Disclosed herein is an improved flyback converter that separates the magnetic components of the converter into a transformer and a separate, discrete energy storage inductor. This arrangement can improve the operating efficiency of the converter by reducing the commutation losses as compared to a conventional flyback converter. The magnetic components may be constructed on separate magnetic cores or may be constructed on magnetic cores having at least one common element, thereby allowing for at least partial magnetic flux cancellation in a portion of the core, reducing core losses.

Disclosed is a nonlinear inductor, a manufacturing method thereof, and a nonlinear inductor row. The nonlinear inductor includes two magnetic core assemblies, a conductor and a magnetic plastic encapsulation layer; the magnetic core assemblies include magnetic cores; each magnetic core includes a flange and a central column arranged on the flange; two central columns of the two magnetic core assemblies are opposite to each other; a non-uniform air gap exists between the two central columns and/or the magnetic core assemblies are made of different materials; the conductor is arranged on the two central columns; the two magnetic core assemblies and the conductor are located in the magnetic plastic encapsulation layer; electrode parts of the conductor are exposed outside the magnetic plastic encapsulation layer; and the magnetic core assemblies and the magnetic plastic encapsulation layer are made of different materials; thereby the nonlinear inductor has stepped saturation characteristics.

Systems and methods for improving winding losses in transformers. In one aspect, a transformer includes a first magnetic core having a first portion in contact with a second magnetic core and a second portion separated from the second magnetic core by a distance d, a plurality of primary windings formed around the second portion, a first secondary winding forming a first layer having a first inner diameter, a second secondary winding forming an n.sup.th layer having a second inner diameter. The plurality of primary windings are positioned between the first layer and the n.sup.th layer, where the plurality of primary windings, and the first secondary winding and the second secondary winding are formed around the second portion, and a difference between the first inner diameter and the second inner diameter defines a distance y, and a ratio of distance y to distance d is between 0.01 to 10.

A transformer for a power converter, comprising: a first auxiliary subcore, a central subcore, and a second auxiliary subcore, each respective subcore comprising a lower plate, at least one pair of central spacers, and an upper plate, the lower plate, at least one pair of central spacers, and the upper plate of each subcore, being respectively separated by a gap; the first auxiliary subcore and the central subcore being separated by a gap; the second auxiliary subcore and the central subcore being separated by a gap; a primary coil, encircling a first spacer of the first auxiliary subcore and a first spacer of the central subcore; and a secondary coil, encircling a second spacer of the second auxiliary subcore and a second spacer of the central subcore.

There are provided a wire wound inductor and a manufacturing method thereof according to an exemplary embodiment in the present disclosure. The wire wound inductor according to an exemplary embodiment in the present disclosure includes a winding coil, a magnetic core embedding the winding coil, and an adhesive portion disposed between the magnetic core and the winding coil and enclosing the winding coil.

A coil device includes a bobbin including a hollow cylindrical portion and first and second flanges disposed at ends of the hollow cylindrical portion, and having a first partition located between the first and second flange and a second partition located between the first partition and second flange; the first winding wound around the outer periphery of the hollow cylindrical portion between first partition and the first flange; the second winding wound around the outer peripheral surface of the hollow cylindrical portion between the first partition and the second flange, and wound around both sides of the second partition according to a predetermined position. The coil device can wind the winding wire of the second winding at a predetermined position, thereby reinforcing the secondary side magnetic coupling while controlling or reducing the leakage inductance manufacturing error between the primary and secondary side due to difference in the secondary side winding.

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.

A thin film inductor is disclosed, which includes a thin film magnetic core. The thin film magnetic core includes at least one magnetic thin film. In each magnetic thin film, at least one type-1 gap is provided. A length direction of the type-1 gap is parallel to a direction of hard magnetization of the magnetic thin film. If the thin film magnetic core comprises at least two magnetic thin films, the at least two magnetic thin films are laminated and overlap each other. A sum of widths of all type-1 gaps in each magnetic thin film is the same.

A thin film inductor is disclosed, which includes a thin film magnetic core. The thin film magnetic core includes at least one magnetic thin film. In each magnetic thin film, at least one type-1 gap is provided. A length direction of the type-1 gap is parallel to a direction of hard magnetization of the magnetic thin film. If the thin film magnetic core comprises at least two magnetic thin films, the at least two magnetic thin films are laminated and overlap each other. A sum of widths of all type-1 gaps in each magnetic thin film is the same.

A power conversion system and a magnetic component thereof are provided. The magnetic component includes a magnetic core assembly, two windings and an air gap. The magnetic core assembly includes two substrates, four winding pillars and an auxiliary pillar unit. The four winding pillars and the auxiliary pillar unit are located between the two substrates. A connecting line of centers of the winding pillars forms a quadrangle which has a first diagonal line and a second diagonal line. One winding is wound around two winding pillars on the first diagonal line, and magnetic fluxes on these two winding pillars have the same direction and amount. The other winding is wound around the other two winding pillars located on the second diagonal line, and magnetic fluxes on these two winding pillars have the same direction and amount. The directions of the magnetic fluxes on the two neighboring winding pillars are opposite.