Magnetic assembly and power module

Patent metadata

Field	Value
Publication number	US-12531180-B2
Application number	US-202217577341-A
Country	US
Kind code	B2
Filing date	Jan 17, 2022
Priority date	Jun 18, 2021
Publication date	Jan 20, 2026
Grant date	Jan 20, 2026

Abstract

The present disclose provides a magnetic assembly and a power module. In one aspect, the magnetic assembly includes a magnetic core having a first magnetic leg and a second magnetic leg spatially separated from the first magnetic leg to define a spatial channel therebetween, and a winding assembly comprising a first winding, a second winding, and a third winding. The first and second windings are wound around the first magnetic leg with at least a part of the first and second windings being accommodated within the spatial channel. The third winding is wound around the first and second magnetic legs. The first winding is disposed between the first magnetic leg and the second winding. The second winding is disposed between the first winding and the third winding.

First claim

What is claimed is:

1 . A magnetic assembly, comprising:
a magnetic core having a first magnetic leg and a second magnetic leg spatially separated from the first magnetic leg to define a spatial channel therebetween; and a winding assembly comprising a first winding, a second winding, and a third winding, the first and second windings being wound around the first magnetic leg with at least a part of the first and second windings being accommodated within the spatial channel, and the third winding being wound around the first and second magnetic legs; wherein the first winding is disposed between the first magnetic leg and the second winding; and wherein the second winding is disposed between the first winding and the third winding, and the second magnetic leg is only wound with the third winding.

2 . The magnetic assembly according to claim 1 , wherein the second winding is connected with a first output port, and the third winding is connected with a second output port, wherein a voltage at the first output port is higher than a voltage at the second output port.

3 . The magnetic assembly according to claim 1 , wherein the first winding is connected with a first output port, and the third winding is connected with a second output port, wherein a voltage at the first output port is greater than a voltage at the second output port.

4 . The magnetic assembly according to claim 1 , wherein the magnetic core further comprises a first magnetic base and a second magnetic base, wherein the first and second magnetic legs are connected between the first and second magnetic bases.

5 . The magnetic assembly according to claim 4 , wherein the magnetic core further comprises a shared lateral leg connected between the first and second magnetic bases, wherein the second magnetic leg is disposed between the shared lateral leg and the first magnetic leg.

6 . The magnetic assembly according to claim 4 , wherein the second magnetic leg comprises one air gap or more air gaps.

7 . The magnetic assembly according to claim 4 , wherein the second magnetic leg comprises a plurality of discretely disposed sub-legs connected between the first and second magnetic bases, such that one air gap or more air gaps are formed between the sub-legs.

8 . The magnetic assembly according to claim 4 , wherein the second magnetic leg comprises a first sub-leg and a second sub-leg discretely disposed from the first sub-leg, wherein the first sub-leg is connected to the first magnetic base, and the second sub-leg is connected to the second magnetic base, wherein an air gap is formed between the first and second sub-legs.

9 . The magnetic assembly according to claim 8 , further comprising an air gap forming material filled in the air gap.

10 . The magnetic assembly according to claim 4 , wherein the magnetic core further comprises:
a third magnetic base, a third magnetic leg, and a fourth magnetic leg, the third and fourth magnetic legs being connected between the second magnetic base and the third magnetic base; wherein the winding assembly further comprises a fourth winding wound around the third magnetic leg, thereby serving as a secondary inductor of the magnetic assembly.

11 . The magnetic assembly according to claim 10 , wherein the third magnetic leg comprises:
a plurality of discretely disposed sub-legs, a first one of the sub-legs being connected to the third magnetic base, and a second one of the sub-legs being disposed between said first one of the sub-legs and the second magnetic base; wherein a first air gap is formed between said first one of the sub-legs and said second one of the sub-legs; and wherein a second air gap is formed between said second one of the sub-legs and the second magnetic base.

12 . The magnetic assembly according to claim 11 , further comprising an air gap forming material filled in the first and second air gaps to secure the sub-legs in place.

13 . The magnetic assembly according to claim 1 , wherein the magnetic core comprises two magnetic sub-cores, and the winding assembly comprises two winding sub-assemblies.

14 . The assembly according to claim 13 , wherein, when the magnetic core is magnetized by a reference current in the winding assembly, a magnetic flux in the first magnetic leg of one of the two magnetic sub-cores is induced along a direction opposite to that of a magnetic flux in the first magnetic leg of the other one of the two magnetic sub-cores, and a magnetic flux in the second magnetic leg of one of the two magnetic sub-cores is induced along a direction opposite to that of a magnetic flux in the second magnetic leg of the other one of the two magnetic sub-cores.

15 . The magnetic assembly according to claim 13 , wherein the second magnetic leg of each of the two magnetic sub-cores comprises a plurality of air gaps.

16 . The magnetic assembly according to claim 13 , wherein the second magnetic leg of each of the two magnetic sub-cores comprises a plurality of sub-legs connected between the first and second magnetic bases, such that one air gap or more air gaps are formed between the sub-legs.

17 . The magnetic assembly according to claim 16 , further comprising an air gap forming material filled in the air gaps to secure the sub-legs in place.

18 . The magnetic assembly according to claim 17 , wherein the air gap forming material is a non-conductive and non-magnetic material.

19 . The magnetic assembly according to claim 13 , wherein the first magnetic legs of the two magnetic sub-cores are disposed between the two magnetic sub-cores.

20 . The magnetic assembly according to claim 13 , wherein the two magnetic sub-cores are disposed between the first magnetic legs of the two magnetic sub-cores.

21 . The magnetic assembly according to claim 13 , wherein the two magnetic sub-cores are adjacent to each other, and the first magnetic legs of the two magnetic sub-cores are adjacent to each other.

22 . The magnetic assembly according to claim 1 , further comprising a case that encases the magnetic core and the winding assembly, and a thermal glue that fills in a vacant apace of the case in which the magnetic core and the winding assembly are encased.

23 . The magnetic assembly according to claim 1 , wherein the third winding comprises a copper sheet.

24 . The magnetic assembly according to claim 23 , wherein the first winding and the second winding are at least partially covered by the third winding.

25 . The magnetic assembly according to claim 23 , wherein a turn number of the third winding is one.

26 . A power converter, comprising:
a first port, a second port, and a third port; a transformer comprising a magnetic core, a primary winding, a first secondary winding, and a second secondary winding; a first circuit electrically coupled between the first port and the primary winding; a second circuit electrically coupled between the second port and the first secondary winding; a third circuit electrically coupled between the third port and the second secondary winding, wherein the third circuit comprises a secondary inductor electrically coupled with the second secondary winding; wherein the magnetic core comprises: a first magnetic leg and a second magnetic leg spatially separated from the first magnetic leg to define a spatial channel therebetween, a winding assembly comprising a first winding, a second winding, and a third winding, th

Assignees

• Delta Electronics Shanghai Co

Inventors

• Yang Haijun
• Hong Tianding
• Gul Warda
• Lu Zengyi
• Jia Minli
• Zhang Jinfa

Classifications

• H02M3/33576

  having at least one active switching element at the secondary side of an isolation transformer · CPC title

• H01F38/14

  Inductive couplings {(for wireless supply or distribution of electric power using inductive coupling H02J50/10)} · CPC title

• H01F27/263

  Fastening parts of the core together · CPC title

• Y02T90/14

  Plug-in electric vehicles · CPC title

• Y02T10/7072

  Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors · CPC title