Integrated magnetic component and converter using the same

Patent metadata

Field	Value
Publication number	US-9667151-B2
Application number	US-201414483168-A
Country	US
Kind code	B2
Filing date	Sep 11, 2014
Priority date	Dec 4, 2013
Publication date	May 30, 2017
Grant date	May 30, 2017

Abstract

An integrated magnetic component includes a magnetic core and a plurality of windings. The magnetic core includes at least four magnetic columns. The windings include a primary winding, a first secondary winding, a second secondary winding, and an inductor winding. The primary winding, the first secondary winding and the second secondary winding are wound on one of the magnetic columns. The inductor winding is wound on another magnetic column, and the inductor winding is coupled to the connection where the first secondary winding and the second secondary winding couple to each other. By integrating a transformer and a filter inductor into the integrated magnetic component, the number of the magnetic components, the overall volume, and the weight may be reduced while the mechanical properties may be promoted and the loss of the component connections may be reduced.

First claim

What is claimed is:

1. An integrated magnetic component, comprising:
a magnetic core having a first magnetic column, a second magnetic column, a third magnetic column, and a fourth magnetic column arranged in sequence; and
a plurality of windings, which are wound on the magnetic core, wherein the plurality of windings comprise a primary winding, a first secondary winding, a second secondary winding, and an inductor winding, wherein:
the primary winding, the first secondary winding and the second secondary winding are wound only on the second magnetic column, and the first secondary winding is coupled to the second secondary winding; and
the inductor winding is wound only on the third magnetic column, and an end of the inductor winding is coupled to a connection where the first secondary winding and the second secondary winding couple to each other.

2. The integrated magnetic component of claim 1 , wherein the first secondary winding, the second secondary winding, and the inductor winding are formed into an integrated winding.

3. The integrated magnetic component of claim 2 , wherein the integrated winding is made of a metal plate.

4. The integrated magnetic component of claim 2 , wherein the integrated winding comprises two through holes, in which one of the through holes is for assembling the second magnetic column, and another one of the through holes is for assembling the third magnetic column.

5. The integrated magnetic component of claim 1 , wherein the primary winding further comprises a bobbin and a coil which is wound on the bobbin.

6. The integrated magnetic component of claim 5 , wherein the bobbin, the first secondary winding and the second secondary winding are positioned on the second magnetic column.

7. The integrated magnetic component of claim 1 , wherein each of the first secondary winding and the second secondary winding comprises an outlet end and a connecting end, wherein an end of the inductor winding is coupled to the connecting end of the first secondary winding and the connecting end of the second secondary winding, wherein the connecting ends of the first secondary winding and the second secondary winding are not at the same side where the outlet ends of the first secondary winding and the second secondary winding are positioned.

8. The integrated magnetic component of claim 1 , wherein the magnetic columns further comprise a fifth magnetic column.

9. The integrated magnetic component of claim 1 , wherein the second magnetic column or the third magnetic column comprises an air gap.

10. The integrated magnetic component of claim 1 , wherein the magnetic core further comprises an upper magnetic cover and a lower magnetic cover, wherein the upper magnetic cover, the lower magnetic cover, and the first, second, third and fourth magnetic columns form a closed magnetic circuit.

11. The integrated magnetic component of claim 1 , wherein both the first secondary winding and the second secondary winding are single-turn windings, and the inductor winding is a double-turn winding.

12. A full-wave rectifier converter, comprising a primary switch unit, a secondary rectifying unit, a filter element and an integrated magnetic component which couples the primary switch unit and the secondary rectifying unit, wherein the integrated magnetic component receives an AC signal from the primary switch unit, wherein the integrated magnetic component comprises a magnetic core and a plurality of windings, wherein the magnetic core comprises a first magnetic column, a second magnetic column, a third magnetic column, and a fourth magnetic column arranged in sequence, and the windings are wound on the magnetic core, and the windings comprise a primary winding, a first secondary winding, a second secondary winding and an inductor winding, wherein:
the primary winding, the first secondary winding, and the second secondary winding are wound only on the second magnetic column, wherein the first secondary winding is coupled to the second secondary winding; and
the inductor winding is wound only on the third magnetic column, wherein an end of the inductor winding is coupled to a connection where the first secondary winding and the second secondary winding couple to each other.

13. The full-wave rectifier converter of claim 12 , wherein the first secondary winding, the second secondary winding, and the inductor winding are formed into an integrated winding.

14. The full-wave rectifier converter of claim 13 , wherein the integrated winding is made of a metal plate.

15. The full-wave rectifier converter of claim 13 , wherein the integrated winding comprises two through holes, in which one of the through holes is for assembling the second magnetic column, and another one of the through holes is for assembling the third magnetic column.

16. The full-wave rectifier converter of claim 12 , wherein the primary winding further comprises a bobbin and a coil which is wound on the bobbin.

17. The full-wave rectifier converter of claim 16 , wherein the bobbin, the first secondary winding and the second secondary winding are positioned on the second magnetic column.

18. The full-wave rectifier converter of claim 12 , wherein each of the first secondary winding and the second secondary winding comprises an outlet end and a connecting end, wherein an end of the inductor winding is coupled to the connecting end of the first secondary winding and the connecting end of the second secondary winding, wherein the connecting ends of the first secondary winding and the second secondary winding are not at the same side where the outlet ends of the first secondary winding and the second secondary winding are positioned.

19. The full-wave rectifier converter of claim 12 , wherein the magnetic columns further comprise a fifth magnetic column.

20. The full-wave rectifier converter of claim 12 , wherein the second magnetic column or the third magnetic column comprises an air gap.

21. The full-wave rectifier converter of claim 12 , wherein the magnetic core further comprises an upper magnetic cover and a lower magnetic cover, wherein the upper magnetic cover, the lower magnetic cover, and the first second, third, and fourth magnetic columns form a closed magnetic circuit.

22. The full-wave rectifier converter of claim 12 , wherein both the first secondary winding and the second secondary winding are single-turn windings, and the inductor winding is a double-turn winding.

23. The full-wave rectifier converter of claim 12 , wherein the primary winding of the integrated magnetic component is coupled to the primary switch unit, and the first secondary winding and the second secondary winding of the integrated magnetic component are coupled to the secondary rectifying unit, wherein an end of the inductor winding of the integrated magnetic component is coupled to the connection where the first secondary winding and the second secondary winding couple to each other, and another end of the inductor winding of the integrated magnetic component is coupled to the filter element.

24. The full-wave rectifier converter of claim 12 , wherein the primary switch unit is a full-bridge converter, a half-bridge converter or a push-pull converter.

25. The full-wave rectifier converter of claim 12 , wherein the secondary rectifying unit comprises a plurality of diodes or a plurality of synchronous rectifiers.

26. The full-wave rectifier converter of claim 12 , wherein

Assignees

• Delta Electronics Shanghai Co

Inventors

• Lu Zeng-Yi
• Yang hai-jun
• Zhang Jin-Fa

Classifications

• H01F27/38 Primary

  Auxiliary core members; Auxiliary coils or windings · CPC title

• H02M3/28

  using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate AC · CPC title

• H02M2001/0064

  Electricity · mapped topic

• H01F27/2866

  Combination of wires and sheets · CPC title

• H01F27/40

  Structural association with built-in electric component, e.g. fuse · CPC title