HK1190499A - Integrated magnetics for soft switching converter - Google Patents

Description

Integrated magnetic element for soft switching converter

Technical Field

The present invention relates to an integrated magnetic component for a switched mode power converter, comprising two magnetic cores forming a figure-8 core structure and at least two first electrical winding wires, wherein the first magnetic cores are E-cores. Furthermore, the invention relates to an integrated magnetic component, a method for manufacturing an integrated magnetic component, a soft-switching converter and an LLC resonant converter according to the independent claims.

Background

Switched mode power supplies, which are key components of telecommunications and commercial systems, are often specified for their size and electrical performance as well as reliability and cost. As the demand for key characteristics of power converters (e.g., power density and efficiency) increases, the demand for these key characteristics increases particularly for inductive components. One way to increase power density and efficiency in such systems is to integrate inductive components. For example, a transformer and an inductor may be integrated into a single magnetic structure, thereby reducing cost, increasing power density, and equivalently increasing power efficiency.

A circuit in which integrating magnetic components is very advantageous is a soft switching converter (US 6,862,195) capable of producing high efficiency when operating at high switching frequencies. A typical soft switching converter uses three magnetic components: a parallel resonant inductor, a two-winding transformer and a series filter inductor. In addition to the number of discrete magnetic components, which results in higher size and cost, the converter also results in at least three windings and multiple interconnections that negatively impact efficiency.

The parallel primary resonant inductor and transformer are typically integrated into one component. The air gap is squeezed hard in a non-ideal transformer to adjust the magnetizing inductance replacing the parallel primary resonant inductance.

In recent years, some efforts have been made to integrate all three magnetic components into a single component for an LLC resonant converter. Some integrated magnetic structures are shown in US 2008/0224809. An additional inductor winding is introduced to form a series resonant inductance to enhance the leakage inductance of the transformer.

Although US 2008/0224809 provides some suitable improvements to a typical soft resonant LLC converter, there are still some failures: most use E-cores from retail sales and the bobbin is inevitably wound with coils. The bobbin negatively impacts cost, power density, power efficiency, and heat distribution. There is additional power loss due to the air gap fringing field and the higher average length of the windings. The bobbin is costly and results in more leakage and inductive losses. Additionally, these spools reduce power density and increase thermal resistance. Furthermore, the integrated magnetic component disclosed in US 2008/0224809 is relatively complex to manufacture due to its complex geometry, its number of windings and the relative positions of these windings with respect to each other.

Disclosure of Invention

The object of the present invention is to create an integrated magnetic component belonging to the initially mentioned technical field, which has a high power density and efficiency, is cheap and easy to manufacture and has a simple design.

The solution of the invention is specified by the features of claim 1. In an integrated magnetic component for a switched-mode power converter, in particular for a soft-switching converter and/or for an LLC resonant converter, according to the invention, comprising two magnetic cores forming a figure-8 core structure, wherein the first magnetic core is an E-core, and at least two first electrical winding wires, at least one of the first electrical winding wires is wound on a flange of the E-core. A "flange" is to be understood as one of the two vertical portions of the upright E-core separating the three horizontal legs of the upright E-core from each other. The term "E core" is to be understood as "E core and/or ER core", wherein the ER core describes the following E core: wherein the central strut of the E-core is cylindrical and/or the lateral struts of the E-core have at least partially rounded side portions, in particular rounded inner side portions.

The use of flanges of the E-core instead of legs to place the windings helps to achieve a straightforward manufacturing process and results in high power density and high efficiency of the integrated magnetic component.

In a preferred embodiment, the second magnetic core of the figure-8 core structure is an E-core. The use of an E-core as the second magnetic core has the following advantages: the two cores have at least substantially the same shape; and therefore the manufacture of the integrated magnetic component and its handling is optimized. In another exemplary embodiment, the figure-8 core structure is an I-core. The use of an I-core has the advantage that it is very easy to handle. However, the second magnetic core may also have a different shape. Which may be a U core, for example. In the latter case, the central leg of the first magnetic core (typically the E core) is preferably longer than the two lateral legs of that particular first magnetic core.

In a preferred embodiment, the integrated magnetic component comprises at least two second electric winding wires. Preferably, the first magnetic core includes one first electric winding wire and one second electric winding wire. Preferably, the second magnetic core also includes a first electric winding wire and a second electric winding wire. The use of at least two second electrical winding wires in addition to the first electrical winding wire has the following advantages: electrical insulation between the two sides of the integrated magnetic component can be easily obtained. However, the use of at least two electric winding wires is not absolutely necessary. It may also be possible to use only one second electrical winding wire.

In an exemplary embodiment, at least one electrical winding is wound directly on one of the magnetic cores. This means that no bobbin is used. The omission of the bobbin has the following advantages: this results in a dramatic improvement in winding window utilization compared to designs where the bobbin is located between the electrical winding wire and the magnetic core. Increased window utilization is associated with increased power density. Another advantage is that: the thermal resistance between the core and the winding decreases. This results in an improved efficiency of the integrated magnetic component. In the exemplary embodiment, all of the electrical winding wire is wound directly on the magnetic core. However, it is also possible to wind only some of the electric winding wire (e.g., only the first electric winding wire) directly onto the magnetic core and use the bobbin for the remaining electric winding wire (e.g., the second electric winding wire).

In a preferred embodiment, the first electrical winding wires are connected to each other by a first welded joint and/or the second electrical winding wires are connected to each other by a second welded joint. This has the following advantages: the manufacture of the integrated magnetic component is simplified since the first magnetic core, on which typically one first electrical winding wire and one second electrical winding wire are at least partially wound, and the second magnetic core, on which typically one first electrical winding wire and one second electrical winding wire are also at least partially wound, can be easily connected and assembled to form the integrated magnetic structure in this way. However, the use of a welded joint is not mandatory. The connection between the respective wires may also be adapted in different ways to establish a suitable electrical and/or mechanical connection.

In a preferred embodiment, at least one of the first electrical winding wires comprises and/or forms two windings. Preferably, each of the two first electrical winding wires comprises and/or forms two windings. However, it is also possible that the first electrical winding wire forms only one winding or more than two windings. In particular, the number of windings may be different for the two first electrical winding wires. One advantage of one electrical winding comprising and/or forming two windings is that: the overall number of electrical winding wires necessary to manufacture the integrated magnetic component is reduced. Thus, the number of welded joints that need to be established during manufacturing is also reduced. This results in an easier and cheaper manufacturing process.

In typical embodiments, at least one of the second electrical winding wire is wound on the flange of one of the E-cores or on the I-core. It is particularly preferable to wind one second electric winding wire on the flange of the first magnetic core (typically, an E-core), and, in the case where the second magnetic core is the E-core, to wind one of the second electric winding wires on the flange of the second magnetic core, or, if the second magnetic core is the I-core, to wind one of the second electric winding wires on the I-core. Winding at least one of the electrical winding wires in this manner is advantageous in that it homogenizes the construction of the integrated magnetic structure and results in improved electrical performance, such as advantageous flux distribution. In principle, however, it is also possible to wind the second electrical winding wire around, for example, the legs of the second magnetic core in a different manner in the case where the second magnetic core is an E core.

In a preferred embodiment, the figure-8 core structure comprises an air gap. In a particularly preferred embodiment, the figure-8 core structure comprises three air gaps, such that-in the case of the second magnetic core being an E-core-typically each of the three legs of the first E-core is separated from the corresponding leg of the second E-core by one air gap. The presence of an air gap has the following advantages: the primary magnetizing inductance, the output filter inductance and the transformer turn ratio of the integrated magnetic component are adjusted. This is particularly preferred in case the air gap is filled with a material having suitable electrical properties, in particular a plastic material. An example of such a suitable electrical property may for instance be non-conducting, which has the advantage that additional skin effect losses are avoided. However, the presence of an air gap is not mandatory. The integrated magnetic component can also be configured without air gaps or with less than three air gaps or even with more than three air gaps.

In a preferred embodiment, one or more air gaps are centrally located in the figure-8 core structure, which means that: the one or more air gaps have the same distance from the flange of each E-core in the case where both magnetic cores are E-cores, or the one or more air gaps have the same distance from the flanges of the E-and I-cores in the case where the second magnetic structure is an I-core. Preferably, the one or more air gaps are substantially parallel to the flanges of the E-core and/or I-core. This arrangement of the air gap has the following advantages: a very suitable flux management and high efficiency of the integrated magnetic component can be obtained. In particular, this arrangement of air gaps produces a sharp reduction in AC copper losses caused by air gap fringing fields. However, it is also possible that the one or more air gaps are not centrally located, and/or that the air gaps are not substantially parallel to the flanges of the E-cores and/or I-cores, and/or that the distances are not the same.

In a preferred embodiment, the figure-8 core structure and/or at least one magnetic core comprises a beveled edge. The inclined edges have the following advantages compared to sharp edges (i.e. edges of substantially 90 °): it is less sharp; and therefore the electric winding wire wound directly onto at least one of the magnetic cores is less prone to be damaged by sharp edges. Instead of a bevelled edge, an at least partly rounded or rounded edge may also be used. Any edge type is in principle suitable as long as it is not sharp enough to damage the electrical winding wire.

In the exemplary embodiment, three windings are wound on each core. In the case of both magnetic cores being E-cores, it is particularly preferred to wind one winding on the first flange of each E-core and two windings on the second flange of each E-core. In the case where one magnetic core is an E-core and the other magnetic core is an I-core, it is particularly preferable to wind one winding on the first flange of the E-core and two windings on the second flange of the E-core and three windings continuously on the I-core.

In an integrated magnetic component according to the invention comprising a magnetic core in the form of an E-core and two electric winding wires, the electric winding wires are wound on the flanges of the E-core. Preferably, the wires are wound around the flange without a wire axis (i.e. directly). In an exemplary embodiment, winding wire is used to wind two windings on one flange of the E-core and one winding on the other flange of the E-core.

A method for manufacturing an integrated magnetic component according to the invention comprises the steps of:

-providing a first winding by winding a first electrical winding wire around a first flange of a first E-core;

-providing a second winding by winding the first electrical winding wire around the second flange of the first E-core;

-providing a fifth winding by winding a second electrical winding wire around the second flange of the first E-core;

-providing a third winding by winding a supplementary first electrical winding wire around the first flange of the second E-core or around the I-core;

-providing a fourth winding by winding the supplemental first electrical winding wire around the second flange of the second E-core or around the I-core; and

-providing a sixth winding by winding a supplemental second gas winding wire around the second flange of the second E-core or around the I-core.

In a preferred method for manufacturing an integrated magnetic component, the first and second E-cores or the I-core are fixed to each other, the first electrical winding wire is soldered to each other, and the second electrical winding wire is soldered to each other, preferably after the six windings have been wound on the cores.

A soft switching converter according to the invention comprises an integrated magnetic component according to the invention.

An LLC converter according to the invention comprises an integrated magnetic component according to the invention.

The integrated magnetic component according to the invention has a compact assembly, which results in a reduction of copper losses and an overall reduction of stray inductances. The transient characteristics of the converter are equally improved.

Other advantageous embodiments and combinations of features are disclosed from the following detailed description and all claims.

Drawings

The drawings used to illustrate the embodiments show:

FIG. 1 is an equivalent circuit of a soft switching converter circuit, which is one possible circuit in which an integrated magnetic component according to the present invention may be used;

FIG. 2 is an equivalent circuit of an LLC resonant converter circuit, which is another possible circuit in which an integrated magnetic component according to the invention may be used;

FIG. 3 is a schematic view of an integrated magnetic component according to the present invention (first embodiment);

FIG. 4 is a magnetoresistive model of the embodiment of FIG. 3;

FIG. 5 is a graph of the operation of the voltage and current of the secondary transformer winding and the flux density (induction) in the transformer core legs, choke core legs and center leg;

FIG. 6 is a schematic view of an integrated magnetic component according to the present invention (second embodiment);

FIG. 7 is a magnetoresistive model of the embodiment of FIG. 6; and

fig. 8 is an operation of curves of series resonant choke current, parallel resonant choke current and primary winding current and flux density (induction) in transformer core legs, choke core legs and center legs.

In the drawings, the same reference numerals are given to the same components.

Detailed Description

Fig. 1 shows an equivalent circuit of a soft switching converter circuit, which is one possible circuit in which the integrated magnetic component according to the invention can be used. The soft switching converter circuit includes: an input circuit comprising four switching devices Q1, Q2, Q3, Q4 and an input capacitor C_in(ii) a An output circuit including four diodes D1, D2, D3, D4 and an output capacitor C_o(ii) a And an integrated magnetic component 1 according to the invention. The equivalent circuit of the integrated magnetic component 1 comprises two input resonant inductors L_r1And L_r2Parallel resonant inductor L_mAnd a transformer T.

Fig. 2 shows an equivalent circuit of an LLC resonant converter circuit, which is another possible circuit in which an integrated magnetic component according to the invention can be used. The LLC resonant converter circuit includes: an input circuit comprising two switching devices Q1, Q2 and an input capacitor C_in(ii) a An output circuit including two diodes D1, D2 and an output capacitor C_o(ii) a And an integrated magnetic component 1a according to the invention. The equivalent circuit of the integrated magnetic component 1a includes a parallel resonant inductor L_mTransformer T and two output filter chokes L_r1--And L_r2。

Fig. 3 shows a schematic view of an integrated magnetic component 1 according to the invention. The integrated magnetic component 1 comprises a figure 8 core structure 2, which figure 8 core structure 2 comprises a first magnetic core 3.1 and a second magnetic core 3.2. Both magnetic cores 3.1 and 3.2 have the form of E cores.

A first electrical winding wire 4.1 is wound around the first magnetic core 3.1. The first electric winding wire 4.1 includes: a first winding 5.1 wound around a first flange of the first core 3.1 and constituting a first output filter choke L_r1The winding of (a); and a second winding 6.1 wound around the second flange of the first core 3.1 and constituting a first secondary winding S1 of the transformer T. A supplemental first electrical winding wire 4.2 is wound around the second magnetic core 3.2. The supplementary first electrical winding wire 4.2 comprises: a third winding 5.2 wound around the first flange of the second core 3.2 and constituting a second output filter choke L_r2The winding of (a); and a fourth winding 6.2 wound around the second flange of the second core 3.2 and constituting a second secondary winding S2 of the transformer T. The first electrical winding wire 4.1 and the supplemental first electrical winding wire 4.2 are connected to each other via a first welded joint 7.1. The first electrical winding wire 4.1 comprises a connection portion 8.1 connecting the first winding 5.1 to the second winding 6.1. By analogy, the supplementary first electrical winding wire 4.2 comprises a connection portion 8.2 connecting the third winding 5.2 to the fourth winding 6.2. The connecting portions 8.1 and 8.2 are placed on opposite sides of the figure-8 core structure 2. The first electrical winding wire 4.1 comprises a wire end portion 10.1 and the supplemental first electrical winding wire 4.2 comprises a wire end portion 10.2. The wire end portions 10.1 and 10.2 are placed on opposite sides of the figure 8 core structure 2.

A second electrical winding wire 9.1 is wound around the second flange of the first magnetic core 3.1 creating a fifth winding 12.1 constituting a first primary winding P1 of the transformer T. A supplementary second electrical winding wire 9.2 is wound around the second flange of the second magnetic core 3.2 creating a sixth winding 12.2 constituting a second primary winding P2 of the transformer T. The second electrical winding wire 9.1 and the complementary second electrical winding wire 9.2 are connected to each other via a second welded joint 7.2. The second electrical winding wire 9.1 comprises a wire end portion 10.3, and the supplemental second electrical winding wire 9.2 comprises a wire end portion 10.4. The wire end portions 10.3 and 10.4 are placed on opposite sides of the figure 8 core structure 2.

The wire end portions 10.1 and 10.3 and the connecting portion 8.1 are placed on one side of the figure 8 core structure 2, while the wire end portions 10.2 and 10.4 and the connecting portion 8.1 are placed on the other side of the figure 8 core structure 2.

The figure 8 core structure 2 comprises three air gaps 11.1, 11.2 and 11.3. The air gaps 11.1 and 11.3 separate the two lateral legs of each magnetic core 3.1, 3.2 from the corresponding lateral legs of the other magnetic core 3.1, 3.2. The central legs of the magnetic cores 3.1, 3.2 are separated by an air gap 11.2.

The six windings 5.1, 5.2, 6.1, 6.2, 12.1 and 12.2 are wound directly (i.e. without an axis) on the four flanges of the figure-8 core structure 2 fed by the two cores 3.1 and 3.2. Each of the magnetic core structures 3.1 and 3.2 comprises a plurality of inclined edges 13. These inclined edges 13 are less prone to damage to the electrical winding wires 4.1, 4.2, 9.1 and 9.2 than sharp 90 degree edges.

Introduction of air gap 11.1 in flux path of transformer T with transformer T and parallel resonant inductor L_mCorresponds to the integration of (see fig. 1). The parallel inductance thus created is adjustable by the configuration of the air gap 11.1, while the turns ratio of the transformer T is constant.

The following fact leads to the elimination of flux in this common central strut and therefore to a reduction in core losses: gapped transformer T and output filter choke L_r1And L_r2Are put together in a common central leg consisting of two central legs of the magnetic cores 3.1 and 3.2.

With parallel input inductance L_mTransformer T and coupled output filter choke L wound on a bobbin-less E-core as shown in fig. 3_r1And L_r2Inductor L of_m、L_r1And L_r2And the integrated structure of the transformer T (shown in fig. 1) can be summarized as follows: the structure comprises two magnetic cores 3.1 and 3.2 formed as E-cores (the use of ER-cores is also possible), three air gaps 11.1, 11.2 and 11.3 and six windings 5.1, 5.2, 6.1, 6.2, 12.1 and 12.2. The windings 12.1 and 12.2 form the two primary windings P1 and P2 of the transformer T. The windings 6.1 and 6.2 form the two secondary stages of the transformer TWindings S1 and S2. The windings 5.1 and 5.2 form a first and a second output filter choke L_r1And L_r2The winding of (2). First and second output filter chokes L_r1And L_r2Are symmetrically wound on the different flanges and optimally coupled.

The corresponding magneto resistive model of the embodiment of fig. 3 is shown in fig. 4. R_LDenotes the reluctance, R, of the inductive core (right lateral legs and lateral flanges of the magnetic cores 3.1 and 3.2 as shown in fig. 3) taking into account its respective air gap 11.3_TDenotes the reluctance of the transformer core (left lateral legs and lateral flanges of the magnetic cores 3.1 and 3.2 as shown in fig. 3) with consideration of its respective air gap 11.1, and R_cThe reluctance of the central core (consisting of the two central legs of the magnetic cores 3.1 and 3.2) is shown taking into account its respective air gap 11.2.

After the application of the mathematical description of the reluctance model and faraday's law on all windings, some equation deduction (modeling) produces an inductance matrix of the integrated component that is calculated as:

wherein

And。

using the element "primary L" of the calculated inductance matrix₁₁Secondary self-inductance L₂₂And mutual inductance M₁₂", magnetizing the inductance L with the parameter of the transformer pi model_mSecondary leakage inductance L_rAnd equivalent secondary turns N_sn"are described as:

is wound with N_sTurns, but the transformer exhibits N_snAnd (4) turning. By introducing an air gap in the central strut, the effective secondary turns N_snBecomes the ratio of the true number of turns N_sHigher, which allows for reduced secondary copper losses.

For no air gap (g) in the central core₃ 0) high permeability low saturation flux density material, R only_c<< R_L，R_TMagnetically decoupling the gapped transformer and the output filter inductor and coupling the primary leakage inductance L_rMagnetizing inductor L_mAnd equivalent secondary turns N_snRespectively simplified into:

，and。

separately calculating the flux and flux density in the transformer legs: () Flux and flux density in the choke leg: () And flux density in the central leg: () The following were used:

wherein, I_mIs the transformer magnetizing current.

For no air gap (g) in the central core₃ 0) high permeability low saturation flux density material, R only_c<< R_L，R_TThe gapped transformer and the output filter inductor are magnetically decoupled, and the transformer leg flux and the filter inductor leg flux are respectively simplified as follows:

fig. 5 illustrates the operation of the curves of voltage and current of the secondary transformer winding and flux density (induction) in the core transformer, choke and center leg. Center core pillar B_cIs reduced and, therefore, core losses therein are minimized. When the transformer and inductor cores are completely separated, the flux circulating in all transformer legs isAnd the flux flowing in all inductor legs is。

Fig. 6 shows a second embodiment of the invention. The integrated magnetic component 1a comprises a figure-8 core structure 2a consisting of two magnetic cores 3.1a and 3.2a and is suitable for LLC resonant converters like the one shown in fig. 2.

Similar to the embodiment shown in fig. 3, the integrated magnetic component 1a comprises a first electrical winding wire 4.1a and a complementary first electrical winding wire 4.2 a. The first electrical winding wire 4.1a comprises a wire end 10.1a, a first winding 5.1a, a connecting portion 8.1a and a second winding 6.1 a. The supplementary first electrical winding wire 4.2a comprises a wire end 10.2a, a third winding 5.2a, a connecting portion 8.2a and a fourth winding 6.2 a. The first electrical winding wire 4.1a and the supplemental first electrical winding wire 4.2a are connected to each other via a welded joint 7.1 a.

Also similar to the embodiment shown in fig. 3, the integrated magnetic component 1a comprises a second electrical winding wire 9.1a and a complementary second electrical winding wire 9.2 a. The second electrical winding wire 9.1a comprises a wire end 10.3a and a fifth winding 12.1 a. The supplementary second electrical winding wire 9.2a comprises a wire end 10.4a and a sixth winding 12.2 a. The second electrical winding wire 9.1a and the complementary second electrical winding wire 9.2a are connected to each other via a welded joint 7.2 a.

The figure 8 core structure 2a comprises three air gaps 11.1a, 11.2a and 11.3 a. The air gaps 11.1a and 11.3a separate the two lateral legs of each magnetic core 3.1a, 3.2a from the corresponding lateral legs of the other magnetic core 3.1a, 3.2 a. The central legs of the magnetic cores 3.1a, 3.2a are separated by an air gap 11.2 a.

The six windings 5.1a, 5.2a, 6.1a, 6.2a, 12.1a and 12.2a are wound directly (i.e. without a bobbin) on the four flanges of the figure-8 core structure 2a fed by the two cores 3.1a and 3.2 a. Each of the magnetic core structures 3.1a and 3.2a comprises a plurality of inclined edges 13 a. These inclined edges 13a are less prone to damage to the electrical winding wires 4.1a, 4.2a, 9.1a and 9.2a than sharp 90-degree edges.

The integrated magnetic component 1a comprises an output wire 14 connected to the solder joint 7.2 a.

Compared to the embodiment shown in fig. 3, all wire end portions 10.1a, 10.2a, 10.3a and 10.4a and connection portions 8.1a and 8.2a are placed on the same side of the figure-8 structure 2 a.

With reference to figures 6 and 2 of the drawings,the first winding 5.1a is wound to form a first resonant inductor L_r1On the first flange of the first magnetic core 3.1a of the winding. The second winding 6.1a is wound on the second flange of the first magnetic core 3.1a constituting the first primary winding P1 of the transformer T. The third winding 5.2a is wound to form the second resonant inductor L_r2On the first flange of the second magnetic core 3.2a of the winding. The fourth winding 6.2a is wound on the second flange of the second magnetic core 3.2a constituting the second primary winding P2 of the transformer T. The fifth winding 12.1a is wound on the second flange of the first core 3.1a constituting the first secondary winding S1 of the transformer T. The sixth winding 12.2a is wound on the second flange of the second core 3.2a constituting the second secondary winding S2 of the transformer T.

The corresponding magneto resistive model of the embodiment of fig. 6 is shown in fig. 7. R_LDenotes the reluctance, R, of the inductive core (left lateral leg and lateral flange of the core as shown in FIGS. 6 for cores 3.1a and 3.2 a) with consideration of its respective air gap 11.3a_TDenotes the reluctance of the transformer core (right lateral legs and transverse flanges of the core legs of cores 3.1a and 3.2a as shown in fig. 6) with consideration of their respective air gaps 11.1a, and R_cThe reluctance of the central core (constituted by the two central legs of the magnetic cores 3.1a and 3.2 a) is indicated, taking into account its respective air gap 11.2 a. After the application of the mathematical description of the reluctance model and faraday's law on all windings, some equation deductions produce an inductance matrix of the integrated component that is calculated as:

wherein

And。

using the element "primary L" of the calculated inductance matrix₁₁Secondary self-inductance L₂₂And mutual inductance M₁₂", magnetizing the inductance L with the parameter of the transformer pi model_mSecondary leakage inductance L_rAnd equivalent primary number of turns N_pn"are described as:

and

。

is wound with N_pTurns, but the transformer exhibits N_pnAnd (4) turning. By introducing an air gap in the central leg, the effective primary number of turns N_pnBecomes the ratio of the true number of turns N_pHigher, which allows to reduce the primary copper losses.

For no air gap (g) in the central core₃ 0) high permeability low saturation flux density material, R only_c<< R_L，R_TMagnetically decoupling the gapped transformer and resonant inductor and coupling the primary leakage inductance L_rMagnetizing inductor L_mAnd equivalent primary number of turns N_pnRespectively simplified into:

and。

the flux and flux density of the legs of this embodiment are calculated as the integrated magnetic element for the soft switching converter.

Fig. 8 illustrates the operation of the curves for series resonant choke current, parallel resonant choke current and primary winding current and flux density (induction) in the core transformer, choke and center leg. Center core pillar B_cIs reduced and, therefore, core losses therein are minimized.

It should be noted that the present invention is not limited to the two embodiments described above. Rather, the scope of protection is defined by the patent claims.

Claims (16)

1. Integrated magnetic component (1) for a switched mode power converter, comprising:

-two magnetic cores (3.1, 3.2) forming a figure 8 core structure (2); and

-at least two first electrical winding wires (4.1, 4.2),

wherein the first magnetic core (3.1) is an E core,

it is characterized in that

At least one of the first electrical winding wires (4.1, 4.2) is wound on the flange of the E-core.

2. Integrated magnetic component (1) according to claim 1, characterized in that the second magnetic core (3.2) is an E-core or an I-core.

3. Integrated magnetic component (1) according to one of the preceding claims, characterized in that the integrated magnetic component (1) comprises at least two second electric winding wires (9.1, 9.2).

4. Integrated magnetic component (1) according to one of the preceding claims, characterized in that at least one of the electrical winding wires (4.1, 4.2, 9.1, 9.2) is wound directly on one of the magnetic cores (3.1, 3.2).

5. Integrated magnetic component (1) according to claim 4, characterized in that the first electrical winding wires (4.1, 4.2) are connected to each other by a first welded joint (7.1) and/or the second electrical winding wires (9.1, 9.2) are connected to each other by a second welded joint (7.1).

6. Integrated magnetic component (1) according to one of the preceding claims, characterized in that at least one of the first electrical winding wires (4.1, 4.2) comprises two windings (5.1, 5.2, 6.1, 6.2, 12.1, 12.2).

7. Integrated magnetic component (1) according to any of claims 3 to 6, characterized in that at least one of the second electrical winding wires (9.1, 9.2) is wound on a flange of one of the E-cores or on the I-core.

8. Integrated magnetic component (1) according to one of the preceding claims, characterized in that the figure-8 core structure (2) comprises air gaps (11.1, 11.2, 11.3).

9. Integrated magnetic component (1) according to claim 8, characterized in that the air gaps (11.1, 11.2, 11.3) are centrally located in the figure-8 core structure (2).

10. Integrated magnetic component (1) according to one of the preceding claims, characterized in that the figure-8 core structure (2) comprises a slanted edge (13).

11. Integrated magnetic component (1) according to one of the preceding claims, characterized in that three windings (5.1, 5.2, 6.1, 6.2, 12.1, 12.2) are wound on each magnetic core.

12. Integrated magnetic component for an integrated magnetic component according to one of the claims 1 to 11, comprising a magnetic core (3.1, 3.2) in the form of an E-core and two electric winding wires, characterized in that the electric winding wires are wound on the flanges of the magnetic core.

13. Method for manufacturing an integrated magnetic component (1), characterized by the steps of:

-providing a first winding (5.1) by winding a first electrical winding wire (4.1) around a first flange of a first E-core (3.1);

-providing a second winding (6.1) by winding the first electrical winding wire (4.1) around a second flange of the first E-core (3.1);

-providing a fifth winding (12.2) by winding a second electrical winding wire (9.1) around the second flange of the first E-core (3.1);

-providing a third winding (5.2) by winding a supplementary first electrical winding wire (4.2) around the first flange or around the I-core of the second E-core (3.2);

-providing a fourth winding (6.2) by winding the supplemental first electrical winding wire around the second flange of the second E-core (3.2) or around the I-core; and

-providing a sixth winding (12.2) by winding a supplementary second electrical winding wire (9.2) around the second flange of the second E-core (3.2) or around the I-core.

14. The method of claim 13, wherein the step of removing the substrate comprises removing the substrate from the substrate

-the first E-core (3.1) and the second E-core (3.2) are fixed to each other,

-the first electrical winding wires (3.1, 3.2) are welded to each other, and

-the second electrical winding wires (9.1, 9.2) are welded to each other.

15. Soft switching converter comprising an integrated magnetic component (1) according to any of claims 1 to 11.

16. LLC converter comprising an integrated magnetic component (1) according to any of claims 1 to 11.