CN-122025386-A - Power conversion module, magnetic component thereof and manufacturing method

Abstract

The magnetic component comprises a magnetic core component, first magnetic columns, second magnetic columns, third magnetic columns, second winding channels, first windings, second windings, third windings, the first windings, the second windings, the first windings and the second windings, wherein the first magnetic columns are arranged oppositely to the third magnetic columns, the second magnetic columns are arranged oppositely to the fourth magnetic columns, the first winding channels comprise a first portion formed between the first magnetic columns and the second portion formed between the second magnetic columns and the third magnetic columns, the first winding channels comprise a first portion formed between the first magnetic columns and the fourth magnetic columns, the second winding channels comprise a second portion formed between the third magnetic columns and the fourth magnetic columns, the first windings are partially arranged in the first portions of the first winding channels and partially arranged in the second portions of the second winding channels, and the second windings are partially arranged in the first portions of the second winding channels and partially arranged in the second portions of the first winding channels. The scheme also relates to a power conversion module.

Inventors

• XIONG YAHONG
• CUI JUNGUO
• QIAN LITAO
• Su qinghua

Assignees

• 台达电子工业股份有限公司

Dates

Publication Date

20260512

Application Date

20211111

Priority Date

20210309

Claims (20)

1. 1. A magnetic assembly, comprising: A magnetic core assembly, comprising: a first magnetic column; A second magnetic pillar; the third magnetic column is arranged opposite to the first magnetic column; The fourth magnetic column is arranged opposite to the second magnetic column, and the first magnetic column and the third magnetic column are positioned between the second magnetic column and the fourth magnetic column; A first winding channel including a first part formed between the first and second magnetic columns and a second part formed between the second and third magnetic columns, and A second winding channel including a first portion formed between the first and fourth magnetic columns and a second portion formed between the third and fourth magnetic columns; a first winding disposed in the first winding path, and The second winding part is arranged in the second winding channel, wherein the magnetic resistance of the second magnetic pillar and the magnetic resistance of the fourth magnetic pillar are respectively larger than the magnetic resistance of the first magnetic pillar and the magnetic resistance of the third magnetic pillar; The whole structure of the magnetic core assembly, the first winding and the second winding are in mirror symmetry with reference to an extension line passing through the first magnetic column and the third magnetic column.
2. 2. The magnetic assembly of claim 1, wherein a length of an air gap of the second magnetic pillar and a length of an air gap of the fourth magnetic pillar are greater than a length of an air gap of the first magnetic pillar and a length of an air gap of the third magnetic pillar, respectively, and a direction of a direct current flowing through the first winding is the same as a direction of a direct current flowing through the second winding.
3. 3. The magnetic assembly of claim 1, wherein the output of the first winding and the output of the second winding are shorted.
4. 4. The magnetic assembly of claim 1, wherein the second magnetic pillar and the fourth magnetic pillar each comprise an air gap.
5. 5. The magnetic assembly of claim 1, wherein the first magnetic pillar is free of an air gap with the third magnetic pillar.
6. 6. The magnetic assembly of claim 1, wherein the magnetic core assembly further comprises a first magnetic cover and a second magnetic cover disposed opposite to each other, the first magnetic pillar, the second magnetic pillar, the third magnetic pillar, and the fourth magnetic pillar being disposed between the first magnetic cover and the second magnetic cover, respectively.
7. 7. The magnetic assembly of claim 6, wherein each of the first, second, third, and fourth magnetic columns includes an air gap, wherein the air gap of each of the first, second, third, and fourth magnetic columns is located in an upper region of the corresponding magnetic column adjacent to the first magnetic cover, the air gap of each of the magnetic columns is located in a lower region of the corresponding magnetic column adjacent to the second magnetic cover, or the air gap of each of the magnetic columns is located in a middle region of the corresponding magnetic column.
8. 8. The magnetic assembly of claim 6, wherein the magnetic assembly further comprises: A main body layer including a first surface and a second surface opposite to each other, wherein the magnetic core assembly is embedded in the main body layer, the first magnetic cover of the magnetic core assembly is adjacent to the first surface, the second magnetic cover of the magnetic core assembly is adjacent to the second surface, and The electric conductor is embedded between the first surface and the second surface of the main body layer, at least partially exposes the first surface or the second surface, and comprises the first winding and the second winding.
9. 9. The magnetic assembly of claim 8, wherein the first surface of the body layer is higher than an upper surface of the first magnetic cover of the magnetic core assembly and the second surface of the body layer is lower than a lower surface of the second magnetic cover of the magnetic core assembly.
10. 10. The magnetic assembly of claim 1, wherein the first and third magnetic posts are formed of a different material than the remainder of the magnetic core assembly.
11. 11. The magnetic assembly of claim 10, wherein the first and third magnetic posts are comprised of ferrite material and the remainder of the magnetic core assembly is comprised of an air-gap distributed iron powder material.
12. 12. The magnetic assembly of claim 1, wherein a direct current through the first winding flows in from the input of the first winding and out from the output of the first winding, and a direct current through the second winding flows in from the input of the second winding and out from the output of the second winding.
13. 13. The magnetic assembly of claim 1, wherein a first voltage across the input and output of the first winding is 180 ° out of phase with a second voltage across the input and output of the first winding.
14. 14. The magnetic assembly of claim 1, wherein a sum of cross-sectional areas of the second magnetic pillar and the fourth magnetic pillar is greater than a sum of cross-sectional areas of the first magnetic pillar and the third magnetic pillar.
15. 15. The magnetic assembly of claim 1, wherein the second magnetic pillar has a cross-sectional area approximately equal to the fourth magnetic pillar with an error of within ± 20%.
16. 16. The magnetic assembly of claim 1, wherein the cross-sectional area of the first magnetic pillar is approximately equal to the cross-sectional area of the third magnetic pillar with an error of within ±20%.
17. 17. The magnetic assembly of claim 1, wherein the two windings are formed of two copper strips embedded in the magnetic core assembly, or the two windings are formed of copper strips embedded in a printed circuit board, or the copper strips forming the first winding and the second winding are isolated by an insulating medium of the printed circuit board at the crossing position of the first winding and the second winding, or the copper strips on the insulating medium of the printed circuit board and the copper strips under the insulating medium are shorted by side plating at the non-crossing position of the first winding and the second winding to form the input end and the output end of the first winding and the second winding, respectively.
18. 18. A power conversion module, comprising: a magnetic assembly according to claim 1, and One of the two power devices is electrically connected with the input end of the first winding, and the other power device is electrically connected with the input end of the second winding.
19. 19. The power conversion module of claim 18, wherein the magnetic core assembly further comprises a first magnetic cover and a second magnetic cover disposed opposite to each other, the first magnetic pillar, the second magnetic pillar, the third magnetic pillar, and the fourth magnetic pillar being respectively located between the first magnetic cover and the second magnetic cover.
20. 20. The power conversion module of claim 19, further comprising a printed circuit board partially between the first and second magnetic covers, and the printed circuit board comprises a first surface and a second surface, the first surface being opposite to the second surface and adjacent to the first magnetic cover, the second surface being adjacent to the second magnetic cover, and the two power devices being disposed on the first surface.

Description

Power conversion module, magnetic component thereof and manufacturing method The application is a divisional application of the application application of which the name is power conversion module and magnetic component thereof, the application number is 202111333821.3 and the application date is 2021, 11 and 11 of the applicant's company of electronic industry Co-Ltd. Technical Field The present disclosure relates to the field of power electronics, and more particularly, to a power conversion module and a magnetic assembly thereof. Background Modern power electronics are widely used in the power, electronics, motor and energy industries as an important component of power conversion. Ensuring long-term stable operation of power electronics and improving power conversion efficiency of power electronics have been important pursuits for those skilled in the art. With the rapid development of technologies such as mobile communication and cloud computing, high-power DC/DC power conversion modules have been widely used in communication products. As products become higher in power and tend to be smaller, new challenges are presented to power conversion modules in terms of conversion efficiency and volume. Therefore, how to design a reasonable structure and layout for the power conversion module, improve the conversion efficiency and reduce the volume of the power conversion module is one of the hot problems in the technical field. In order to achieve the advantages of reducing the volume of the output filter and increasing the output power, the conventional power conversion module generally uses a parallel circuit architecture, that is, includes at least two parallel power conversion circuits, for example, includes two Buck (Buck) power conversion circuits connected in parallel, and in order to optimize the ripple characteristics of the output currents of the parallel circuits, the inductors of the two power conversion circuits in the power conversion module are formed into a magnetically integrated coupling relationship by using a magnetic integration technology, that is, the two inductors of the two power conversion circuits form a two-phase coupled inductor. The magnetic assembly used in the magnetic integration technology of the conventional power conversion module comprises two windings and a magnetic core, so that two-phase coupled inductors are formed through the matching of the two windings and the magnetic core. However, due to the relation between the winding positions and the winding modes of the two windings of the magnetic component of the traditional power conversion module, the output end of the inductor formed by one winding is relatively close to the output terminal of the power conversion module, while the output end of the inductor formed by the other winding is relatively far away from the output terminal of the power conversion module, namely, the distance between the output end of the inductor coupled by two phases and the output terminal of the power conversion module is inconsistent, so that the equivalent direct current series resistance of the inductor coupled by two phases is asymmetric, the current of the inductor coupled by two phases is uneven, the direct current flux of the side column of the magnetic core is large, and the flux saturation of the side column of the magnetic core is easily caused, which is unfavorable for the performance improvement of the power conversion module. Therefore, how to develop a power conversion module and a magnetic component thereof to solve the problems of the prior art, so as to achieve the purpose of optimizing the power conversion module, is an extremely needed object in the art. Disclosure of Invention The purpose of the present disclosure is to provide a power conversion module and a magnetic component thereof, so as to solve the problem that the distance between the output end of the two-phase coupled inductor and the output terminal of the power conversion module of the conventional power conversion module is inconsistent, so that the equivalent dc series resistance of the two-phase coupled inductor is asymmetric, and the current of the two-phase coupled inductor is uneven, thereby causing the defect that the magnetic flux of the side column of the E-type magnetic core is easy to saturate, and being unfavorable for the performance improvement of the power conversion module. In order to achieve the above-mentioned object, the present disclosure provides a magnetic assembly comprising a magnetic core assembly, a first magnetic pillar, a second magnetic pillar, a third magnetic pillar disposed opposite to the first magnetic pillar, and a fourth magnetic pillar disposed opposite to the second magnetic pillar, wherein the first magnetic pillar and the third magnetic pillar are disposed between the second magnetic pillar and the fourth magnetic pillar, a first winding channel comprises a first portion formed between the first magnetic pillar and the s