US-20260128205-A1 - MAGNETIC COMPONENT

US20260128205A1US 20260128205 A1US20260128205 A1US 20260128205A1US-20260128205-A1

Abstract

A magnetic component includes a primary winding, a secondary winding and at least one tertiary winding stacked with each other to form a symmetrical inductance structure or an asymmetrical inductance structure. Through the relationship of the distances between the primary winding, the secondary winding and the at least one tertiary winding of the symmetrical inductance structure, the leakage inductance can be balanced, the tolerance can be stabilized, the reverse current can be eliminated, the AC loss of the tertiary winding can be reduced, and/or the total loss can be reduced. Through the relationship of the distances between the primary winding, the secondary winding and the at least one tertiary winding of the asymmetrical inductance structure, the leakage inductance can be adjusted more flexibly, the tolerance can be stabilized, and the couple energy can be reduced.

Inventors

Yu-Cheng Lai
Po-Chun Sun
Yi-Min Hsieh
Shao-Wei Chang
Chun-Hung Lee
Chun-Ying Liao

Assignees

CYNTEC CO., LTD.

Dates

Publication Date: 20260507
Application Date: 20251031

Claims (20)

1 . A magnetic component comprising: a core; a primary winding disposed in the core; a secondary winding disposed in the core; a magnetic member disposed between the primary winding and the secondary winding; a first tertiary winding disposed outside the primary winding; and a second tertiary winding disposed outside the secondary winding; wherein the secondary winding is apart from the second tertiary winding by a first distance d1, the secondary winding is apart from the first tertiary winding by a second distance d2, the primary winding is apart from the first tertiary winding by a third distance d3, and the primary winding is apart from the second tertiary winding by a fourth distance d4; wherein the first distance d1, the second distance d2, the third distance d3 and the fourth distance d4 satisfy a relationship as follows: 0.8 < d ⁢ 1 + d ⁢ 2 d ⁢ 3 + d ⁢ 4 < 1 . 2 .
2 . The magnetic component of claim 1 , wherein the core has an inner leg; wherein the primary winding, the secondary winding, the first tertiary winding and the second tertiary winding are disposed at different positions along a length direction of the inner leg without overlapping.
3 . The magnetic component of claim 1 , wherein a number of turns of each of the first tertiary winding and the second tertiary winding is less than a number of turns of each of the primary winding and the secondary winding.
4 . The magnetic component of claim 3 , wherein the number of turns of each of the first tertiary winding and the second tertiary winding is less than ½ of the number of turns of each of the primary winding and the secondary winding.
5 . The magnetic component of claim 1 , wherein at least one of the primary winding, the secondary winding, the first tertiary winding and the second tertiary winding is wound by a multi-stranded insulated wire.
6 . The magnetic component of claim 5 , wherein the multi-stranded insulated wire comprises a plurality of stranded wire layers, each of the plurality of stranded wire layers is covered by a first insulation layer, a first stranded wire layer of the plurality of stranded wire layers comprises a plurality of strands, and each of the plurality of strands is covered by a second insulation layer.
7 . The magnetic component of claim 1 , wherein any of the primary winding, the secondary winding, the first tertiary winding and the second tertiary winding is a Litz wire or a copper sheet.
8 . The magnetic component of claim 1 , wherein the core comprises an I-core, a first U-core and a second U-core, the first U-core and the second U-core are arranged side by side to provide an inner leg, a heat dissipation material is filled in a gap of the inner leg, and the I-core is disposed on the first U-core and the second U-core.
9 . The magnetic component of claim 1 , wherein the core has an inner leg and at least two outer legs; wherein the primary winding, the secondary winding, the first tertiary winding and the second tertiary winding are wound around the inner leg.
10 . The magnetic component of claim 1 , further comprising: a casing, the core being disposed in the casing; a thermal conductive filler filled into the casing, the thermal conductive filler covering at least a part of an inner leg of the core and at least a part of the primary winding, the secondary winding, the first tertiary winding and the second tertiary winding; and an electric conductive member disposed above an opening of the core and the casing, the electric conductive member comprising two conductive metals covered by an insulation material; wherein the first tertiary winding and the second tertiary winding are connected to the electric conductive member, and a part of the electric conductive member is bent into the thermal conductive filler.
11 . The magnetic component of claim 10 , wherein the two conductive metals are oppositely disposed at two sides of the core and are not in contact with the core and the casing; wherein two bending structures of the two conductive metals located outside the core extend to the thermal conductive filler, and the two bending structures are not in contact with the core and do not extend to a bottom of the casing.
12 . The magnetic component of claim 1 , further comprising: a casing, the core being disposed in the casing; a thermal conductive filler filled into the casing, the thermal conductive filler covering at least a part of an inner leg of the core and at least a part of the primary winding, the secondary winding, the first tertiary winding and the second tertiary winding; and an electric conductive member disposed beside the core, the electric conductive member comprising two conductive metals covered by an insulation material; wherein the first tertiary winding and the second tertiary winding are connected to the electric conductive member, and a part of the electric conductive member is covered by the thermal conductive filler.
13 . The magnetic component of claim 12 , wherein the two conductive metals are disposed side by side at a side of the core and are not in contact with the core; wherein two bending structures of the two conductive metals located outside the core extend to the thermal conductive filler and are not in contact with the core; wherein the first tertiary winding and the second tertiary winding extend to a bottom of the casing and are connected to a plurality of engaging holes of the two conductive metals, such that the first tertiary winding and the second tertiary winding are connected in parallel; wherein two horizontal structures of the two conductive metals extend out of the insulation material to form two electrodes for the first tertiary winding and the second tertiary winding; wherein an insulation member is disposed at the bottom of the casing and the plurality of engaging holes of the two conductive metals are disposed in an accommodating space of the insulation member.
14 . A magnetic component comprising: a core; a primary winding disposed in the core; a secondary winding disposed in the core; and a tertiary winding disposed between the primary winding and the secondary winding; wherein the secondary winding is apart from the tertiary winding by a first distance d1, and the primary winding is apart from the tertiary winding by a second distance d2; wherein the first distance d1 and the second distance d2 satisfy a relationship as follows: 0.8 < d ⁢ 2 d ⁢ 1 < 1 . 2 .
15 . The magnetic component of claim 14 , wherein the core has an inner leg; wherein the primary winding, the secondary winding and the tertiary winding are disposed at different positions along a length direction of the inner leg without overlapping.
16 . The magnetic component of claim 14 , wherein a number of turns of the tertiary winding is less than a number of turns of each of the primary winding and the secondary winding.
17 . The magnetic component of claim 16 , wherein the number of turns of the tertiary winding is less than ½ of the number of turns of each of the primary winding and the secondary winding.
18 . The magnetic component of claim 14 , wherein at least one of the primary winding, the secondary winding and the tertiary winding is wound by a multi-stranded insulated wire.
19 . The magnetic component of claim 18 , wherein the multi-stranded insulated wire comprises a plurality of stranded wire layers, each of the plurality of stranded wire layers is covered by a first insulation layer, a first stranded wire layer of the plurality of stranded wire layers comprises a plurality of strands, and each of the plurality of strands is covered by a second insulation layer.
20 . The magnetic component of claim 14 , wherein any of the primary winding, the secondary winding and the tertiary winding is a Litz wire or a copper sheet.

Description

CROSS REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Application No. 63/716,703, filed on Nov. 5, 2024. The content of the application is incorporated herein by reference. BACKGROUND OF THE INVENTION 1. Field of the Invention The invention relates to a magnetic component and, more particularly, to a magnetic component capable of adjusting leakage inductance. 2. Description of the Related Art A transformer is an important magnetic component used for increasing or decreasing voltage. In most of circuits, there is always a transformer installed therein. In a multi-port charger, the electromagnetic coupling and voltage stability between the ports of the multi-port charger are closely related to leakage inductance of the transformer. Leakage inductance determines the quality of energy coupling and the degree of interference between the ports of the multi-port charger. Thus, how to adjust leakage inductance of the transformer for the multi-port charger has become a significant design issue. SUMMARY OF THE INVENTION The invention provides a magnetic component capable of adjusting leakage inductance, so as to solve the aforesaid problems. According to an embodiment of the invention, a magnetic component comprises a core, a primary winding, a secondary winding, a magnetic member, a first tertiary winding and a second tertiary winding. The primary winding is disposed in the core. The secondary winding is disposed in the core. The magnetic member is disposed between the primary winding and the secondary winding. The first tertiary winding is disposed outside the primary winding. The second tertiary winding is disposed outside the secondary winding. The secondary winding is apart from the second tertiary winding by a first distance d1, the secondary winding is apart from the first tertiary winding by a second distance d2, the primary winding is apart from the first tertiary winding by a third distance d3, and the primary winding is apart from the second tertiary winding by a fourth distance d4. The first distance d1, the second distance d2, the third distance d3 and the fourth distance d4 satisfy a relationship as follows: 0.8<d⁢1+d⁢2d⁢3+d⁢4<1.2. In an embodiment, the core has an inner leg. The primary winding, the secondary winding, the first tertiary winding and the second tertiary winding are disposed at different positions along a length direction of the inner leg without overlapping. In an embodiment, a number of turns of each of the first tertiary winding and the second tertiary winding is less than a number of turns of each of the primary winding and the secondary winding. In an embodiment, the number of turns of each of the first tertiary winding and the second tertiary winding is less than ½ of the number of turns of each of the primary winding and the secondary winding. In an embodiment, at least one of the primary winding, the secondary winding, the first tertiary winding and the second tertiary winding is wound by a multi-stranded insulated wire. In an embodiment, the multi-stranded insulated wire comprises a plurality of stranded wire layers, each of the plurality of stranded wire layers is covered by a first insulation layer, a first stranded wire layer of the plurality of stranded wire layers comprises a plurality of strands, and each of the plurality of strands is covered by a second insulation layer. In an embodiment, any of the primary winding, the secondary winding, the first tertiary winding and the second tertiary winding is a Litz wire or a copper sheet. In an embodiment, the core comprises an I-core, a first U-core and a second U-core, the first U-core and the second U-core are arranged side by side to provide an inner leg, a heat dissipation material is filled in a gap of the inner leg, and the I-core is disposed on the first U-core and the second U-core. In an embodiment, the core has an inner leg and at least two outer legs; wherein the primary winding, the secondary winding, the first tertiary winding and the second tertiary winding are wound around the inner leg. In an embodiment, the magnetic component further comprises a casing, a thermal conductive filler and an electric conductive member. The core is disposed in the casing. The thermal conductive filler is filled into the casing. The thermal conductive filler covers at least a part of an inner leg of the core and at least a part of the primary winding, the secondary winding, the first tertiary winding and the second tertiary winding. The electric conductive member is disposed above an opening of the core and the casing. The electric conductive member comprises two conductive metals covered by an insulation material. The first tertiary winding and the second tertiary winding are connected to the electric conductive member, and a part of the electric conductive member is bent into the thermal conductive filler. In an embodiment, the two conductive metals are oppositely disposed at two sides of the