This application claims priority to Chinese Patent Application No. 202311289844.8, filed on Sep. 28, 2023, which is hereby incorporated by reference in its entirety.
This application relates to the field of power electronics technologies, and in particular, to a PFC circuit, a PFC apparatus, a power module, and an integrated inductor.
With gradual application of a third generation wide-bandgap semiconductor power device, a switch-mode power supply develops towards higher power density, a higher switching frequency, and ultra-high efficiency. The switch-mode power supply may include a power factor correction (PFC) circuit. The PFC circuit can improve a ratio of effective power to apparent power of an alternating current input to the switch-mode power supply, increase a power factor, and reduce harmonic content. When a power device in the switch-mode power supply works, a switching frequency is high. This easily causes high-speed voltage and current changes, and serious common-mode noise is generated through distributed capacitance (also referred to as parasitic capacitance) of a system to the ground. This deteriorates performance of the switch-mode power supply. Therefore, a measure needs to be taken to suppress the common-mode noise.
A method for suppressing common-mode noise is to insert a common-mode filter network between an input alternating current power supply and a power device. However, when a large common-mode inductance is required in the common-mode filter network, it is difficult to design a common-mode inductor because a printed circuit board (PCB) has a limited area.
This application provides a PFC circuit, a PFC apparatus, a power module, and an integrated inductor, to reduce an occupied board area while suppressing common-mode noise of the PFC circuit.
According to a first aspect, this application provides a power factor correction PFC circuit, including S first bridge arms, a second bridge arm, a voltage stabilization capacitor, and an integrated inductor. The S first bridge arms, the second bridge arm, and the voltage stabilization capacitor are connected in parallel. The integrated inductor includes a magnetic core, S first windings, and S second windings. First ends of the S first windings are all configured to connect to a first end of an alternating current power supply, and second ends of the S first windings are respectively connected to midpoints of the S first bridge arms. The S second windings form a balancing unit. A first end of the balancing unit is configured to connect to a second end of the alternating current power supply, and a second end of the balancing unit is connected to a midpoint of the second bridge arm. S may be an integer greater than or equal to 1. The magnetic core in the integrated inductor includes M+1 first magnetic yokes sequentially arranged in parallel. The S first windings and the S second windings are disposed in spaces formed by any two adjacent first magnetic yokes of the M+1 first magnetic yokes. Two adjacent first magnetic yokes corresponding to a space in which the S first windings are located are the same, and two adjacent first magnetic yokes corresponding to a space in which the S second windings are located are the same. In addition, one of the two adjacent first magnetic yokes corresponding to the space in which the S first windings are located is different from the two adjacent first magnetic yokes corresponding to the space in which the S second windings are located, and M may be an integer greater than or equal to 2. In other words, the space in which the S first windings are located is different from the space in which the S second windings are located.
In this application, when the PFC circuit is mounted on a printed circuit board PCB, a 1st first magnetic yoke of the M+1 first magnetic yokes in the integrated inductor is configured to connect to the PCB, and the M+1 first magnetic yokes are arranged in parallel along a direction. The direction is perpendicular to a surface that is of the PCB and on which the PFC circuit is mounted, and the S first windings and the S second windings in the integrated inductor are respectively located in the spaces formed by the two groups of two adjacent first magnetic yokes. In this way, when the S first windings and the S second windings in the integrated inductor are all connected to the PFC circuit of the foregoing structure, positions occupied by the S first windings on the PCB overlap positions occupied by the S second windings on the PCB. An area occupied by the integrated inductor on the PCB is approximately equal to an area of the 1st first magnetic yoke. In comparison with S discrete first inductors and S discrete second inductors directly disposed in the PFC circuit, the S first windings and the S second windings in this application can reduce a board area occupied by the PFC circuit, reduce material costs, and improve product power density.
With reference to the first aspect, in a feasible implementation, each of the S first bridge arms includes two high-frequency switches connected in series. Each of the second bridge arm includes two low-frequency switches connected in series. A switching frequency of the high-frequency switch is greater than a frequency of the alternating current power supply, and a switching frequency of the low-frequency switch is equal to the frequency of the alternating current power supply. Herein, each high-frequency switch and each low-frequency switch may be an IGBT, a MOSFET, gallium nitride (GaN), silicon carbide (SIC), or the like. In this application, each inductor (for example, the S first windings), the voltage stabilization capacitor, each high-frequency switch, and each low-frequency switch in the PFC circuit work together, so that distortion of a current waveform can be improved, a phase difference between a voltage and a current can be reduced, and a power factor can be increased.
According to a second aspect, this application further provides a power factor correction PFC circuit, including a rectifier unit, S PFC branches, a filter capacitor, and an integrated inductor. The integrated inductor includes a magnetic core, S first windings, and S second windings. Herein, S may be an integer greater than or equal to 1. Each of the S PFC branches includes one first winding in the S first windings, a diode, and a first switch. The diode and the first switch in each PFC branch are connected in series and then connected in parallel to the filter capacitor. A first end of the first winding in each PFC branch is connected to a first output end of the rectifier unit, and a second end of the first winding in each PFC branch is connected to a point at which the diode and the first switch in the PFC branch are connected in series. The S second windings form a balancing unit. A first end of the balancing unit is connected to a second output end of the rectifier unit, and a second end of the balancing unit is connected to a point at which the filter capacitor and the first switch are connected. The magnetic core in the integrated inductor includes M+1 first magnetic yokes sequentially arranged in parallel. The S first windings and the S second windings are disposed in spaces formed by any two adjacent first magnetic yokes of the M+1 first magnetic yokes. Two adjacent first magnetic yokes corresponding to a space in which the S first windings are located are the same, and two adjacent first magnetic yokes corresponding to a space in which the S second windings are located are the same. In addition, one of the two adjacent first magnetic yokes corresponding to the space in which the S first windings are located is different from the two adjacent first magnetic yokes corresponding to the space in which the S second windings are located, and M may be an integer greater than or equal to 2. In other words, the space in which the S first windings are located is different from the space in which the S second windings are located.
In this application, when the PFC circuit is mounted on a printed circuit board PCB, a 1st first magnetic yoke of the M+1 first magnetic yokes in the integrated inductor is configured to connect to the PCB, and the M+1 first magnetic yokes are arranged in parallel along a direction. The direction is perpendicular to a surface that is of the PCB and on which the PFC circuit is mounted, and the S first windings and the S second windings in the integrated inductor are respectively located in the spaces formed by the two groups of two adjacent first magnetic yokes. In this way, when the S first windings and the S second windings in the integrated inductor are all connected to the PFC circuit of the foregoing structure, positions occupied by the S first windings on the PCB overlap positions occupied by the S second windings on the PCB. An area occupied by the integrated inductor on the PCB is approximately equal to an area of the 1st first magnetic yoke. In comparison with S discrete first inductors and S discrete second inductors directly disposed in the PFC circuit, the S first windings and the S second windings in this application can reduce a board area occupied by the PFC circuit, reduce material costs, and improve product power density.
With reference to the first aspect or the second aspect, in a feasible implementation, when S is greater than or equal to 2, the balancing unit includes the S second windings that are sequentially connected in series. In this way, the balancing unit formed by the S second windings may be considered as a total inductor, and a proper impedance may be provided for the PFC circuit, so that common-mode noise of the PFC circuit is reduced, and EMI is optimized.
With reference to the first aspect or the second aspect, in a feasible implementation, inductances of the S first windings are the same, and inductances of the S second windings are the same. One of the S first windings corresponds to one phase in the PFC circuit. The S first windings with a same inductance and the S second windings with a same inductance are disposed, so that common-mode noise of the PFC circuit can be suppressed, and EMI can be optimized.
With reference to the first aspect or the second aspect, in a feasible implementation, M is greater than or equal to 3, and the integrated inductor further includes S third windings. Two adjacent first magnetic yokes corresponding to a space in which the S third windings are located are the same. One of the two adjacent first magnetic yokes corresponding to the space in which the S third windings are located is different from the two adjacent first magnetic yokes corresponding to the space in which the S first windings are located. One of the two adjacent first magnetic yokes corresponding to the space in which the S third windings are located is different from the two adjacent first magnetic yokes corresponding to the space in which the S second windings are located. A quantity of turns of the third winding meets any one of the following: The quantity of turns of the third winding is different from a quantity of turns of the first winding; the quantity of turns of the third winding is different from a quantity of turns of the second winding; and the quantity of turns of the third winding is different from the quantity of turns of the first winding and the quantity of turns of the second winding. In this way, the third winding may be used as a backup winding. When the inductance of the first winding is inappropriate, the third winding with a more appropriate inductance may be used to replace the first winding, and the third winding is connected to the PFC circuit, to suppress common-mode noise of the PFC circuit. Alternatively, when the inductance of the second winding is inappropriate, the third winding with a more appropriate inductance may be used to replace the second winding, and the third winding is connected to the PFC circuit, to suppress common-mode noise of the PFC circuit.
With reference to the first aspect or the second aspect, in a feasible implementation, the magnetic core further includes M*N magnetic cylinders and P second magnetic yokes arranged in parallel, where N is an integer greater than or equal to S, P is an integer greater than or equal to 1, and a difference between N and P is less than or equal to 1.
The P second magnetic yokes are all perpendicular to the M+1 first magnetic yokes, and are disposed between the 1st first magnetic yoke and a last first magnetic yoke of the M+1 first magnetic yokes. Each of the P second magnetic yokes is in communication with the 1st first magnetic yoke and the last first magnetic yoke.
N magnetic cylinders are disposed in a layer of space formed by any two adjacent first magnetic yokes of the M+1 first magnetic yokes, and each of the N magnetic cylinders in each layer of space is in contact with two adjacent first magnetic yokes corresponding to the layer of space. The N magnetic cylinders in each layer of space are all parallel to the P second magnetic yokes, and the N magnetic cylinders in each layer of space and the P second magnetic yokes are alternately arranged.
One winding is disposed on each of the M*N magnetic cylinders.
In this application, magnetic fluxes generated by windings disposed on two adjacent magnetic cylinders in a same layer of space cancel on a second magnetic yoke between the two magnetic cylinders. Therefore, currents in windings on magnetic cylinders in a same layer of space do not affect each other, and windings on different magnetic cylinders in the same layer of space are not coupled. Magnetic fluxes generated by two windings respectively located in an upper layer of space and a lower layer of space of a same first magnetic yoke cancel on the first magnetic yoke. Therefore, the two windings respectively located in the upper layer of space and the lower layer of space of the same first magnetic yoke are not coupled. This can simplify circuit control logic. In addition, effect of connecting the two groups of windings in the integrated inductor in the PFC circuit is same as effect of disposing two groups of discrete inductors in the PFC circuit. A board area occupied by the PFC circuit can be reduced, and common-mode noise of the PFC circuit can be suppressed.
According to a third aspect, this application further provides a power factor correction PFC apparatus, including a printed circuit board and the PFC circuit according to the first aspect, any possible implementation of the first aspect, the second aspect, or any implementation of the second aspect. The PFC circuit is connected to the printed circuit board. The M+1 first magnetic yokes in the integrated inductor are arranged in parallel along a first direction, the first direction is perpendicular to a first surface of the printed circuit board, the M+1 first magnetic yokes are all parallel to the first surface, and the first surface is used for mounting the PFC circuit.
According to a fourth aspect, this application further provides a power module, including a direct current DC/DC converter and the PFC circuit according to the first aspect, any possible implementation of the first aspect, the second aspect, or any implementation of the second aspect. An output end of the PFC circuit is connected to an input end of the DC/DC converter.
The DC/DC converter is configured to perform DC/DC conversion based on a direct current voltage provided by the PFC circuit.
In this application, an apparatus like a PFC apparatus or the power module includes the PFC circuit. The PFC circuit includes an integrated inductor. The integrated inductor may provide two groups of windings connected to the PFC circuit to suppress common-mode noise of the PFC circuit. The integrated inductor includes M+1 first magnetic yokes arranged in parallel, the two groups of windings are respectively located in spaces formed by two groups of two adjacent first magnetic yokes, and positions occupied by the two groups of windings on the PCB connected to the PFC circuit overlap. Therefore, a board area occupied by the PFC circuit can be reduced. The PFC circuit is used in the apparatus like the power module and the PFC apparatus, so that common-mode noise can be suppressed, product energy density can be improved, EMI can be optimized, and working efficiency can be improved.
According to a fifth aspect, this application further provides an integrated inductor, including a magnetic core and M*N windings. The magnetic core includes M+1 first magnetic yokes, P second magnetic yokes, and M*N magnetic cylinders. M is an integer greater than or equal to 2, both N and P are integers greater than or equal to 1, and a difference between N and P is less than or equal to 1.
The M+1 first magnetic yokes are sequentially arranged in parallel. The P second magnetic yokes are all perpendicular to the M+1 first magnetic yokes, and are arranged in parallel between a 1st first magnetic yoke and a last first magnetic yoke of the M+1 first magnetic yokes. Each of the P second magnetic yokes is in communication with the 1st first magnetic yoke and the last first magnetic yoke.
N magnetic cylinders are disposed in a layer of space formed by any two adjacent first magnetic yokes of the M+1 first magnetic yokes, and each of the N magnetic cylinders in each layer of space is in contact with two adjacent first magnetic yokes corresponding to the layer of space. The N magnetic cylinders in each layer of space are all parallel to the P second magnetic yokes, and the N magnetic cylinders in each layer of space and the P second magnetic yokes are alternately arranged.
The M*N windings are respectively disposed on the M*N magnetic cylinders.
With reference to the fifth aspect, in a feasible implementation, N is an integer greater than or equal to 2, and N is greater than P.
The N magnetic cylinders in each layer of space and the P second magnetic yokes are alternately arranged, so that any two adjacent magnetic cylinders in the N magnetic cylinders in each layer of space are spaced apart by one of the P second magnetic yokes.
With reference to the fifth aspect, in a feasible implementation, N is an integer greater than or equal to 1, and Nis equal to P.
With reference to the fifth aspect, in a feasible implementation, N is an integer greater than or equal to 1, and N is less than P.
The N magnetic cylinders in each layer of space and the P second magnetic yokes are alternately arranged, so that any two adjacent second magnetic yokes in the P second magnetic yokes are spaced apart by one of the N magnetic cylinders in each layer of space.
With reference to the fifth aspect, in a feasible implementation, the 1st first magnetic yoke of the M+1 first magnetic yokes is configured to connect to the printed circuit board.
In this application, two groups of windings are integrated into a same integrated inductor, the two groups of windings are disposed in two different layers of spaces in the integrated inductor, and an arrangement direction of the two layers of spaces is perpendicular to a surface that is of a PCB and on which the integrated inductor is mounted. This can reduce a board area occupied by the integrated inductor, and reduce a space and costs. In addition, the integrated inductor is connected to a PFC circuit to suppress common-mode noise of the PFC circuit. This helps optimize EMI and improve product power density.
A PFC circuit provided in this application may be widely applied to various power supply products, such as a DC/DC conversion power supply in a photovoltaic scenario, a power supply used by a communication base station, a data center power supply, and a high-power industrial power supply.
When the PFC circuit is applied to various power supply products, the PFC circuit needs to be connected to a printed circuit board PCB. Therefore, this application further provides a PFC apparatus. The PFC apparatus includes a PFC circuit and a PCB. When the PFC circuit works, common-mode noise is easily generated, and electromagnetic interference (EMI) exists. Currently, the common-mode noise may be suppressed by adding a common-mode inductor to the PFC circuit. However, in this case, the PFC circuit occupies a large board area, and both common-mode noise suppression and product energy density improvement cannot be implemented. In the PFC apparatus provided in this application, the PFC circuit mounted on the PCB includes an integrated inductor. The integrated inductor includes M+1 first magnetic yokes sequentially arranged in parallel, and the M+1 first magnetic yokes are arranged in parallel along a first direction. The first direction is perpendicular to a first surface of the printed circuit board. Herein, the M+1 first magnetic yokes are all parallel to the first surface, and the first surface is used for mounting the PFC circuit. M is an integer greater than or equal to 2. In this way, the PFC circuit including the integrated inductor is mounted on the PCB, and the integrated inductor provides two groups of windings connected to the PFC circuit, so that the common-mode noise of the PFC circuit can be suppressed. In addition, the two groups of windings provided by the integrated inductor are respectively located in spaces formed by two groups of two adjacent first magnetic yokes, and positions occupied by the two groups of windings on the PCB overlap. Therefore, an area occupied by the integrated inductor on the PCB is basically an area of a surface that is of a first magnetic yoke and that is parallel to the PCB. In this way, in comparison with two groups of discrete inductors disposed in the PFC circuit, the two groups of windings in this application can greatly reduce a board area occupied by the PFC circuit, thereby implementing both common-mode noise suppression and product energy density improvement.
The following describes the PFC circuit provided in embodiments of this application by using examples with reference to
In the PFC circuit, the magnetic core of the integrated inductor includes M+1 first magnetic yokes sequentially arranged in parallel. Herein, M may be an integer greater than or equal to 2. The S first windings and the S second windings are disposed in spaces formed by any two adjacent first magnetic yokes of the M+1 first magnetic yokes. Two adjacent first magnetic yokes corresponding to a space in which the S first windings are located are the same, and two adjacent first magnetic yokes corresponding to a space in which the S second windings are located are the same. In addition, one of the two adjacent first magnetic yokes corresponding to the space in which the S first windings are located is different from the two adjacent first magnetic yokes corresponding to the space in which the S second windings are located. For example, when the M+1 first magnetic yokes include a magnetic yoke A, a magnetic yoke B, and a magnetic yoke C, the S first windings may be disposed in a space formed by the magnetic yoke A and the magnetic yoke B, and the S second windings may be disposed in a space formed by the magnetic yoke B and the magnetic yoke C. For another example, when the M+1 first magnetic yokes include a magnetic yoke A, a magnetic yoke B, a magnetic yoke C, and a magnetic yoke D, the S first windings may be disposed in a space formed by the magnetic yoke A and the magnetic yoke B, and the S second windings may be disposed in a space formed by the magnetic yoke C and the magnetic yoke D.
When the PFC circuit is mounted on a printed circuit board PCB, a 1st first magnetic yoke of the M+1 first magnetic yokes in the integrated inductor is configured to connect to the PCB, and the M+1 first magnetic yokes are arranged in parallel along a first direction. The first direction is perpendicular to a first surface of the PCB, and the first surface is a surface used by the PCB for mounting the PFC circuit. In this case, when the S first windings and the S second windings in the integrated inductor are all connected to the PFC circuit shown in
In some feasible implementations, when S is greater than or equal to 2, the balancing unit includes the S second windings that are sequentially connected in series. In this case, in the PFC circuit shown in
In some feasible implementations, inductances of the S first windings are the same, and inductances of the S second windings are the same. As shown in
The following specifically describes a principle of suppressing common-mode noise by adding a balancing unit in the PFC circuit.
In the PFC circuit, a first capacitor exists between a midpoint of the first bridge arm and a reference ground. The first capacitor may actually include a Y capacitor, a parasitic capacitor, and the like. That is, the first capacitor may be an equivalent capacitor. A second capacitor exists between a midpoint of the second bridge arm and the reference ground. The second capacitor may actually include a Y capacitor, a parasitic capacitor, and the like. That is, the second capacitor may also be an equivalent capacitor. The first capacitor may be represented by Cd, and the second capacitor may be represented by Cb.
It can be learned from circuit analysis that the S first windings, the S second windings, S first capacitors, and the second capacitor in the PFC circuit may form a Wheatstone bridge. When the Wheatstone bridge is balanced, common-mode noise of the PFC circuit is not transmitted outside the PFC circuit, so that the common-mode noise of the PFC circuit can be effectively reduced, and EMI can be optimized. S may be an integer greater than or equal to 1. For different values of S, equations for Wheatstone bridge equilibria are different. Therefore, cases in which values of S are 2, 3, and 1 are described as examples respectively. When S is 2, the PFC circuit includes two first bridge arms and one second bridge arm, and an integrated inductor includes two first windings and two second windings. In this case, the PFC circuit is a two-phase interleaved bridgeless PFC circuit. A structure of the PFC circuit is shown in
In the PFC circuit, impedances of the four bridge arms of the Wheatstone bridge and the first winding, the second winding, the first capacitor, and the second capacitor in the PFC circuit meet the following relationship (2):
When Sis 3, the PFC circuit includes three first bridge arms and one second bridge arm, and the integrated inductor includes three first windings and three second windings. In this case, the PFC circuit is a three-phase interleaved bridgeless PFC circuit. A structure of the PFC circuit is shown in
In the PFC circuit, the impedances of the four bridge arms of the Wheatstone bridge and the first winding, the second winding, the first capacitor, and the second capacitor in the PFC circuit meet the following relationship (3):
When S is 1, the PFC circuit includes one first bridge arm and one second bridge arm, and the integrated inductor includes one first winding and one second winding. In this case, the PFC circuit is a non-interleaved bridgeless PFC circuit. A structure of the PFC circuit is shown in
In the PFC circuit, the impedances of the four bridge arms of the Wheatstone bridge and the first winding, the second winding, the first capacitor, and the second capacitor in the PFC circuit meet the following relationship (4):
In this application, a balancing unit formed by the second winding is added to the PFC circuit including the first winding, that is, two groups of inductors with proper inductance values are disposed in the PFC circuit, so that a Wheatstone bridge equivalent to the PFC circuit is balanced, the common-mode noise of the PFC circuit can be suppressed, and EMI can be optimized.
In some feasible implementations, when M is greater than or equal to 3, the integrated inductor in the PFC circuit may further include S third windings. Two adjacent first magnetic yokes corresponding to a space in which the S third windings are located are the same, one of the two adjacent first magnetic yokes corresponding to the space in which the S third windings are located is different from two adjacent first magnetic yokes corresponding to a space in which the S first windings are located. In addition, one of the two adjacent first magnetic yokes corresponding to the space in which the S third windings are located is different from two adjacent first magnetic yokes corresponding to a space in which the S second windings are located. In this case, the S first windings, the S second windings, and the S third windings are respectively located in different spaces. For example, when the M+1 first magnetic yokes include a magnetic yoke A, a magnetic yoke B, a magnetic yoke C, and a magnetic yoke D, the S first windings may be located in a space formed by the magnetic yoke A and the magnetic yoke B, the S second windings may be located in a space formed by the magnetic yoke B and the magnetic yoke C, and the S third windings may be located in a space formed by the magnetic yoke C and the magnetic yoke D. Herein, inductances of the S third windings may be the same. Further, a quantity of turns of the third winding meets any one of the following: The quantity of turns of the third winding is different from a quantity of turns of the first winding; the quantity of turns of the third winding is different from a quantity of turns of the second winding; and the quantity of turns of the third winding is different from the quantity of turns of the first winding and the quantity of turns of the second winding. In this way, the third winding may be used as a backup winding. When an inductance of the first winding is inappropriate, the third winding with a more appropriate inductance may be used to replace the first winding, and the third winding is connected to the PFC circuit, to suppress common-mode noise of the PFC circuit. Alternatively, when an inductance of the second winding is inappropriate, the third winding with a more appropriate inductance may be used to replace the second winding, and the third winding is connected to the PFC circuit, to suppress common-mode noise of the PFC circuit.
Optionally, the integrated inductor may further include S fourth windings, where M is greater than or equal to 4. The fourth windings, the third windings, the first windings, and the second windings are respectively located in different spaces. Similar to the third winding, the fourth winding may also be used as a backup winding. When inductances of the first winding and the second winding are inappropriate, the third winding and the fourth winding with more appropriate inductances may be used to replace the first winding and the second winding, and the third winding and the fourth winding are connected to the PFC circuit, to reduce the common-mode noise of the PFC circuit. It should be noted that the third winding and the fourth winding are merely examples, and windings used as backup windings in the integrated inductor may further include a fifth winding, a sixth winding, and . . . , which may be specifically determined based on factors such as an actual scenario requirement and costs. A quantity of backup windings is not limited in this application.
In this application, at least three groups of windings in different spaces are disposed in the integrated inductor, to provide a backup winding for the PFC circuit. When an element parameter in the PFC circuit changes, two groups of windings with proper inductance values can be provided to connect to the PFC circuit. In this way, the Wheatstone bridge equivalent to the PFC circuit can be balanced, the common-mode noise in the PFC circuit can be suppressed, and the EMI can be optimized. In addition, when a plurality of groups of windings are disposed in the integrated inductor, a board area occupied by the PFC circuit is not increased. In comparison with a plurality of groups of discrete inductors, the plurality of groups of windings can greatly reduce the occupied board area, and improve product power density.
In some feasible implementations, a magnetic core of the integrated inductor may further include M*N magnetic cylinders and P second magnetic yokes arranged in parallel, where N is an integer greater than or equal to S, P is an integer greater than or equal to 1, and a difference between N and P is less than or equal to 1. Herein, N may be greater than P by 1, N is equal to P, or N is less than P by 1. The P second magnetic yokes are all perpendicular to the M+1 first magnetic yokes, and are disposed between a 1st first magnetic yoke and a last first magnetic yoke of the M+1 first magnetic yokes. Each of the P second magnetic yokes is in communication with the 1st first magnetic yoke and the last first magnetic yoke. Herein, when the second magnetic yoke is in communication with the first magnetic yoke, magnetic induction lines generated by a winding may be transmitted from the second magnetic yoke to the first magnetic yoke in communication with the second magnetic yoke, or the magnetic induction lines are transmitted from the first magnetic yoke to the second magnetic yoke in communication with the first magnetic yoke, to create a condition for forming a closed loop for a transmission path of the magnetic induction lines of the winding.
N magnetic cylinders are disposed in a layer of space formed by any two adjacent first magnetic yokes of the M+1 first magnetic yokes in the integrated inductor, and each of the N magnetic cylinders in each layer of space is in contact with two adjacent first magnetic yokes corresponding to the layer of space. Herein, the magnetic cylinder is in contact with two adjacent first magnetic yokes, and may provide a transmission path for magnetic induction lines generated by a winding disposed on the magnetic cylinder, so that the magnetic induction lines can be transmitted in a closed loop. The N magnetic cylinders in each layer of space are all parallel to the P second magnetic yokes, and the N magnetic cylinders in each layer of space and the P second magnetic yokes are alternately arranged. One winding is disposed on each of the M*N magnetic cylinders. Herein, magnetic induction lines generated by a winding disposed on any magnetic cylinder in each layer of space pass through a second magnetic yoke adjacent to the magnetic cylinder, and do not pass through another magnetic cylinder in the layer of space. Magnetic fluxes generated by windings disposed on two adjacent magnetic cylinders in a same layer of space cancel on a second magnetic yoke between the two magnetic cylinders. Therefore, currents in windings on magnetic cylinders in a same layer of space do not affect each other, and windings on different magnetic cylinders in the same layer of space are not coupled. For example, a first winding L11 and a first winding L12 in the S first windings are not coupled, and a second winding L21 and a second winding L22 in the S second windings are not coupled. In this way, circuit control logic can be simplified. In addition, magnetic fluxes generated by two windings respectively located in an upper layer of space and a lower layer of space of a same first magnetic yoke cancel on the first magnetic yoke. Therefore, the two windings respectively located in the upper layer of space and the lower layer of space of the same first magnetic yoke are not coupled. For example, when S is 2, the first winding L11 is not coupled to the second winding L21, and the first winding L12 is not coupled to the second winding L22. This can simplify circuit control logic. In this application, effect of connecting the two groups of windings in the integrated inductor in the PFC circuit is same as effect of disposing two groups of discrete inductors in the PFC circuit. A board area occupied by the PFC circuit can be reduced, and the common-mode noise of the PFC circuit can be suppressed.
According to a value relationship between the quantity P of the second magnetic yokes and the quantity N of the magnetic cylinders in a same layer of space, the integrated inductor may include the following types of structures.
(a) N is greater than P by 1, and N is an integer greater than or equal to 2. In this case, the N magnetic cylinders in each layer of space and the P second magnetic yokes are alternately arranged, so that any two adjacent magnetic cylinders in the N magnetic cylinders may be spaced apart by one of the P second magnetic yokes.
(b) N is equal to P, and Nis an integer greater than or equal to 1. In this case, the N magnetic cylinders in each layer of space and the P second magnetic yokes are alternately arranged.
(c) N is less than P by 1, and Nis an integer greater than or equal to 1. In this case, the N magnetic cylinders in each layer of space and the P second magnetic yokes are alternately arranged, so that any two adjacent second magnetic yokes of the P second magnetic yokes may be spaced apart by one of the N magnetic cylinders.
When second magnetic yokes are respectively added to the left of the winding L11 and the left of the winding L21, or second magnetic yokes are respectively added to the right of the winding L12 and the right of the winding L22, N is 2, and P is also 2. In this case, the foregoing case (b) is met. When second magnetic yokes are respectively added to the left of the winding L11 and the left of the winding L21, and second magnetic yokes are respectively added to the right of the winding L12 and the right of the winding L22, N is 2, and P is 3. In this case, the foregoing case (c) is met.
It should be noted that an example in which an arrangement direction of the S first magnetic yokes is a vertical direction is used in
In this application, two groups of inductors are disposed in the PFC circuit, so that a Wheatstone bridge equivalent to the PFC circuit is balanced, and common-mode noise of the PFC circuit can be suppressed. The two groups of inductors may be two groups of windings in an integrated inductor, and the two groups of windings are respectively located in spaces formed by two groups of first magnetic yokes in the integrated inductor, so that a board area occupied by the integrated inductor is smaller than a board area occupied by two groups of normal discrete inductors. In this way, an occupied board area and costs can be reduced while common-mode noise of the PFC circuit is suppressed, and product power density can be improved.
In the PFC circuit, the magnetic core of the integrated inductor includes M+1 first magnetic yokes sequentially arranged in parallel. Herein, M may be an integer greater than or equal to 2. The S first windings and the S second windings are disposed in spaces formed by any two adjacent first magnetic yokes of the M+1 first magnetic yokes. Two adjacent first magnetic yokes corresponding to a space in which the S first windings are located are the same, and two adjacent first magnetic yokes corresponding to a space in which the S second windings are located are the same. In addition, one of the two adjacent first magnetic yokes corresponding to the space in which the S first windings are located is different from the two adjacent first magnetic yokes corresponding to the space in which the S second windings are located. In this case, the first windings and the second windings are respectively located in different spaces.
When the PFC circuit is mounted on a printed circuit board PCB, a 1st first magnetic yoke of the M+1 first magnetic yokes in the integrated inductor is configured to connect to the PCB, and the M+1 first magnetic yokes are arranged in parallel along a first direction. The first direction is perpendicular to a first surface of the PCB, and the first surface is a surface used by the PCB for mounting the PFC circuit. In this case, when the S first windings and the S second windings in the integrated inductor are all connected to the PFC circuit shown in
In some feasible implementations, when S is greater than or equal to 2, the balancing unit includes the S second windings that are sequentially connected in series. In this case, in the PFC circuit shown in
In some feasible implementations, inductances of S first windings are the same, and inductances of S second windings are the same. As shown in
The following specifically describes a principle of suppressing the common-mode noise by adding a balancing unit in the PFC circuit.
In the PFC circuit, a first capacitor exists between a second end of a first winding in each of the S first PFC branches and a reference ground. The first capacitor may actually include a Y capacitor, a parasitic capacitor, and the like. That is, the first capacitor may be an equivalent capacitor. A second capacitor exists between a second end of the balancing unit and the reference ground. The second capacitor may actually include a Y capacitor, a parasitic capacitor, and the like. That is, the second capacitor may also be an equivalent capacitor. Herein, the first capacitor may be represented by Cd, and the second capacitor may be represented by Cb.
It can be learned from circuit analysis that the S first windings, the S second windings, S first capacitors, and the second capacitor in the PFC circuit may form a Wheatstone bridge. When the Wheatstone bridge is balanced, the common-mode noise of the PFC circuit is not transmitted outside the PFC circuit, so that the common-mode noise of the PFC circuit can be effectively reduced, and EMC can be optimized. S may be an integer greater than or equal to 1. For different values of S, equations for Wheatstone bridge equilibria are different. Therefore, cases in which values of S are 2, 3, and 1 are described as examples respectively.
When Sis 2, the PFC circuit includes two PFC branches, and an integrated inductor includes two first windings and two second windings. In this case, the PFC circuit is a two-phase bridge PFC circuit. A structure of the PFC circuit is shown in
When S is 3, the PFC circuit includes three PFC branches, and the integrated inductor includes three first windings and three second windings. In this case, the PFC circuit is a three-phase bridge PFC circuit. In a Wheatstone bridge equivalently obtained by the PFC circuit, when impedances Z1, Z2, Z3, and Z4 of four bridge arms of the Wheatstone bridge meet the foregoing relationship (1), the Wheatstone bridge is balanced, and the PFC circuit has the minimum common-mode noise. In the PFC circuit, the impedances of the four bridge arms of the Wheatstone bridge and the first winding, the second winding, the first capacitor, and the second capacitor in the PFC circuit meet the foregoing relationship (3).
When S is 1, the PFC circuit includes one PFC branch, and the integrated inductor includes one first winding and one second winding. In this case, the PFC circuit is a single-phase bridge PFC circuit. In a Wheatstone bridge equivalently obtained by the PFC circuit, when impedances Z1, Z2, Z3, and Z4 of four bridge arms of the Wheatstone bridge meet the foregoing proportional relationship (1), the Wheatstone bridge is balanced, and the PFC circuit has the minimum common-mode noise. In the PFC circuit, the impedances of the four bridge arms of the Wheatstone bridge and the first winding, the second winding, the first capacitor, and the second capacitor in the PFC circuit meet the foregoing relationship (4).
In this application, a balancing unit formed by the second winding is added to the PFC circuit including the first winding, that is, two groups of inductors with proper inductance values are disposed in the PFC circuit, so that the Wheatstone bridge equivalent to the PFC circuit is balanced, the common-mode noise of the PFC circuit can be suppressed, and the EMI can be optimized.
In some feasible implementations, M is greater than or equal to 3, and the integrated inductor further includes S third windings. Two adjacent first magnetic yokes corresponding to a space in which the S third windings are located are the same, one of the two adjacent first magnetic yokes corresponding to the space in which the S third windings are located is different from two adjacent first magnetic yokes corresponding to a space in which the S first windings are located. In addition, one of the two adjacent first magnetic yokes corresponding to the space in which the S third windings are located is different from two adjacent first magnetic yokes corresponding to a space in which the S second windings are located. In this case, the S first windings, the S second windings, and the S third windings are respectively located in different spaces. Further, a quantity of turns of the third winding meets any one of the following: The quantity of turns of the third winding is different from a quantity of turns of the first winding; the quantity of turns of the third winding is different from a quantity of turns of the second winding; and the quantity of turns of the third winding is different from the quantity of turns of the first winding and the quantity of turns of the second winding. In this way, the third winding may be used as a backup winding. When the inductance of the first winding is inappropriate, the third winding with a more appropriate inductance may be used to replace the first winding, and the third winding is connected to the PFC circuit, to reduce the common-mode noise of the PFC circuit. Alternatively, when the inductance of the second winding is inappropriate, the third winding with a more appropriate inductance may be used to replace the second winding, and the third winding is connected to the PFC circuit, to reduce the common-mode noise of the PFC circuit.
It should be noted that the third winding is merely an example, and the backup winding in the integrated inductor may further include a fourth winding, a fifth winding, and . . . , which may be specifically determined based on factors such as an actual scenario requirement and costs. A quantity of backup windings is not limited in this application.
In this application, at least three groups of windings in different spaces are disposed in the integrated inductor, to provide a backup winding for the PFC circuit. In this case, when an element parameter in the PFC circuit changes, two groups of windings with proper inductance values can be provided to connect to the PFC circuit. In this way, the Wheatstone bridge equivalent to the PFC circuit can be balanced, the common-mode noise in the PFC circuit can be suppressed, and the EMI can be optimized. In addition, when a plurality of groups of windings are disposed in the integrated inductor, a board area an area occupied by the PFC circuit is not increased. In comparison with a plurality of groups of discrete inductors, the plurality of groups of windings can greatly reduce the occupied board area, and improve product power density.
In some feasible implementations, a magnetic core further includes M*N magnetic cylinders and P second magnetic yokes arranged in parallel, where N is an integer greater than or equal to S, P is an integer greater than or equal to 1, and a difference between N and P is less than or equal to 1. Herein, N may be greater than P by 1, N is equal to P, or Nis less than P by 1. The P second magnetic yokes are all perpendicular to M+1 first magnetic yokes, and are disposed between a 1st first magnetic yoke and a last first magnetic yoke of the M+1 first magnetic yokes. Each of the P second magnetic yokes is in communication with the 1st first magnetic yoke and the last first magnetic yoke. Herein, when the second magnetic yoke is in communication with the first magnetic yoke, there may be no air gap at a place where the second magnetic yoke and the first magnetic yoke are in contact.
N magnetic cylinders are disposed in a layer of space formed by any two adjacent first magnetic yokes of the M+1 first magnetic yokes in the integrated inductor, and each of the N magnetic cylinders in each layer of space is in contact with two adjacent first magnetic yokes corresponding to the layer of space. Herein, the magnetic cylinder is in contact with two adjacent first magnetic yokes, and may provide a transmission path for magnetic induction lines generated by a winding disposed on the magnetic cylinder, so that the magnetic induction lines can be transmitted in a closed loop. The N magnetic cylinders in each layer of space are all parallel to the P second magnetic yokes, and the N magnetic cylinders in each layer of space and the P second magnetic yokes are alternately arranged. One winding is disposed on each of the M*N magnetic cylinders. Herein, magnetic induction lines generated by a winding disposed on any magnetic cylinder in each layer of space pass through a second magnetic yoke adjacent to the magnetic cylinder, and do not pass through another magnetic cylinder in the layer of space. Magnetic fluxes generated by windings disposed on two adjacent magnetic cylinders in a same layer of space cancel on a second magnetic yoke between the two magnetic cylinders. Therefore, currents in windings on magnetic cylinders in a same layer of space do not affect each other, and windings on different magnetic cylinders in the same layer of space are not coupled. This can simplify circuit control logic. In addition, magnetic fluxes generated by two windings respectively located in an upper layer of space and a lower layer of space of a same first magnetic yoke cancel on the first magnetic yoke. Therefore, the two windings respectively located in the upper layer of space and the lower layer of space of the same first magnetic yoke are not coupled. This can simplify the circuit control logic. In this application, effect of connecting the two groups of windings in the integrated inductor in the PFC circuit is same as effect of disposing two groups of discrete inductors in the PFC circuit. A board area occupied by the PFC circuit can be reduced, and common-mode noise of the PFC circuit can be suppressed.
According to a value relationship between the quantity P of the second magnetic yokes and the quantity N of magnetic cylinders in a same layer of space, structures of the integrated inductor may include three cases (a), (b), and (c) mentioned above.
When second magnetic yokes are respectively added to the left of the winding L11 and the left of the winding L21, or second magnetic yokes are respectively added to the right of the winding L12 and the right of the winding L22, N is 2, and P is also 2. In this case, the foregoing case (b) is met. When second magnetic yokes are respectively added to the left of the winding L11 and the left of the winding L21, and second magnetic yokes are respectively added to the right of the winding L12 and the right of the winding L22, N is 2, and P is 3. In this case, the foregoing case (c) is met.
It should be noted that an example in which an arrangement direction of S first magnetic yokes is a vertical direction is used in
In this application, two groups of inductors are disposed in the PFC circuit, so that a Wheatstone bridge equivalent to the PFC circuit is balanced, and common-mode noise of the PFC circuit can be suppressed. The two groups of inductors may be two groups of windings in an integrated inductor, and the two groups of windings are respectively located in spaces formed by two groups of first magnetic yokes in the integrated inductor, so that a board area occupied by the integrated inductor is smaller than a board area occupied by two groups of normal discrete inductors. In this way, an occupied board area and costs can be reduced while common-mode noise of the PFC circuit is suppressed, and product power density can be improved.
This application further provides an integrated inductor. The integrated inductor may include a magnetic core and M*N windings. The magnetic core includes M+1 first magnetic yokes, P second magnetic yokes, and M*N magnetic cylinders. M is an integer greater than or equal to 2, both N and P are integers greater than or equal to 1, and a difference between N and P is less than or equal to 1. The M+1 first magnetic yokes in the integrated inductor are sequentially arranged in parallel. The P second magnetic yokes are all perpendicular to the M+1 first magnetic yokes, and are arranged in parallel between a 1st first magnetic yoke and a last first magnetic yoke in the M+1 first magnetic yokes. In addition, each of the P second magnetic yokes is in communication with the 1st first magnetic yoke and the last first magnetic yoke. Herein, when the second magnetic yoke is in communication with the first magnetic yoke, magnetic induction lines generated by a winding may be transmitted from the second magnetic yoke to the first magnetic yoke in communication with the second magnetic yoke, or the magnetic induction lines are transmitted from the first magnetic yoke to the second magnetic yoke in communication with the first magnetic yoke, to create a condition for forming a closed loop for a transmission path of the magnetic induction lines of the winding.
N magnetic cylinders are disposed in a layer of space formed by any two adjacent first magnetic yokes of the M+1 first magnetic yokes in the integrated inductor, and each of the N magnetic cylinders in each layer of space is in contact with two adjacent first magnetic yokes corresponding to the layer of space. Herein, that the magnetic cylinder is in contact with the first magnetic yoke means that magnetic induction lines generated by a winding can be transmitted from a magnetic cylinder corresponding to the winding to a first magnetic yoke in contact with the magnetic cylinder. Actually, the magnetic cylinder may be bonded to the first magnetic yoke to implement contact with the first magnetic yoke; or the magnetic cylinder may be in contact with the first magnetic yoke in another manner, for example, the magnetic cylinder and the first magnetic yoke are integrally formed. This is not limited in this application. The N magnetic cylinders in each layer of space are all parallel to the P second magnetic yokes, and the N magnetic cylinders in each layer of space and the P second magnetic yokes are alternately arranged. The M*N windings included in the integrated inductor are respectively disposed on the M*N magnetic cylinders. Herein, magnetic induction lines generated by a winding disposed on any magnetic cylinder in each layer of space pass through a second magnetic yoke adjacent to the magnetic cylinder, and do not pass through another magnetic cylinder in the layer of space. Magnetic fluxes generated by windings disposed on two adjacent magnetic cylinders in a same layer of space cancel on a second magnetic yoke between the two magnetic cylinders. Therefore, currents in windings on magnetic cylinders in a same layer of space do not affect each other, and windings on different magnetic cylinders in the same layer of space are not coupled. In addition, magnetic fluxes generated by two windings respectively located in an upper layer of space and a lower layer of space of a same first magnetic yoke cancel on the first magnetic yoke. Therefore, the two windings respectively located in the upper layer of space and the lower layer of space of the same first magnetic yoke are not coupled. This can simplify the circuit control logic.
In some feasible implementations, the 1st first magnetic yoke of the M+1 first magnetic yokes is configured to connect to a printed circuit board PCB. When the integrated inductor is mounted on the PCB, the M+1 first magnetic yokes in the integrated inductor are arranged in parallel along a first direction, the first direction is perpendicular to a first surface of the PCB, and the first surface is a surface used by the PCB for mounting the integrated inductor. In this way, when the integrated inductor is mounted on the PCB board and is connected to the PFC circuit shown in
In this embodiment of this application, that the difference between N and P is less than or equal to 1 means that an absolute value of the difference between N and P is 0 or 1, which may specifically include the following cases: N is greater than P by 1, N is equal to P, and Nis less than P by 1. The following describes a structure of the integrated inductor in detail based on values of N and P.
(a) N is greater than P by 1, and N is an integer greater than or equal to 2. In the integrated inductor, the N magnetic cylinders in each layer of space and the P second magnetic yokes are alternately arranged, so that any two adjacent magnetic cylinders in the N magnetic cylinders in each layer of space are spaced apart by one of the P second magnetic yokes. A quantity of magnetic cylinders in each layer of space is greater than a quantity of second magnetic yokes by 1.
For example, the M+1 first magnetic yokes are sequentially arranged along a vertical direction. When N is 2 and P is 1, a structure of the integrated inductor may be shown in
For example, the M+1 first magnetic yokes are sequentially arranged along the vertical direction. When N is 3 and P is 2, a structure of the integrated inductor may be shown in
(b) N is equal to P, and N is an integer greater than or equal to 1. In the integrated inductor, the N magnetic cylinders in each layer of space and the P second magnetic yokes are alternately arranged, and the quantity of magnetic cylinders in each layer of space is equal to the quantity of second magnetic yokes.
For example, the M+1 first magnetic yokes are sequentially arranged along the vertical direction. When N is 1 and P is 1, a structure of the integrated inductor may be shown in
For example, the M+1 first magnetic yokes are sequentially arranged along the vertical direction. When N is 2 and P is 2, a structure of the integrated inductor may be shown in
(c) N is less than P by 1, and N is an integer greater than or equal to 1. In the integrated inductor, the N magnetic cylinders in each layer of space and the P second magnetic yokes are alternately arranged, so that any two adjacent second magnetic yokes in the P second magnetic yokes are spaced apart by one of the N magnetic cylinders in each layer of space. The quantity of magnetic cylinders in each layer of space is less than the quantity of second magnetic yokes by 1.
For example, the M+1 first magnetic yokes are sequentially arranged along the vertical direction. When N is 1 and P is 2, a structure of the integrated inductor may be shown in
For example, the M+1 first magnetic yokes are sequentially arranged along the vertical direction. When N is 2 and P is 3, a structure of the integrated inductor may be shown in
It should be noted that M may be 2, or may be an integer greater than 2. When M is 2, windings in an upper layer of space and a lower layer of space have different inductances, and may be respectively used as a first winding and a second winding. The first winding and the second winding are connected to components in the PFC circuit, so that common-mode noise of the PFC circuit is reduced, and a PCB area occupied by the PFC circuit is reduced. When M is greater than 2, windings in two layers of spaces that meet a requirement in the M layers of spaces of the integrated inductor may be selected as a first winding and a second winding respectively, and are used in the PFC circuit. Windings in other layers of spaces of the integrated inductor may provide redundancy, to provide a plurality of windings with optional inductances when a parameter of the PFC circuit changes. This meets requirements of the PFC circuit in different application scenarios.
Optionally, the M+1 first magnetic yokes may be sequentially arranged along a horizontal direction or another direction. When the M+1 first magnetic yokes are sequentially arranged along the horizontal direction, a structure of the integrated inductor may adaptively change. This is not limited in this application.
In the integrated inductor, there may be an air gap between any magnetic cylinder and two first magnetic yokes adjacent to the magnetic cylinder, and there may be one or more air gaps. In
In this application, two groups of windings are integrated into a same integrated inductor, the two groups of windings are disposed in two different layers of spaces in the integrated inductor, and an arrangement direction of the two layers of spaces is perpendicular to a surface that is of the PCB and on which the integrated inductor is mounted. This can reduce a board area occupied by the integrated inductor, and reduce a space and costs. In addition, the integrated inductor is connected to the PFC circuit to suppress common-mode noise of the PFC circuit. This helps optimize EMI and improve product power density.
Number | Date | Country | Kind |
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202311289844.8 | Sep 2023 | CN | national |