetic module 10, a secondary winding (one turn) is formed between the first secondary terminal and the second secondary terminal, wound around the magnetic leg 601. In this modified example, the secondary winding includes the second main body 720.

[0134] The magnetic module 10 of this modified example also functions as a transformer having a primary winding and a secondary winding, similar to the magnetic module 10 of the embodiment. In the magnetic module 10 (transformer) of this modified example, the turns ratio of the primary winding to the secondary winding is 2:1.

[0135] This modified magnetic module 10 can also be applied to the power conversion circuit A1 (modified TLVR circuit) to reduce the maximum applied voltage of the secondary circuit 2 in the power conversion circuit A1.

[0136] In this modified example of the magnetic component 100, as shown in Figure 14, the width D10 of the first main body 710, the width D20 of the second main body 720, and the width D30 of the third main body 730 are all the same.

[0137] Furthermore, the thickness D11 of the first main body portion 710 and the thickness D31 of the third main body portion 730 are the same. Therefore, the cross-sectional area of ​​the second main body portion 720 and the cross-sectional area of ​​the third main body portion 730 are the same. As a result, in the magnetic component 100, the resistance value per unit length of the members constituting the primary winding (first main body portion 710 and third main body portion 730) is constant.

[0138] On the other hand, as shown in Figure 14, the thickness D21 of the second main body portion 720 is smaller than the thickness D11 of the first main body portion 710 and smaller than the thickness D31 of the third main body portion 730. Therefore, the cross-sectional area of ​​the second main body portion 720 is smaller than the cross-sectional area of ​​the first main body portion 710 and smaller than the cross-sectional area of ​​the third main body portion 730. As a result, in the magnetic component 100, the resistance value per unit length of the members constituting the primary winding (first main body portion 710 and third main body portion 730) is smaller than the resistance value per unit length of the members constituting the secondary winding (second main body portion 720).

[0139] Furthermore, in the modified magnetic component 100, the thickness D21 of the second main body 720 is less than half the thickness D11 of the first main body 710 and less than half the thickness D31 of the third main body 730. Therefore, the cross-sectional area of ​​the second main body 720 is less than half the cross-sectional area of ​​the first main body 710 and less than half the cross-sectional area of ​​the third main body 730. As a result, the resistance per unit length of the first main body 710 is less than half the resistance per unit length of the second main body 720, and the resistance per unit length of the third main body 730 is less than half the resistance per unit length of the second main body 720.

[0140] Furthermore, in this modified magnetic module 10, the turns ratio between the primary winding and the secondary winding is 2:1. Therefore, the series equivalent resistance of the primary winding is smaller than the series equivalent resistance of the secondary winding. This makes it possible to further reduce losses due to the primary winding in this modified magnetic module 10.

[0141] Furthermore, as shown in Figure 11, in this modified example of the magnetic component 100, the component constituting the secondary winding (second main body 720) is positioned between the components constituting the primary winding (first main body 710 and third main body 730). This makes it possible to improve the strength of the magnetic coupling between the primary winding and the secondary winding.

[0142] (2.3) Modification 3 The magnetic module 10 of this modification will be described with reference to Figures 15 to 18. Note that the core block 60 (see Figure 1) is not shown in Figure 16.

[0143] The magnetic module 10 of this modified example differs from the magnetic module 10 of the embodiment mainly in that the turns ratio between the primary winding and the secondary winding is 3:1. The configuration of the magnetic module 10 of this modified example that is substantially the same as that of the magnetic module 10 of the embodiment will be omitted from the explanation as appropriate.

[0144] As shown in Figures 15 to 18, the modified magnetic module 10 comprises a magnetic component 100 and a mounting substrate 900. The magnetic component 100 comprises a core block 60, a first conductor portion 71, a second conductor portion 72, a third conductor portion 73, and further comprises a fourth conductor portion 74. The mounting substrate 900 comprises a substrate body 90 and a plurality of pattern conductors 9.

[0145] As shown in Figures 15 to 17, the first conductor portion 71 comprises a first main body portion 710, a first left-side projection portion 718, and a first right-side projection portion 719. The first main body portion 710 comprises a first central plate portion 711, a first left-side plate portion 712, and a first right-side plate portion 713.

[0146] The second conductor portion 72 comprises a second main body portion 720. The second main body portion 720 comprises a second central plate portion 721, a second left-side plate portion 722, and a second right-side plate portion 723. The second conductor portion 72 does not have a second left-side projection portion 728 and a second right-side projection portion 729 (see Figure 4), but may have them.

[0147] The third conductor portion 73 comprises a third main body portion 730. The third main body portion 730 comprises a third central plate portion 731, a third left-side plate portion 732, and a third right-side plate portion 733. The third conductor portion 73 does not have a third left-side projection portion 738 and a third right-side projection portion 739 (see Figure 4), but may have them. In this modified example, the third left-side projection portion 738 may be, for example, a plate-shaped portion extending rearward from the lower end of the third left-side plate portion 732. Also, in this modified example, the third right-side projection portion 739 may be, for example, a plate-shaped portion extending forward from the lower end of the third right-side plate portion 733.

[0148] The fourth conductor portion 74 is formed from a conductive material such as copper. The material of the fourth conductor portion 74 may be the same as the material of the first conductor portion 71, the second conductor portion 72, and the third conductor portion 73. The fourth conductor portion 74 is, for example, a plate-like shape with a uniform thickness in all parts except the corners.

[0149] As shown in Figures 15 to 17, the fourth conductor portion 74 has a fourth main body portion 740 that is C-shaped when viewed from above. The fourth main body portion 740 is (slightly) larger than the third main body portion 730.

[0150] The fourth main body portion 740 integrally includes a fourth central plate portion 741, a fourth left-side plate portion 742, and a fourth right-side plate portion 743. The fourth central plate portion 741 is a rectangular plate in top view, has thickness in the vertical direction, and extends in the left-right direction. The fourth left-side plate portion 742 is a rectangular plate in side view, has thickness in the left-right direction, and extends downward from the left end of the fourth central plate portion 741. The fourth right-side plate portion 743 is a rectangular plate in side view, has thickness in the left-right direction, and extends downward from the right end of the fourth central plate portion 741.

[0151] In the following, for convenience, the lower end of the fourth left plate portion 742 of the fourth main body portion 740 may be referred to as the "first end of the fourth main body portion 740." Also, the lower end of the fourth right plate portion 743 of the fourth main body portion 740 may be referred to as the "second end of the fourth main body portion 740."

[0152] As shown in Figure 15, the fourth main body 740 is positioned outside the third main body 730 and is arranged to surround the central magnetic leg 601 of the core block 60. The fourth main body 740 is arranged concentrically with the first main body 710, the second main body 720, and the third main body 730. The front-to-back width of the fourth main body 740 is the same as the front-to-back width of the first main body 710, the second main body 720, and the third main body 730.

[0153] The fourth main body portion 740 surrounds the outer surface of the third main body portion 730 from three sides: above, to the left, and to the right. Specifically, the fourth central plate portion 741 is positioned above the third central plate portion 731 with a gap in between, and covers the upper surface of the third central plate portion 731. The fourth left side plate portion 742 is positioned to the left of the third left side plate portion 732 with a gap in between, and covers the left side of the third left side plate portion 732. The fourth right side plate portion 743 is positioned to the right of the third right side plate portion 733 with a gap in between, and covers the right side of the third right side plate portion 733.

[0154] As shown in Figures 15 to 17, the fourth conductor portion 74 further comprises a fourth left projection 748 and a fourth right projection 749. The fourth left projection 748 is a rectangular plate in top view, has thickness in the vertical direction, and extends in the left-right direction. The fourth left projection 748 extends to the left from the lower end of the fourth left plate portion 742. The fourth right projection 749 is a rectangular plate in top view, has thickness in the vertical direction, and extends in the left-right direction. The fourth right projection 749 extends to the right from the lower end of the fourth right plate portion 743. In Figure 17, for convenience, the boundary between the fourth left plate portion 742 and the fourth left projection 748, and the boundary between the fourth right plate portion 743 and the fourth right projection 749 are shown by dashed lines.

[0155] In the fourth conductor portion 74, the first end and the fourth left protrusion 748 of the fourth main body portion 740 are fixed to the pattern conductor 9 of the mounting substrate 900 (the first primary side conductor 911 in the example of Figure 17) by, for example, soldering. In addition, the second end and the fourth right protrusion 749 of the fourth main body portion 740 are fixed to the pattern conductor 9 of the mounting substrate 900 (the third primary side conductor 913 in the example of Figure 17) by, for example, soldering. The presence of the fourth left protrusion 748 and the fourth right protrusion 749 of the fourth conductor portion 74 facilitates mounting onto the mounting substrate 900.

[0156] As shown in Figure 15, in this modified example of the magnetic component 100, the first end of the fourth main body 740, the first end of the third main body 730, the first end of the second main body 720, the first end of the first main body 710, the second end of the first main body 710, the second end of the second main body 720, the second end of the third main body 730, and the second end of the fourth main body 740 are arranged in that order along a predetermined direction (left-right direction).

[0157] As shown in Figures 15 to 18, in this modified example, the plurality of pattern conductors 9 include a first primary side conductor 911, a second primary side conductor 912, a third primary side conductor 913, and further includes a fourth primary side conductor 914. The plurality of pattern conductors 9 also include a first secondary side conductor 921 and a second secondary side conductor 922.

[0158] As shown in Figures 15 to 17, the first end (left end) of the first primary conductor 911 functions as a connection terminal (first primary terminal) connected to an external member. The first end of the fourth main body 740 is connected to the second end (right end) of the first primary conductor 911.

[0159] The third primary conductor 913 is provided on the first surface 901 of the substrate body 90 in a C-shape when viewed from above. The first end (left end) of the third primary conductor 913 is connected to the first end of the third main body portion 730. The second end (right end) of the third primary conductor 913 is connected to the second end of the fourth main body portion 740.

[0160] The fourth primary conductor 914 is provided on the first surface 901 of the substrate body 90 in a C-shape that is smaller than the third primary conductor 913 when viewed from above. The first end (left end) of the fourth primary conductor 914 is connected to the first end of the second main body portion 720. The second end (right end) of the fourth primary conductor 914 is connected to the second end of the third main body portion 730.

[0161] The second end of the second main body 720 is connected to the first end (left end) of the second primary conductor 912. The second end (right end) of the second primary conductor 912 functions as a connection terminal (second primary terminal) that is connected to an external component.

[0162] In this modified example of the magnetic module 10, the second end of the fourth main body 740 and the first end of the third main body 730 are connected by a third primary conductor 913, and the second end of the third main body 730 and the first end of the second main body 720 are connected by a fourth primary conductor 914. As a result, in the magnetic module 10, a primary winding (3 turns) wound around the magnetic leg 601 is formed between the first primary terminal and the second primary terminal. In this embodiment, the primary winding includes the second main body 720, the third main body 730, the fourth main body 740, the third primary conductor 913, and the fourth primary conductor 914. In this modified example, the fourth primary conductor 914 functions as a connecting member 8 that connects the end of the second main body 720 and the end of the third main body 730. Furthermore, the third primary conductor 913 functions as a connecting member 8 that connects the end of the third main body 730 and the end of the fourth main body 740.

[0163] The magnetic module 10 of this modified example also functions as a transformer having a primary winding and a secondary winding, similar to the magnetic module 10 of the embodiment. In the magnetic module 10 (transformer) of this modified example, the turns ratio of the primary winding to the secondary winding is 3:1.

[0164] Thus, the turns ratio between the primary winding and the secondary winding is not limited to 2:1 as in the magnetic module 10 of the embodiment, but may be 3:1. Furthermore, in the magnetic module 10, the turns ratio between the primary winding and the secondary winding may be n:m, where n > m, n is an integer of 2 or more, and m is an integer of 1 or more. In other words, in the magnetic component 100, by adding another conductor section, such as the fourth conductor section described in this modified example, and connecting them appropriately with the pattern conductor 9, it is possible to increase the number of turns of the primary winding to 4 or more, or increase the number of turns of the secondary winding to 2 or more.

[0165] This modified magnetic module 10 can also be applied to the power conversion circuit A1 (modified TLVR circuit) to reduce the maximum applied voltage of the secondary circuit 2 in the power conversion circuit A1.

[0166] In this modified example of the magnetic component 100, as shown in Figures 15 to 17, the thickness of the first main body portion 710 is smaller than the thickness of the second main body portion 720, the third main body portion 730, and the fourth main body portion 740. Therefore, in the magnetic component 100, the resistance per unit length of the members constituting the primary winding (second main body portion 720, third main body portion 730, and fourth main body portion 740) is smaller than the resistance per unit length of the members constituting the secondary winding (first main body portion 710).

[0167] Furthermore, in the modified magnetic component 100, the thickness of the first main body portion 710 is less than 1 / 3 of the thickness of the second main body portion 720, less than 1 / 3 of the thickness of the third main body portion 730, and less than 1 / 3 of the thickness of the fourth main body portion 740. Therefore, the resistance per unit length of the second main body portion 720 is less than 1 / 3 of the resistance per unit length of the first main body portion 710, the resistance per unit length of the third main body portion 730 is less than 1 / 3 of the resistance per unit length of the first main body portion 710, and the resistance per unit length of the fourth main body portion 740 is less than 1 / 3 of the resistance per unit length of the first main body portion 710.

[0168] Furthermore, in the modified magnetic module 10, the turns ratio between the primary winding and the secondary winding is 3:1. Therefore, the series equivalent resistance of the primary winding is smaller than the series equivalent resistance of the secondary winding. This makes it possible to further reduce losses due to the primary winding.

[0169] (2.4) Modification 4 The magnetic module 10 of this modification will be described with reference to Figures 19 to 22. Note that the core block 60 (see Figure 1) is not shown in Figures 20 and 21.

[0170] The magnetic module 10 of this modified example differs from the magnetic module 10 of the embodiment mainly in that the magnetic component 100 further comprises an additional conductive portion. The configuration of the magnetic module 10 of this modified example that is substantially the same as that of the magnetic module 10 of the embodiment will be omitted from the explanation as appropriate.

[0171] As shown in Figures 19 to 22, the modified magnetic module 10 comprises a magnetic component 100 and a mounting substrate 900. The magnetic component 100 comprises a core block 60, a first conductor portion 71, a second conductor portion 72, a third conductor portion 73, and an additional conductor portion. The magnetic component 100 also comprises a fourth conductor portion 74 and a fifth conductor portion 75 as additional conductor portions. The mounting substrate 900 comprises a substrate body 90 and a plurality of pattern conductors 9.

[0172] The fourth conductor section 74 (additional conductor section) has a C-shaped fourth main body section 740 (additional main body section) (when viewed along the axial direction of the magnetic leg 601). The fourth main body section 740 is (slightly) larger than the second main body section 720 and (slightly) smaller than the third main body section 730.

[0173] The fourth main body portion 740 integrally includes a fourth central plate portion 741, a fourth left-side plate portion 742, and a fourth right-side plate portion 743.

[0174] As shown in Figure 19, the fourth main body 740 (additional main body) is positioned between the second main body 720 and the third main body 730, surrounding the central magnetic leg 601 of the core block 60. The fourth main body 740 is positioned concentrically with the first main body 710, the second main body 720, and the third main body 730. The front-to-back width of the fourth main body 740 is the same as the front-to-back width of the first main body 710, the second main body 720, and the third main body 730.

[0175] In the fourth conductor portion 74, the first end of the fourth main body portion 740 is fixed to the pattern conductor 9 of the mounting substrate 900 (the first secondary conductor 921 in the example shown in Figures 19 to 21) by, for example, soldering. The second end of the fourth main body portion 740 is also fixed to the pattern conductor 9 of the mounting substrate 900 (the second secondary conductor 922 in the example shown in Figures 19 to 21) by, for example, soldering.

[0176] The fifth conductor portion 75 is formed from a conductive material such as copper. The material of the fifth conductor portion 75 may be the same as the material of the first conductor portion 71, the second conductor portion 72, and the third conductor portion 73. The fifth conductor portion 75 is, for example, a plate-like shape with a uniform thickness in all parts except the corners.

[0177] The fifth conductor section 75 (additional conductor section) has a C-shaped fifth main body section 750 (additional main body section) (when viewed along the axial direction of the magnetic leg 601). The fifth main body section 750 is (slightly) larger than the third main body section 730.

[0178] The fifth main body portion 750 integrally includes a fifth central plate portion 751, a fifth left-side plate portion 752, and a fifth right-side plate portion 753. The fifth central plate portion 751 is a rectangular plate in top view, has thickness in the vertical direction, and extends in the left-right direction. The fifth left-side plate portion 752 is a rectangular plate in side view, has thickness in the left-right direction, and extends downward from the left end of the fifth central plate portion 751. The fifth right-side plate portion 753 is a rectangular plate in side view, has thickness in the left-right direction, and extends downward from the right end of the fifth central plate portion 751.

[0179] In the following, for convenience, the lower end of the fifth left plate portion 752 of the fifth main body portion 750 may be referred to as the "first end of the fifth main body portion 750." Also, the lower end of the fifth right plate portion 753 of the fifth main body portion 750 may be referred to as the "second end of the fifth main body portion 750."

[0180] As shown in Figure 19, the fifth main body 750 (additional main body) is positioned outside the third main body 730 and surrounds the central magnetic leg 601 of the core block 60. The fifth main body 750 is concentric with the first main body 710, the second main body 720, and the third main body 730. The front-to-back width of the fifth main body 750 is the same as the front-to-back width of the first main body 710, the second main body 720, and the third main body 730.

[0181] As shown in Figure 19, the fifth conductor portion 75 further comprises a fifth left projection 758 and a fifth right projection 759. The fifth left projection 758 is a rectangular plate in top view, has thickness in the vertical direction, and extends in the left-right direction. The fifth left projection 758 extends to the left from the lower end of the fifth left plate portion 752. The fifth right projection 759 is a rectangular plate in top view, has thickness in the vertical direction, and extends in the left-right direction. The fifth right projection 759 extends to the right from the lower end of the fifth right plate portion 753.

[0182] In the fifth conductor portion 75, the first end and the fifth left protrusion 758 of the fifth main body portion 750 are fixed to the pattern conductor 9 of the mounting substrate 900 (the first secondary conductor 921 in the example shown in Figures 19 to 21) by, for example, soldering. In addition, the second end and the fifth right protrusion 759 of the fifth main body portion 750 are fixed to the pattern conductor 9 of the mounting substrate 900 (the second secondary conductor 922 in the example shown in Figures 19 to 21) by, for example, soldering. The presence of the fifth left protrusion 758 and the fifth right protrusion 759 of the fifth conductor portion 75 facilitates mounting onto the mounting substrate 900.

[0183] In this modified example, the thickness of the first main body portion 710, the thickness of the fourth main body portion 740, and the thickness of the fifth main body portion 750 are the same. Therefore, the cross-sectional area of ​​the first main body portion 710, the cross-sectional area of ​​the fourth main body portion 740, and the cross-sectional area of ​​the fifth main body portion 750 are the same.

[0184] As shown in Figure 19, in this modified example of the magnetic component 100, the first end of the fifth main body 750, the first end of the third main body 730, the first end of the fourth main body 740, the first end of the second main body 720, the first end of the first main body 710, the second end of the first main body 710, the second end of the second main body 720, the second end of the fourth main body 740, the second end of the third main body 730, and the second end of the fifth main body 750 are arranged in that order along a predetermined direction (left-right direction).

[0185] As shown in Figure 21, in this modified example of the magnetic module 10, similar to the magnetic module 10 of the embodiment, the first end of the second main body 720 and the second end of the third main body 730 are connected by a third primary conductor 913 (connecting member 8). As a result, the magnetic module 10 has a primary winding (two turns) wound around the magnetic leg 601.

[0186] On the other hand, the first secondary conductor 921 further comprises a third portion and a fourth portion in addition to the first and second portions. As shown in Figure 19, each of the third and fourth portions penetrates the substrate body 90 vertically. Each of the third and fourth portions of the first secondary conductor 921 is a so-called "via," similar to the first portion.

[0187] The upper end of the third portion of the first secondary conductor 921 is connected to the first end of the fourth main body portion 740. The lower end of the third portion is connected to the front end of the second portion.

[0188] The upper end of the fourth portion of the first secondary conductor 921 is connected to the first end of the fifth main body portion 750. The lower end of the fourth portion is connected to the front end of the second portion.

[0189] As described above, in the modified magnetic module 10, the first secondary conductor 921 comprises a first portion connected to the first end of the first main body portion 710, a third portion connected to the first end of the fourth main body portion 740, a fourth portion connected to the first end of the fifth main body portion 750, and a second portion connecting the first, third, and fourth portions. As a result, in the modified magnetic module 10, the first end of the first main body portion 710 (the lower end of the first left side plate portion 712), the first end of the fourth main body portion 740 (the lower end of the fourth left side plate portion 742), and the first end of the fifth main body portion 750 (the lower end of the fifth left side plate portion 752) are connected to a common pattern conductor 9 (the first secondary conductor 921) and are at the same potential.

[0190] Furthermore, the second secondary conductor 922 comprises a third portion and a fourth portion in addition to the first and second portions. As shown in Figure 19, each of the third and fourth portions penetrates the substrate body 90 vertically. Each of the third and fourth portions of the second secondary conductor 922 is a so-called "via," similar to the first portion.

[0191] The upper end of the third portion of the second secondary conductor 922 is connected to the second end of the fourth main body portion 740. The lower end of the third portion is connected to the front end of the second portion.

[0192] The second end of the fifth main body 750 is connected to the upper end of the fourth portion of the second secondary conductor 922. The lower end of the fourth portion is connected to the front end of the second portion.

[0193] Thus, in the modified magnetic module 10, the second secondary conductor 922 comprises a first portion connected to the second end of the first main body 710, a third portion connected to the second end of the fourth main body 740, a fourth portion connected to the second end of the fifth main body 750, and a second portion connecting the first, third, and fourth portions. As a result, in the modified magnetic module 10, the second end of the first main body 710 (the lower end of the first right-side plate portion 713), the second end of the fourth main body 740 (the lower end of the fourth right-side plate portion 743), and the second end of the fifth main body 750 (the lower end of the fifth right-side plate portion 753) are connected to another common pattern conductor 9 (the second secondary conductor 922) and are at the same potential.

[0194] In short, in this modified magnetic module 10, the additional main body sections (the fourth main body section 740 and the fifth main body section 750) are electrically connected in parallel with the first main body section 710. Then, the first main body section 710, the fourth main body section 740, and the fifth main body section 750 each constitute a secondary winding (one turn in parallel with each other).

[0195] The magnetic module 10 of this modified example also functions as a transformer having a primary winding and a secondary winding, similar to the magnetic module 10 of the embodiment. In the magnetic module 10 (transformer) of this modified example, the turns ratio of the primary winding to the secondary winding is 2:1.

[0196] This modified magnetic module 10 can also be applied to the power conversion circuit A1 (modified TLVR circuit) to reduce the maximum applied voltage of the secondary circuit 2 in the power conversion circuit A1.

[0197] Furthermore, in this modified magnetic module 10, the components constituting the primary winding (second main body portion 720 and third main body portion 730) are sandwiched between the components constituting the secondary winding (first main body portion 710, fourth main body portion 740 and fifth main body portion 750). This makes it possible to improve the strength of the magnetic coupling between the primary winding and the secondary winding. In addition, it becomes possible to confine the radiated noise emitted from the primary winding within the magnetic component 100.

[0198] (2.5) Modification 5 The magnetic module 10 of this modification will be described with reference to Figures 23 to 24.

[0199] The magnetic module 10 of this modified example differs from the magnetic module 10 of Modified Example 2 (see Figures 10-12 and 14) mainly in that the magnetic component 100 further comprises an additional conductive portion. The configuration of the magnetic module 10 of this modified example that is substantially the same as that of the magnetic module 10 of Modified Example 2 will be omitted from explanation as appropriate. Note that the magnetic module 10 of this modified example has substantially the same structure as the magnetic module 10 of Modified Example 4, except for the different names of its parts.

[0200] In this modified example of the magnetic module 10, the magnetic component 100 includes a fourth conductor portion 74 and a fifth conductor portion 75 as additional conductor portions.

[0201] The fourth conductor section 74 (additional conductor section) has a C-shaped fourth main body section 740 (additional main body section) (when viewed along the axial direction of the magnetic leg 601). The fourth main body section 740 is smaller (by a factor) than the first main body section 710.

[0202] The fourth main body portion 740 integrally includes a fourth central plate portion 741, a fourth left-side plate portion 742, and a fourth right-side plate portion 743.

[0203] As shown in Figure 23, the fourth main body 740 (additional main body) is positioned inside the first main body 710, surrounding the central magnetic leg 601 of the core block 60.

[0204] As shown in Figure 23, the fourth conductor portion 74 further comprises a fourth left projection 748 and a fourth right projection 749. The fourth left projection 748 is a rectangular plate in top view, has thickness in the vertical direction, and extends to the right from the lower end of the fourth left plate portion 742. The fourth right projection 749 is a rectangular plate in top view, has thickness in the vertical direction, and extends to the left from the lower end of the fourth right plate portion 743.

[0205] The fifth conductor section 75 (additional conductor section) has a C-shaped fifth main body section 750 (additional main body section) (when viewed along the axial direction of the magnetic leg 601). The fifth main body section 750 is (slightly) larger than the third main body section 730.

[0206] The fifth main body portion 750 integrally includes a fifth central plate portion 751, a fifth left side plate portion 752, and a fifth right side plate portion 753.

[0207] As shown in Figure 23, the fifth main body 750 (additional main body) is positioned outside the third main body 730 and is arranged to surround the central magnetic leg 601 of the core block 60.

[0208] As shown in Figure 23, the fifth conductor portion 75 further has a fifth left-side projection 758 and a fifth right-side projection 759.

[0209] In this modified example, the thickness of the second main body portion 720, the thickness of the fourth main body portion 740, and the thickness of the fifth main body portion 750 are the same. Therefore, the cross-sectional area of ​​the second main body portion 720, the cross-sectional area of ​​the fourth main body portion 740, and the cross-sectional area of ​​the fifth main body portion 750 are the same.

[0210] As shown in Figure 23, in this modified example of the magnetic component 100, the first end of the fifth main body 750, the first end of the third main body 730, the first end of the second main body 720, the first end of the first main body 710, the first end of the fourth main body 740, the second end of the fourth main body 740, the second end of the first main body 710, the second end of the second main body 720, the second end of the third main body 730, and the second end of the fifth main body 750 are arranged in that order along a predetermined direction (left-right direction).

[0211] As shown in Figure 24, in this modified example of the magnetic module 10, similar to the magnetic module 10 of Modification 2, the first end of the first main body 710 and the second end of the third main body are connected by a third primary conductor 913 (connecting member 8). This results in the magnetic module 10 having a primary winding (two turns) wound around the magnetic leg 601.

[0212] Furthermore, in the modified magnetic module 10, as shown in Figure 23, the first end of the second main body 720 (the lower end of the second left plate portion 722), the first end of the fourth main body 740 (the lower end of the fourth left plate portion 742), and the first end of the fifth main body 750 (the lower end of the fifth left plate portion 752) are connected to a common pattern conductor 9 (the first secondary conductor 921) and are at the same potential. In addition, the second end of the second main body 720 (the lower end of the second right plate portion 723), the second end of the fourth main body 740 (the lower end of the fourth right plate portion 743), and the second end of the fifth main body 750 (the lower end of the fifth right plate portion 753) are connected to another common pattern conductor 9 (the second secondary conductor 922) and are at the same potential.

[0213] In short, in this modified magnetic module 10, the additional main body sections (the fourth main body section 740 and the fifth main body section 750) are electrically connected in parallel with the second main body section 720. The second main body section 720, the fourth main body section 740, and the fifth main body section 750 each constitute a secondary winding (one turn in parallel with each other).

[0214] The magnetic module 10 of this modified example also functions as a transformer having a primary winding and a secondary winding, similar to the magnetic module 10 of Modified Example 2. In the magnetic module 10 (transformer) of this modified example, the turns ratio of the primary winding to the secondary winding is 2:1.

[0215] This modified magnetic module 10 can also be applied to the power conversion circuit A1 (modified TLVR circuit) to reduce the maximum applied voltage of the secondary circuit 2 in the power conversion circuit A1.

[0216] Furthermore, in this modified magnetic module 10, similar to the magnetic module 10 equipped with the magnetic component 100 of Modified Modification 4, it is possible to improve the strength of the magnetic coupling between the primary winding and the secondary winding. In addition, it is possible to confine the radiated noise emitted from the primary winding within the magnetic component 100.

[0217] (2.6) Modification 6 The magnetic module 10 of this modification will be described with reference to Figures 25 to 26.

[0218] The magnetic module 10 of this modified example differs from the magnetic module 10 of Modified Example 2 (see Figures 10 to 14) mainly in that the magnetic component 100 does not have a second conductor portion 72. The configuration of the magnetic module 10 of this modified example that is substantially the same as that of the magnetic module 10 of Modified Example 2 will be omitted from explanation as appropriate. For convenience, in this modified example, the component corresponding to the "third conductor portion 73" in the magnetic module 10 of Modified Example 2 will be referred to as the "second conductor portion 72".

[0219] As shown in Figures 25 to 26, the magnetic module 10 of this modified example comprises a magnetic component 100 and a mounting substrate 900. The magnetic component 100 comprises a core block 60, a first conductor portion 71, and a second conductor portion 72. The mounting substrate 900 comprises a substrate body 90 and a plurality of pattern conductors 9. The core block 60 has a central magnetic leg 601, a left magnetic leg 602, and a right magnetic leg 603.

[0220] As shown in Figures 25 to 26, the first conductor portion 71 comprises a C-shaped first main body portion 710 (viewed along the axial direction of the magnetic leg 601), a first left-side projection portion 718, and a first right-side projection portion 719. The first main body portion 710 is arranged to surround the magnetic leg 601. The first main body portion 710 comprises a first central plate portion 711, a first left-side plate portion 712, and a first right-side plate portion 713.

[0221] The second conductor portion 72 comprises a C-shaped second body portion 720 that is larger than the first body portion 710 (when viewed along the axial direction of the magnetic leg 601), a second left projection portion 728, and a second right projection portion 729. The second body portion 720 is positioned outside the first body portion 710 and is arranged to surround the magnetic leg 601. The second body portion 720 comprises a second central plate portion 721, a second left plate portion 722, and a second right plate portion 723. In this modified example, the second left projection portion 728 is plate-shaped and extends to the left from the lower end of the second left plate portion 722. The second right projection portion 729 is plate-shaped and extends to the right from the lower end of the second right plate portion 723.

[0222] In this modified example, the thickness of the first main body portion 710 and the thickness of the second main body portion 720 are the same. Therefore, the cross-sectional area of ​​the first main body portion 710 and the cross-sectional area of ​​the second main body portion 720 are the same.

[0223] As shown in Figure 25, in this modified example of the magnetic component 100, the first end of the second main body 720, the first end of the first main body 710, the second end of the first main body 710, and the second end of the second main body 720 are arranged in that order along a predetermined direction (left-right direction).

[0224] As shown in Figures 25 to 26, the multiple pattern conductors 9 include a first primary conductor 911, a second primary conductor 912, and a third primary conductor 913, but do not include a first secondary conductor 921 and a second secondary conductor 922 (see Figures 11 and 13).

[0225] In this modified magnetic module 10, the first end of the second main body 720 is connected to the second end (right end) of the first primary conductor 911. The first end of the first main body 710 is connected to the first end (left end) of the third primary conductor 913, and the second end of the second main body 720 is connected to the second end (right end) of the third primary conductor 913. The second end of the first main body 710 is connected to the first end (left end) of the second primary conductor 912.

[0226] In this modified magnetic module 10, the first end of the first main body 710 and the second end of the second main body 720 are connected by a third primary conductor 913 (pattern conductor 9). This creates a winding (two turns) that is wound around the magnetic leg 601 between the first primary terminal and the second primary terminal. In this modified magnetic module 10, the winding functions as an inductor.

[0227] Thus, in this modified example of the magnetic module 10, it is possible to configure the windings of the magnetic module 10 (for example, an inductor) using the pattern conductor 9 provided on the mounting substrate 900.

[0228] (2.7) Other Modifications In one modification, the control circuit 20 may increase the output current by increasing the switching frequency of the switching elements Q11 to QN1 (while keeping the on time the same as before the increase in current demand) when the current demand of the load 40 increases rapidly.

[0229] In one modified example, the connecting member 8 is not limited to the pattern conductor 9 provided on the mounting substrate 900, but may be any suitable metal member or the like.

[0230] (3) Embodiments As can be seen from the above embodiments and modifications, the following embodiments are disclosed herein.

[0231] The magnetic component (100) of the first embodiment comprises a core block (60), a first conductor portion (71), a second conductor portion (72), and a third conductor portion (73). The core block (60) has magnetic legs (601). The first conductor portion (71) has a C-shaped first body portion (710). The first body portion (710) is arranged around the magnetic legs (601). The second conductor portion (72) has a C-shaped second body portion (720) that is larger than the first body portion (710). The second body portion (720) is arranged outside the first body portion (710) and surrounds the magnetic legs (601). The third conductor portion (73) has a C-shaped third body portion (730) that is larger than the second body portion (720). The third main body (730) is positioned outside the second main body (720) and surrounds the magnetic legs (601).

[0232] This embodiment has the advantage of being able to reduce the maximum applied voltage of the secondary circuit (2) in the power conversion circuit (A1).

[0233] The magnetic component (100) of the second embodiment is used in the first embodiment as a component constituting at least a part of an inductor in a multiphase step-down DC-DC converter.

[0234] According to this embodiment, the maximum applied voltage of the secondary circuit (2) in a multiphase step-down DC-DC converter can be reduced.

[0235] In the magnetic component (100) of the third embodiment, in the first or second embodiment, one of the first conductor portion (71), second conductor portion (72), and third conductor portion (73) further has a projection that protrudes from the end of the corresponding main body portion of the first main body portion (710), second main body portion (720), and third main body portion (730). Another conductor portion of the first conductor portion (71), second conductor portion (72), and third conductor portion (73) further has another projection that protrudes from the end of the corresponding main body portion of the first main body portion (710), second main body portion (720), and third main body portion (730). The projection direction of the one projection of the one conductor portion is perpendicular to the projection direction of the other projection of the other conductor portion.

[0236] According to this embodiment, the ease of mounting the magnetic component (100) is improved.

[0237] In the magnetic component (100) of the fourth embodiment, in any one of the first to third embodiments, the resistance per unit length of the first body portion (710) is less than half the resistance per unit length of the second body portion (720). The resistance per unit length of the third body portion (730) is less than half the resistance per unit length of the second body portion (720).

[0238] According to this embodiment, when the primary winding is formed by the first main body (710) and the third main body (730), and the secondary winding is formed by the second main body (720), it becomes easier to make the series equivalent resistance of the primary winding smaller than the series equivalent resistance of the secondary winding.

[0239] In the magnetic component (100) of the fifth embodiment, in any one of the first to third embodiments, the resistance per unit length of the second main body (720) is less than half the resistance per unit length of the first main body (710). The resistance per unit length of the third main body (730) is less than half the resistance per unit length of the first main body (710).

[0240] According to this embodiment, when the primary winding is formed by the second main body (720) and the third main body (730), and the secondary winding is formed by the first main body (710), it becomes easier to make the series equivalent resistance of the primary winding smaller than the series equivalent resistance of the secondary winding.

[0241] The sixth embodiment of the magnetic module (10) functions as a transformer. The magnetic module (10) comprises a magnetic component (100) of any one of the first to fourth embodiments and a connecting member (8). The connecting member (8) connects the end of the first body (710) and the end of the third body (730). The primary winding of the transformer includes the first body (710), the connecting member (8), and the third body (730). The secondary winding of the transformer includes the second body (720). The turns ratio of the primary winding to the secondary winding is n:m, where n > m, n is an integer of 2 or more, and m is an integer of 1 or more.

[0242] According to this embodiment, the maximum applied voltage of the secondary circuit (2) in the power conversion circuit (A1) can be reduced.

[0243] In the seventh embodiment of the magnetic module (10), in the sixth embodiment, the magnetic component (100) further comprises an additional conductor portion. The additional conductor portion includes at least one of a fourth conductor portion (74) and a fifth conductor portion (75). The fourth conductor portion (74) has a C-shaped fourth body portion (740) that is smaller than the first body portion (710). The fourth body portion (740) is positioned inside the first body portion (710) and surrounds the magnetic leg (601). The fifth conductor portion (75) has a C-shaped fifth body portion (750) that is larger than the third body portion (730). The fifth body portion (750) is positioned outside the third body portion (730) and surrounds the magnetic leg (601). The fourth body portion (740) is electrically connected in parallel with the second body portion (720). The fifth main body (750) is electrically connected in parallel with the second main body (720).

[0244] According to this embodiment, it is possible to improve the strength of the magnetic coupling between the primary winding and the secondary winding. In addition, it becomes easier to confine the radiated noise emitted from the primary winding within the magnetic component (100).

[0245] The magnetic module (10) of the eighth embodiment functions as a transformer. The magnetic module (10) comprises a magnetic component (100) of any one of the first to third and fifth embodiments, and a connecting member (8). The connecting member (8) connects the end of the second body (720) to the end of the third body (730). The primary winding of the transformer includes the second body (720), the connecting member (8), and the third body (730). The secondary winding of the transformer includes the first body (710). The turns ratio of the primary winding to the secondary winding is n:m, where n > m, n is an integer of 2 or more, and m is an integer of 1 or more.

[0246] According to this embodiment, the maximum applied voltage of the secondary circuit (2) in the power conversion circuit (A1) can be reduced.

[0247] In the magnetic module (10) of the ninth embodiment, the magnetic component (100) further comprises an additional conductor portion. The additional conductor portion includes at least one of a fourth conductor portion (74) and a fifth conductor portion (75). The fourth conductor portion (74) has a C-shaped fourth body portion (740) that is larger than the second body portion (720) and smaller than the third body portion (730). The fourth body portion (740) is positioned between the second body portion (720) and the third body portion (730) and surrounds the magnetic leg (601). The fifth conductor portion (75) has a C-shaped fifth body portion (750) that is larger than the third body portion (730). The fifth body portion (750) is positioned outside the third body portion (730) and surrounds the magnetic leg (601). The fourth main body (740) is electrically connected in parallel with the first main body (710). The fifth main body (750) is electrically connected in parallel with the first main body (710).

[0248] According to this embodiment, it is possible to improve the strength of the magnetic coupling between the primary winding and the secondary winding. In addition, it becomes easier to confine the radiated noise emitted from the primary winding within the magnetic component (100).

[0249] In the magnetic module (10) of the tenth embodiment, in any one of the sixth to ninth embodiments, the series equivalent resistance of the primary winding is smaller than the series equivalent resistance of the secondary winding.

[0250] According to this embodiment, it is possible to reduce losses due to the primary winding.

[0251] The magnetic module (10) of the eleventh embodiment includes a mounting substrate (900) on which magnetic components (100) are mounted, in any one of the sixth to tenth embodiments. The connecting member (8) includes a pattern conductor (9) provided on the mounting substrate (900).

[0252] According to this embodiment, it is possible to construct the windings of the transformer using the pattern conductor (9) provided on the mounting board (900).

[0253] A twelfth embodiment of the magnetic module (10) comprises a magnetic component (100) and a mounting substrate (900). The magnetic component (100) comprises a core block (60), a first conductor portion (71), and a second conductor portion (72). The core block (60) has magnetic legs (601). The first conductor portion (71) has a C-shaped first body portion (710). The first body portion (710) is arranged to surround the magnetic legs (601). The second conductor portion (72) has a C-shaped second body portion (720) that is larger than the first body portion (710). The second body portion (720) is arranged to surround the magnetic legs (601) at an external position to the first body portion (710). The first and second ends of the first main body (710) and the first and second ends of the second main body (720) are arranged along a predetermined direction in the order of the first end of the second main body (720), the first end of the first main body (710), the second end of the first main body (710), and the second end of the second main body (720). The first end of the first main body (710) and the second end of the second main body (720) are connected by a pattern conductor (9) of the mounting substrate (900).

[0254] According to this embodiment, it is possible to use the pattern conductor (9) provided on the mounting substrate (900) to construct the windings of the magnetic module (10) (for example, an inductor).

[0255] 10 Magnetic module 100 Magnetic components 60 Core block 601 Magnetic legs 71 First conductor section 710 First main body section 72 Second conductor section 720 Second main body section 73 Third conductor section 730 Third main body section 74 Fourth conductor section 740 Fourth main body section 75 Fifth conductor section 750 Fifth main body section 8 Connecting member 9 Pattern conductor 900 Mounting board

Claims

1. A magnetic component comprising: a core block having magnetic legs; a first conductor portion having a C-shaped first body portion, the first body portion being arranged to surround the magnetic legs; a second conductor portion having a C-shaped second body portion larger than the first body portion, the second body portion being arranged to surround the magnetic legs at a position outside the first body portion; and a third conductor portion having a C-shaped third body portion larger than the second body portion, the third body portion being arranged to surround the magnetic legs at a position outside the second body portion.

2. The magnetic component according to claim 1, used as a component constituting at least a part of an inductor in a multiphase step-down DC-DC converter.

3. The magnetic component according to claim 1 or 2, wherein one of the first conductor portion, the second conductor portion, and the third conductor portion further has a projection that protrudes from the end of the corresponding main body portion among the first main body portion, the second main body portion, and the third main body portion, and the other conductor portion among the first conductor portion, the second conductor portion, and the third conductor portion further has another projection that protrudes from the end of the corresponding main body portion among the first main body portion, the second main body portion, and the third main body portion, and the projection direction of the one projection of the one conductor portion is perpendicular to the projection direction of the other projection of the other conductor portion.

4. The magnetic component according to any one of claims 1 to 3, wherein the resistance per unit length of the first main body is less than half the resistance per unit length of the second main body, and the resistance per unit length of the third main body is less than half the resistance per unit length of the second main body.

5. The magnetic component according to any one of claims 1 to 3, wherein the resistance per unit length of the second main body is less than half the resistance per unit length of the first main body, and the resistance per unit length of the third main body is less than half the resistance per unit length of the first main body.

6. A magnetic module having the function of a transformer, comprising: a magnetic component according to any one of claims 1 to 4; and a connecting member connecting the end of the first main body and the end of the third main body, wherein the primary winding of the transformer includes the first main body, the connecting member, and the third main body; the secondary winding of the transformer includes the second main body; and the turns ratio of the primary winding to the secondary winding is n:m, where n>m, n is an integer of 2 or more, and m is an integer of 1 or more.

7. The magnetic module according to claim 6, wherein the magnetic component further comprises an additional conductor portion, the additional conductor portion having a C-shaped fourth body portion smaller than the first body portion, the fourth conductor portion being positioned inside the first body portion and surrounding the magnetic legs; and a C-shaped fifth body portion larger than the third body portion, the fifth conductor portion being positioned outside the third body portion and surrounding the magnetic legs, the fourth body portion being electrically connected in parallel with the second body portion, and the fifth body portion being electrically connected in parallel with the second body portion.

8. A magnetic module having the function of a transformer, comprising: a magnetic component according to any one of claims 1 to 3, 5; and a connecting member connecting the end of the second main body and the end of the third main body, wherein the primary winding of the transformer includes the second main body, the connecting member, and the third main body; the secondary winding of the transformer includes the first main body; and the turns ratio of the primary winding to the secondary winding is n:m, where n>m, n is an integer of 2 or more, and m is an integer of 1 or more.

9. The magnetic module according to claim 8, wherein the magnetic component further comprises an additional conductor portion, the additional conductor portion having a C-shaped fourth body portion that is larger than the second body portion and smaller than the third body portion, and the fourth conductor portion being positioned to surround the magnetic legs at a location between the second body portion and the third body portion; and a fifth conductor portion having a C-shaped fifth body portion that is larger than the third body portion, and the fifth conductor portion being positioned to surround the magnetic legs at a location outside the third body portion, wherein the fourth body portion is electrically connected in parallel with the first body portion, and the fifth body portion is electrically connected in parallel with the first body portion.

10. The magnetic module according to any one of claims 6 to 9, wherein the series equivalent resistance of the primary winding is smaller than the series equivalent resistance of the secondary winding.

11. The magnetic module according to any one of claims 6 to 10, comprising a mounting substrate on which the magnetic components are mounted, wherein the connecting member includes a pattern conductor provided on the mounting substrate.

12. A magnetic module comprising a magnetic component and a mounting substrate, wherein the magnetic component comprises: a core block having magnetic legs; a first conductor portion having a C-shaped first body portion, the first body portion being arranged to surround the magnetic legs; and a second conductor portion having a C-shaped second body portion larger than the first body portion, the second body portion being arranged to surround the magnetic legs outside the first body portion, the first and second ends of the first body portion and the first and second ends of the second body portion being arranged in the order of the first end of the second body portion, the first end of the first body portion, the second end of the first body portion, and the second end of the second body portion being connected by a pattern conductor of the mounting substrate.

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