Resonant converter

Patent metadata

Field	Value
Publication number	US-2025323571-A1
Application number	US-202519077912-A
Country	US
Kind code	A1
Filing date	Mar 12, 2025
Priority date	Mar 15, 2024
Publication date	Oct 16, 2025
Grant date	—

Abstract

A resonant converter includes a first circuit board, a second circuit board, and a planar transformer. The planar transformer includes an iron core, a plurality of wirings, and a first conductive column. A first core column of the iron core penetrates through a first circuit board through hole of the first circuit board and a second circuit board through hole of the second circuit board respectively. The wirings are formed around the first circuit board through hole and the second circuit board through hole respectively, and the first conductive column electrically connects the wirings to form a winding of the planar transformer. A first via is used to electrically connect the winding and the power component embedded in any one sub-layer board of the first circuit board or the second circuit board, and the iron core is used to sleeve the winding to form the planar transformer.

First claim

What is claimed is:

1 . A resonant converter comprising:
a first circuit board and a second circuit board respectively comprising a plurality of sub-layer boards, a primary-side circuit disposed on the first circuit board, two secondary-side circuits respectively disposed on the first circuit board and the second circuit board, and the primary-side circuit or the two secondary-side circuits comprising a power component, wherein the power component is embedded in any one of the sub-layer boards, a planar transformer disposed on the first circuit board and the second circuit board, and electrically connected to the primary-side circuit and the two secondary-side circuits, and the planar transformer comprising: a first circuit board through hole penetrating the first circuit board, a second circuit board through hole penetrating the second circuit board, an iron core comprising a first core column penetrating the first circuit board through hole and the second circuit board through hole, a plurality of wirings respectively formed around the first circuit board through hole and the second circuit board through hole, a first conductive column disposed between the first circuit board and the second circuit board, and electrically connected to a wiring arranged around the first circuit board through hole and a wiring arranged around the second circuit board through hole to form a winding of the planar transformer, and a first via formed on the first circuit board and the second circuit board, and configured to electrically connect the power component and the winding disposed on the sub-layer board, wherein the iron core is configured to sleeve the winding of the first circuit board and the second circuit board to form the planar transformer.

2 . The resonant converter as claimed in claim 1 , wherein the number of the power component is plural, and comprises:
two first switches respectively disposed on the first circuit board and the second circuit board, two second switches respectively disposed on the first circuit board and the second circuit board, and two output capacitors disposed on the first circuit board and the second circuit board, and electrically connected to the first switch and the second switch on the same circuit board to form the two secondary-side circuits, and the two first switches, the two second switches, and the two output capacitors respectively embedded in any one of the sub-layer boards of the first circuit board and the second circuit board, wherein the plurality of wirings comprise the two secondary-side wirings and are configured to be as two secondary-side windings electrically connected to the two secondary-side circuits, and the first switches, the second switches, and the output capacitors of the first circuit board and the second circuit board are electrically connected to the two secondary-side windings through the corresponding first vias respectively.

3 . The resonant converter as claimed in claim 1 , wherein the number of the power component is plural, and comprises:
a first power switch disposed on the first circuit board, and a second power switch disposed on the first circuit board, and the first power switch and the second power switch forming a primary-side switch bridge arm of the primary-side circuit, and the first power switch and the second power switch respectively embedded in any one of the sub-layer boards, wherein the plurality of wirings comprise two primary-side wirings respectively disposed on the first circuit board and the second circuit board are configured to be as a primary-side winding electrically connected to the primary-side circuit, and the first power switch and the second power switch are electrically connected to the primary-side winding through the corresponding first vias respectively.

4 . The resonant converter as claimed in claim 1 , further comprising:
two second vias respectively formed on the first circuit board and the second circuit board, wherein the winding is two modular windings respectively embedded in in any one of the sub-layer boards of the first circuit board and the second circuit board, and the two modular windings are electrically connected to the primary-side circuit or the two secondary-side circuits through the two second vias.

5 . The resonant converter as claimed in claim 4 , wherein the two modular windings respectively comprise:
a plurality of conductive materials respectively formed between a first layer and a second layer of the two modular windings, and the plurality of wirings interleavingly extend to the first layer and the second layer through the plurality of conductive materials.

6 . The resonant converter as claimed in claim 5 , wherein the plurality of wirings are arranged on the first layer in a first extension direction, and the plurality of wirings are arranged on the second layer in a second extension direction.

7 . The resonant converter as claimed in claim 6 , wherein the wirings on different layers form an acute angle with the conductive materials as the center, and the acute angle is between 25 degrees and 35 degrees.

8 . The resonant converter as claimed in claim 4 , further comprising:
an electrical wiring configured to electrically connect the first via and the second via so that the power component electrically connected to the modular winding through the electrical wiring.

9 . The resonant converter as claimed in claim 1 , wherein the primary-side circuit comprises:
two modular windings respectively embedded in in any one of the sub-layer boards of the first circuit board and the second circuit board, and each of the two modular windings comprising an inductor wiring, a second conductive column disposed between the first circuit board and the second circuit board, and electrically connected to the two modular wirings to form an inductor winding, and a third via formed on the first circuit board or the second circuit board, and configured to electrically connect the two modular windings to the primary-side circuit.

10 . A resonant converter comprising:
a first circuit board and a second circuit board respectively comprising a plurality of sub-layer boards, a primary-side circuit disposed on the first circuit board, two secondary-side circuits respectively disposed on the first circuit board and the second circuit board, and the two secondary-side circuits respectively comprising a first switch, a second switch, and an output capacitor, and the output capacitor electrically connected to the first switch and the second switch, and a planar transformer disposed on the first circuit board and the second circuit board, and electrically connected to the first switch, the second switch, and the output capacitor of the first circuit board and the second circuit board, and the planar transformer comprising: a first circuit board through hole penetrating the first circuit board, a second circuit board through hole penetrating the second circuit board, an iron core comprising a first core column penetrating the first circuit board through hole and the second circuit board through hole, a primary-side wiring formed on the first circuit board and the second circuit board, two secondary-side wirings respectively formed on the first circuit board and the second circuit board, and respectively formed around the first circuit board through hole and the second circuit board through hole; wherein two first terminals of the two secondary-side wirings respectively electrically connected to the first switches of the first circuit board and the second circuit board, and two second terminals of the two secondary-side wirings respectively electrically connected to the se

Assignees

• Delta Electronics Inc

Inventors

• Chang Yi-Sheng
• Hsu Cheng-Chan
• Lai Chien-An

Classifications

• H05K7/2089

  for power electronics, e.g. for inverters for controlling motor · CPC title

• H02M1/0048

  Circuits or arrangements for reducing losses (using snubbers H02M1/34) · CPC title

• H02M3/33573

  Full-bridge at primary side of an isolation transformer · CPC title

• H02M3/33571

  Half-bridge at primary side of an isolation transformer · CPC title

• H02M3/01 Primary

  Resonant DC/DC converters · CPC title