# US 2018/0323720 A1 · Integrated magnetic component and power converter

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- Number: US 2018/0323720 A1
- Document ID: US20180323720A1
- Status: Published application
- Kind: A1
- Application number: 15/973,139
- Filed: 2018-05-07
- Published: 2018-11-08
- Earliest claimed: 2017-05-08
- Assignees: Delta Electronics (Thailand) Public Co., Ltd.
- Applicants: Delta Electronics (Thailand) Public Co., Ltd.
- Inventors: Hugues Douglas Njiende; Osman Erinc; Daniel Ruff
- Web page: https://patentgrep.com/patent/US20180323720A1

## CPC

- H01F 3/14: Constrictions; Gaps, e.g. air-gaps (in magnetic shunt paths H01F3/12)
- H01F 27/24: Magnetic cores
- H01F 27/2823: {Wires (H01F27/2866 takes precedence)}
- H01F 27/38: Auxiliary core members; Auxiliary coils or windings
- H02M 3/01: {Resonant DC/DC converters}
- H02M 3/285: {Single converters with a plurality of output stages connected in parallel (parallel operation of a plurality of converters in DC distribution networks H02J1/10)}
- H02M 3/33573: {Full-bridge at primary side of an isolation transformer}
- H02M 1/0058: {by employing soft switching techniques, i.e. commutation of transistors when applied voltage is zero or when current flow is zero (using an auxiliary actively switched resonant commutation circuit connected to an intermediate DC voltage or between two push-pull branches of an inverter bridge H02M7/4811; in resonant inverters H02M7/4815; in inverters operating from a resonant DC source H02M7/4826)}
- H02M 1/0064: {Magnetic structures combining different functions, e.g. storage, filtering or transformation}
- Y02B 70/10: Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes
- H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H02M: APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF (transformers H01F; dynamo-electric converters H02K47/00; controlling transformers, reactors or choke coils, control or regulation of electric motors, generators or dynamo-electric converters H02P)
- Y02B: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS

## Abstract

The invention relates to an integrated magnetic component (802) for a power converter including N>=2 LLC converters configured for interleaved operation. The integrated magnetic component (802) includes a first yoke and a second yoke and for each LLC converter a winding carrying leg which comprises a primary winding (820c) and a secondary winding (821c), wherein the primary winding (820c) and the secondary winding (821c) are wound on the respective winding carrying leg. The integrated magnetic component (802) further includes one or more return legs. Herein the winding carrying legs and the one or more return legs are arranged side by side, each leg being magnetically connected to both yokes and the winding carrying legs include a transformer air gap (819) whereas the at least one return leg is air gap free and at least one return leg is arranged between two winding carrying legs. The invention further relates to a power converter including a switching converter stage (811a, 811b, 811c), a rectifier stage (813a, 813b, 813c) and a resonant stage, the resonant stage including N>=2 parallel LLC converters.

## Claims

### Claim 1

1) Integrated magnetic component for a power converter including N>=2 LLC converters configured for interleaved operation, said integrated magnetic component includes
a) a first yoke and a second yoke,
b) for each LLC converter, a winding carrying leg comprising a primary winding and a secondary winding, the primary winding and the secondary winding being wound on the respective winding carrying leg,
c) the integrated magnetic component further includes one or more return legs,
d) wherein the winding carrying legs and the one or more return legs are arranged side by side, each leg being magnetically connected to both yokes, and wherein the winding carrying legs include a transformer air gap whereas the at least one return leg is air gap free wherein
e) at least one return leg is arranged between two winding carrying legs.

### Claim 2 (depends on 1)

2) Integrated magnetic component according to claim 1, comprising N−1 return legs where the winding carrying legs and the return legs are arranged side by side alternatingly.

### Claim 3 (depends on 1)

3) Integrated magnetic component according to claim 1, wherein the integrated magnetic component is formed by a plurality of stacked core elements, wherein the stacked core elements are either multi-leg core elements or I-cores.

### Claim 4 (depends on 1)

4) Integrated magnetic component according to claim 1, wherein the primary winding and the secondary winding on each winding carrying leg are spatially distanced from each other, to generate a flux leakage path, defining a series inductance of a series inductor of the respective LLC converter.

### Claim 5 (depends on 1)

5) Integrated magnetic component according to claim 1, which further comprises
a) a third yoke arranged between the first and the second yoke dividing each winding carrying leg in a transformer section and a first choke section,
b) the first choke section of each winding carrying leg comprising a first choke air gap and a first choke winding for defining a first series inductance of a first series inductor of a LLC converter,
c) the transformer section comprising the transformer air gap and the primary and the secondary winding.

### Claim 6 (depends on 5)

6) Integrated magnetic component according to claim 5, wherein the integrated magnetic component is formed by a plurality of stacked core elements, and wherein the plurality of stacked core elements comprises three multi-leg core elements or two multi-leg core elements and one I-core.

### Claim 7 (depends on 5)

7) Integrated magnetic component according to claim 5, wherein the integrated magnetic component further comprises
a) a fourth yoke dividing each transformer section in a second choke section and a sub-transformer section,
b) the second choke section of each winding carrying leg comprising a second choke air gap and a second choke winding for defining a second series inductance of a second series inductor of a LLC converter,
c) the sub-transformer section comprising the transformer air gap and the primary and the secondary winding.

### Claim 8 (depends on 7)

8) Integrated magnetic component according to claim 7, wherein the integrated magnetic component is formed by a plurality of stacked core elements, and wherein the plurality of stacked core elements comprises four multi-leg core elements or three multi-leg core elements and one I-core.

### Claim 9 (depends on 5)

9) Integrated magnetic component according to claim 5, wherein the first choke winding of an LLC converter and the primary winding of the same LLC converter are realized with a single wire, the winding of said first choke winding and the winding of said primary winding being connected in series by said single wire.

### Claim 10 (depends on 5)

10) Integrated magnetic component according to claim 5 wherein the first choke winding of an LLC converter is wound on a winding carrying leg different from the winding carrying leg, where the primary winding and the secondary winding of the same LLC converter are wound, the winding of said first choke winding and the winding of said primary winding being connected in series.

### Claim 11 (depends on 3)

11) Integrated magnetic component according to claim 3, wherein N=2.

### Claim 12 (depends on 11)

12) The integrated magnetic component according to claim 11, wherein the multi-leg core elements are E-cores.

### Claim 13 (depends on 3)

13) Integrated magnetic component according to claim 3, wherein N=3.

### Claim 14 (depends on 3)

14) Integrated magnetic component according to claim 3, wherein the transformer air gap of the winding carrying leg is arranged between a leg of a core element and a flange of a core element or between two legs of core elements which are abutting each other with their legs.

### Claim 15 (depends on 1)

15) Integrated magnetic component according to claim 1, wherein the primary windings are split in a first primary winding part and a second primary winding part.

### Claim 16 (depends on 1)

16) Power converter including a switching converter stage, a rectifier stage and a resonant stage, the resonant stage including N>=2 parallel LLC converters wherein a transformer, a parallel inductor and a series inductor of the LLC converters are formed by an integrated magnetic component according to claim 1.

### Claim 17 (depends on 14)

17) Power converter according to claim 14, wherein N=2.

### Claim 18 (depends on 14)

18) Power converter according to claim 14 wherein N=3.