CN212850244U - Power supply module - Google Patents

Abstract

The utility model provides a power supply module, which comprises a circuit substrate; a magnetic element disposed on a first side of the circuit substrate; the magnetic element comprises a magnetic core and a winding, the magnetic core comprises an upper cover plate, a lower cover plate and two winding posts, and the upper cover plate and the lower cover plate are connected with the two winding posts to form a magnetic circuit; the winding comprises a plurality of connecting pins, the connecting pins are fixed and electrically connected with the circuit substrate, and the winding is wound on the winding post and at least partially exposed out of the magnetic core; the rectifying unit comprises a plurality of switching tubes, the switching tubes are arranged on the first side and/or the second side of the circuit substrate, and the switching tubes are arranged adjacent to the connecting pins of the corresponding windings; and the filter circuit comprises a plurality of filter capacitors and is arranged on the first side and/or the second side of the circuit substrate. The winding is exposed to the air, so that heat dissipation is facilitated; and the connecting pin, the switch tube and the filter capacitor of the winding are arranged close to each other, so that the loop path is reduced to the maximum extent, the line loss is reduced, and the power density is improved.

Description

Power supply module

Technical Field

The present disclosure relates to a power module, and more particularly, to a high power density rectifier power module.

Background

Miniaturization and high power density have become trends in server power supplies. For example, the front stage of the server power supply generally needs to adopt a Totem pole PFC, the rear stage adopts an LLC resonant conversion circuit, and the heating elements thereof mainly include various switching tubes and magnetic elements, and the heat generation is particularly significant under a high-power working condition. The switching tube can be used for heat dissipation by means of a radiator, and under the condition of high power, the winding of the magnetic element generates heat seriously, so that the difficulty of heat dissipation is caused. On the other hand, how to realize modularization and improve power density are also design difficulties.

The existing magnetic core generally adopts a magnetic element with side columns, and although the side column magnetic core is beneficial to improving the efficiency of the magnetic element, the winding generates heat seriously due to the blocking of the side column magnetic core. And with the frequency of the converter being increased, the volume of the magnetic element is reduced, so that the heat dissipation is extremely difficult, and even the circuit cannot work normally. In addition, the existing design has long rectifying path and large line loss, which is not beneficial to improving the efficiency and power density of the power supply. And the rectifying circuit contains many components and parts, if the layout is unreasonable, the rectifying effect can be influenced, and meanwhile, the occupied space is larger, which is not beneficial to realizing the miniaturization and high power density of the power module. Therefore, how the magnetic element is connected to the rectifying circuit, the length of the ac loop, and the layout of the rectifying device have a great influence on the performance of the server power supply.

SUMMERY OF THE UTILITY MODEL

In view of the above, an object of the present disclosure is to provide a power module, which integrates a magnetic element, a switching tube and a filter circuit on the same circuit substrate, thereby saving space, minimizing a path of a rectifying circuit, reducing loss, facilitating heat dissipation, improving rectifying efficiency, and realizing miniaturization and high power density of a power supply.

To achieve the above objective, the present disclosure provides a power module, which includes a circuit substrate, a magnetic element, at least one rectifying unit, and a filter circuit. The circuit substrate comprises a first side and an opposite second side; the magnetic element is arranged on the first side of the circuit substrate; the magnetic element comprises a magnetic core and a winding, the magnetic core comprises an upper cover plate, a lower cover plate and two winding posts, and the upper cover plate and the lower cover plate are connected with the two winding posts to form a magnetic circuit; the winding comprises a plurality of connecting pins, and the connecting pins are fixed and electrically connected with the circuit substrate; the winding is wound on the winding post and at least partially exposed out of the magnetic core; the rectifying unit comprises a plurality of switching tubes, the switching tubes are arranged on the first side and/or the second side of the circuit substrate, and the switching tubes are arranged adjacent to the connecting pins of the corresponding windings; and the filter circuit comprises a plurality of filter capacitors and is arranged on the first side and/or the second side of the circuit substrate.

In some embodiments, the magnetic element is a transformer including a primary winding and a secondary winding.

In some embodiments, the rectifying unit is a full bridge circuit connected to the secondary winding.

In some embodiments, the full bridge circuit comprises two bridge arms, each bridge arm comprises an upper bridge arm and a lower bridge arm which are connected in series, the upper bridge arm comprises a plurality of switching tubes which are connected in parallel, and the lower bridge arm comprises a plurality of switching tubes which are connected in parallel.

In some embodiments, the secondary winding is a center-tapped winding, and the rectification unit is a full-wave rectification circuit connected to the secondary winding.

In some embodiments, the full-wave rectification circuit comprises a first branch circuit and a second branch circuit, wherein the first branch circuit comprises a plurality of parallel-connected switching tubes, and the second branch circuit comprises a plurality of parallel-connected switching tubes.

In some embodiments, the magnetic element is a coupled inductor comprising a first winding and a second winding.

In some embodiments, the rectifying unit is a full bridge circuit.

In some embodiments, the full bridge circuit comprises a first bridge arm and a second bridge arm, each bridge arm comprises two switching tubes connected in series; the middle point of the first bridge arm is electrically connected with the first end of the power grid through the first winding, and the middle point of the second bridge arm is electrically connected with the second end of the power grid through the second winding.

In some embodiments, the full bridge circuit comprises three bridge arms, each bridge arm comprising two switching tubes connected in series; the middle points of the two bridge arms are respectively and electrically connected with the first end of the power grid through the corresponding windings in the first winding and the second winding, and the middle point of the remaining bridge arm is electrically connected with the second end of the power grid.

In some embodiments, the switching tubes are disposed on the upper and lower sides of the connection pins, respectively.

In some embodiments, at least a portion of the filter capacitors are disposed proximate the upper and lower edges of the circuit substrate.

In some embodiments, the magnetic element is provided with a positioning plate, and the positioning plate is attached to the circuit substrate; the positioning plate is provided with a positioning hole, and the connecting pin of the winding penetrates through the positioning hole and then is fixed and electrically connected with the circuit substrate.

In some embodiments, the magnetic element further comprises a skeleton, the skeleton is sleeved on the winding post, and the winding is wound on the skeleton; the framework is provided with a positioning piece which is clamped in the positioning hole of the positioning plate.

In some embodiments, the frame and the positioning plate are fixed by dispensing.

In some embodiments, the magnetic core comprises a first magnetic core and a second magnetic core spliced with each other, and the first magnetic core and the second magnetic core are both U-shaped; or the first magnetic core and the second magnetic core are respectively in a U shape and an I shape.

In some embodiments, the magnetic core further comprises two side legs disposed between the upper cover plate and the lower cover plate; wherein, the axis that two side posts are located is perpendicular with the axis that two wrapping posts are located.

In some embodiments, the winding is litz wire.

In some embodiments, the circuit substrate is vertically disposed on the main board; the lower edge of the circuit substrate is provided with a lead terminal, and the lead terminal is inserted on the mainboard and electrically connected with the mainboard.

In some embodiments, the lower cover plate of the magnetic element is flush with the lower edge of the circuit substrate.

In some embodiments, the two primary windings include at least two primary connection pins, and the primary connection pins are electrically connected to the motherboard.

In some embodiments, the winding is formed by winding multiple wires in parallel.

The winding of the magnetic element in the utility model is wound on the winding post and exposed in the air, which is beneficial to heat dissipation in the environment with high power density; the positions of a connecting pin of a winding of the magnetic element, the switch tube and the filter capacitor are arranged in a close manner, so that the path of a rectification loop is reduced to the maximum extent, and the line loss is reduced; the circuit structures are approximately distributed in a bilateral symmetry manner, which is beneficial to natural current sharing; furthermore, the circuit substrate is vertically inserted on the mainboard, and the three-dimensional layout is adopted, so that the space is saved and the power density is improved compared with the planar layout.

Drawings

Fig. 1-2 are perspective views of power modules at different viewing angles according to an embodiment of the present invention.

Fig. 3 is an exploded view of a magnetic element according to an embodiment of the present invention.

Fig. 4 is a schematic circuit diagram of a power module according to a first embodiment of the present invention.

Fig. 5 is a schematic structural diagram of a power module corresponding to the circuit in fig. 4.

Fig. 6 is a schematic structural diagram of a power module according to an embodiment of the present invention

Fig. 7 is a schematic circuit diagram of a power module according to a second embodiment of the present invention.

Fig. 8 is a schematic circuit diagram of a power module according to a third embodiment of the present invention.

Fig. 9 is a schematic circuit diagram of a power module according to a fourth embodiment of the present invention.

Fig. 10 is a schematic circuit diagram of a power module according to a fifth embodiment of the present invention.

Fig. 11 is a schematic structural diagram of a power module corresponding to the circuit in fig. 10.

Fig. 12 is a schematic circuit diagram of a power module according to a sixth embodiment of the present invention.

Fig. 13 is a schematic structural diagram of a power module corresponding to the circuit in fig. 12.

Fig. 14 is a schematic structural diagram of a magnetic element according to an embodiment of the present invention.

Fig. 15 is a schematic view illustrating an installation of the magnetic element and the circuit board according to an embodiment of the present invention.

List of reference numerals

1: power supply module

10: circuit board

10 a: first side of circuit substrate

10 b: second side of the circuit substrate

101: lead terminal

11: magnetic element

110: magnetic core

110 a: first magnetic core

110 b: second magnetic core

111: winding wire

1101: upper cover plate

1102: lower cover plate

1103: wrapping post

1104: side column

1110: connecting pin

113: positioning plate

1130: locating hole

114: framework

1140: locating piece

20: rectifying unit

21: first rectifying unit

22: second rectifying unit

SW11-SW14, SW21-SW 24: switch tube

30: filter circuit

301: filter capacitor

Detailed Description

Some exemplary embodiments that incorporate the features and advantages of the present disclosure will be described in detail in the specification which follows. It is to be understood that the disclosure is capable of various modifications in various embodiments without departing from the scope of the disclosure, and that the description and drawings are to be regarded as illustrative in nature, and not as restrictive.

Fig. 1-2 are structural perspective views of different viewing angles of a power module according to an embodiment of the present invention, fig. 3 is an exploded view of a magnetic element according to an embodiment of the present invention, and fig. 4 is a circuit schematic diagram of a power module according to a first embodiment of the present invention. As shown in fig. 1 to 4, the power module 1 includes: the circuit board comprises a circuit substrate 10, at least one magnetic element 11 and at least one rectifying unit. Wherein the circuit substrate 10 comprises a first side 10a and an opposite second side 10 b; the magnetic element 11 is disposed on the first side 10a of the circuit substrate 10 and includes a magnetic core 110 and a winding 111. In the present embodiment, the rectifying unit includes a plurality of switching tubes SW disposed on the second side 10b of the circuit substrate 10 and electrically connected to the corresponding windings 111 of the magnetic element 11. In some embodiments, the switching tube SW in the rectifying unit may also be disposed on the first side 10a of the circuit substrate 10. In some embodiments, a portion of the switching tube SW of the rectifying unit may be disposed on the first side 10a of the circuit substrate 10, and a portion of the switching tube SW may be disposed on the second side 10b of the circuit substrate 10.

Further, as shown in fig. 3, the magnetic core 110 includes an upper plate 1101, a lower plate 1102, and two winding posts 1103, and the upper plate 1101 and the lower plate 1102 connect the two winding posts 1103 to form a magnetic circuit. The winding 111 is wound around the two winding posts 1103, and the winding 111 is at least partially exposed to the magnetic core 110, i.e., exposed to the air. The winding is exposed in the air, and heat dissipation is facilitated. The number of windings is not limited in this embodiment, and in other embodiments, a plurality of windings may be provided. In this embodiment, the magnetic core 110 includes a first magnetic core 110a and a second magnetic core 110b spliced to each other, and the first magnetic core 110a and the second magnetic core 110b are each U-shaped. In other embodiments, the first and second magnetic cores 110a and 110b are U-shaped and I-shaped, respectively. The U-shaped magnetic core is favorable for directly blowing wind to the winding of the magnetic element, and takes away heat under the condition of not increasing wind current, so that the magnetic element works in a reasonable temperature range.

Further, in some embodiments, the magnetic core 110 further comprises two side legs 1104, as shown in fig. 3, the two side legs 1104 are disposed between the upper plate 1101 and the lower plate 1102; the axes of the two side posts 1104 (shown by the dotted line a) are perpendicular to the axes of the two winding posts 1103 (shown by the dotted line B), and the side posts can facilitate the processing of the air gaps of the winding posts. Of course, in other embodiments, the magnetic core 110 may not be provided with side pillars, and the present invention is not limited thereto.

Further, the winding 111 includes at least two connection pins 1110, and the connection pins 1110 are electrically connected to the circuit substrate 10. As shown in fig. 1-2, the connection pins 1110 are arranged in sequence on the circuit substrate 10, and are disposed near the middle of the circuit substrate 10; of course, in other embodiments, the connecting pins 1110 may be arranged in other forms, and the present invention is not limited to the form, arrangement, and the like of the connecting pins 1110. The rectifying unit includes a plurality of switching tubes SW disposed adjacent to the connection pins 1110 of the winding 111. As shown, the switching tubes SW are disposed at the upper and lower sides of the connection pin 1110, respectively. The switching tubes SW are adjacently distributed above and below the connecting pin 1110, so that the rectifying path can be reduced; the connecting pins 1110 and the switch tubes SW are arranged in a left-right symmetrical distribution, so that natural current sharing of the circuit can be well guaranteed.

Further, the power module 1 further includes a filter circuit 30 disposed at an output end of the rectifying unit. Specifically, the filter circuit 30 includes a plurality of filter capacitors 301, and as shown in fig. 1, the filter capacitors 301 may be disposed on the first side 10a of the circuit substrate 10 or disposed on the second side 10b of the circuit substrate 10. That is, a part of the filter capacitor 301 may be disposed on the first side 10a of the circuit substrate 10, and a part of the filter capacitor 301 may be disposed on the second side 10b of the circuit substrate 10. In some embodiments, the filter capacitor 301 is disposed near the upper edge and/or the lower edge of the circuit substrate 10 and close to the switch SW, which can reduce the loop path, reduce the loss, and improve the efficiency. In other embodiments, the filter circuit may also be an LC filter circuit, a CLC filter circuit or an LCL filter circuit, and is not limited thereto.

In some embodiments, the power module described above may be applied in an LLC resonant converter circuit. Fig. 4 is a schematic circuit diagram of a power module according to a first embodiment of the present invention, and fig. 5 is a schematic structural diagram of the power module corresponding to fig. 4. The power supply module may include, for example, a first rectifying unit 21 and a second rectifying unit 22 as shown in fig. 4, each connected to two secondary windings of the transformer 11. In this embodiment, the first rectifying unit 21 and the second rectifying unit 22 are full bridge circuits. As shown in fig. 4, each full bridge circuit includes two bridge arms, each of which includes an upper bridge arm and a lower bridge arm connected in series, in this embodiment, the first rectifying unit 21 includes 4 switching tubes (SW11 to SW14), and the second rectifying unit 22 includes 4 switching tubes (SW21 to SW 24). Specifically, as shown in fig. 5, the four switching tubes SW (i.e., SW11 to SW14) of the first rectifying unit 21 are disposed around the connection pin 1110 of one secondary winding, and the four switching tubes SW (i.e., SW21 to SW24) of the second rectifying unit 22 are disposed around the connection pin 1110 of the other secondary winding. The connection pin is only illustrated in the figure, and is only used for explaining the position relation between the connection pin and the switch tube, and the utility model discloses do not limit the shape structure of connecting the pin. The switching tubes SW are adjacently distributed above and below the connecting pin 1110, so that secondary side rectification paths can be reduced; the connecting pins 1110 of the secondary winding and the switch tube SW are arranged in a left-right symmetrical distribution, so that the natural current equalization of the secondary circuit can be well ensured.

In the case of a large current, the upper arm may include a plurality of switching tubes SW connected in parallel, and the lower arm may include a plurality of switching tubes SW connected in parallel. For example, as shown in fig. 6, the upper and lower arms of the rectifying unit each include two parallel switching tubes SW, that is, each rectifying unit may include 8 switching tubes SW, and the switching tubes SW are adjacently disposed around the connection pin 1110 of the corresponding winding 111. It should be noted that the present invention does not limit the circuit structure of the rectifying unit. And the first rectifying unit 21 and the second rectifying unit 22 may be, but are not limited to, the same circuit structure. In some embodiments, the switch SW can be, but is not limited to, a mosfet. In addition, in fig. 4, the output terminals of the first rectifying unit 21 and the second rectifying unit 22 may be connected in parallel and then connected to the circuit substrate 10. In fig. 4, the two primary windings of the magnetic element 11 are connected in series, and in other embodiments, the two primary windings may also be connected in parallel.

According to the power module shown in fig. 1-2 and fig. 4-6, the power module is applied to the LLC resonant converter, and the two secondary rectifying circuits of the magnetic element can be symmetrical by the arrangement of the magnetic element 11, the switching tube SW in the secondary rectifying circuit, and the filter capacitor 301, so as to achieve better natural current sharing. On the basis, the path among the secondary winding of the magnetic element, the switch tube and the GND is shortened, the loss on the path is reduced, and the rectification efficiency is improved. And the winding of the magnetic element is exposed in the air in a large area, and is favorable for heat dissipation in the environment with high power density.

Fig. 7 is a schematic diagram of a power conversion circuit according to a second embodiment of the present invention, in which the power module 1 has only one rectifying unit 20, and the connection pins of the two secondary windings are connected in parallel and then connected to the rectifying unit 20. In other embodiments, the two secondary windings may be connected in series and then electrically coupled to the rectifying unit 20. Also, in this embodiment, the rectifying unit may be a full bridge circuit including four synchronous rectifying tubes (SW11 to SW 14). Similarly, the upper arm and the lower arm of the full bridge circuit can both comprise a plurality of switching tubes SW connected in parallel.

Fig. 8 is a schematic circuit diagram of a power module according to a third embodiment of the present invention. As shown in fig. 8, in this embodiment, the secondary winding is a center-tapped winding; the first rectifying unit 21 and the second rectifying unit 22 are full-wave rectifying circuits. Further, the first rectifying unit 21, which is a full-wave rectifying circuit, includes a first branch and a second branch, and in this embodiment, the first branch includes a switching tube (SW11), and the second branch includes a switching tube (SW 12). The second rectifying unit 22, which is a full-wave rectifying circuit, includes a first branch including a switching tube (SW21) and a second branch including a switching tube (SW 22). In other embodiments, the first branch of the first rectification unit 21 may include a plurality of switching tubes (SW11) connected in parallel, the second branch of the first rectification unit 21 may include a plurality of switching tubes (SW12) connected in parallel, the first branch of the second rectification unit 22 may include a plurality of switching tubes (SW21) connected in parallel, and the second branch of the second rectification unit 22 may include a plurality of switching tubes (SW22) connected in parallel.

Fig. 9 is a schematic circuit diagram of a power module according to a fourth embodiment of the present invention, and as shown in fig. 9, the secondary winding of the magnetic element 11 is a center tap winding, the rectifying unit 20 is a full-wave rectifying circuit, and the secondary winding is connected in parallel to the rectifying unit 20.

In other embodiments, the power module shown in fig. 1-2 can also be applied to the previous stage of the Totem pole PFC. As shown in fig. 10, fig. 10 is a schematic circuit diagram of a power module according to a fifth embodiment of the present invention, and fig. 11 is a schematic structural diagram of the power module corresponding to the circuit in fig. 10. The magnetic element 11 is a coupled inductor and includes a first winding and a second winding. Specifically, the rectifying unit is a full-bridge circuit and comprises a first bridge arm and a second bridge arm, the first bridge arm comprises two switching tubes SW11 and SW13 which are connected in series, and the second bridge arm comprises two switching tubes SW12 and SW14 which are connected in series; the middle point of the first bridge arm is electrically connected with the first end of the power grid through the first winding, and the middle point of the second bridge arm is electrically connected with the second end of the power grid through the second winding. As shown in fig. 11, the two switching tubes SW11 and SW13 of the first arm are provided at the upper and lower ends of the first winding connection pin, and the two switching tubes SW12 and SW14 of the second arm are provided at the upper and lower ends of the second winding connection pin. It should be noted that, in some other embodiments, the power module shown in fig. 1-2 may also be applied to a bridgeless PFC or other PFC circuits, which is not limited by the present invention.

Fig. 12 is a schematic circuit diagram of a power module according to a sixth embodiment of the present invention, and fig. 13 is a schematic structure diagram of the power module corresponding to the circuit in fig. 12. The magnetic element 11 is a coupled inductor and includes a first winding and a second winding. The rectifying unit is a full-bridge circuit and comprises three bridge arms, and each bridge arm comprises two switching tubes (SW 11-SW 16) which are connected in series; the middle points of two bridge arms are respectively and electrically connected with the first end of the power grid through a winding, and the middle points of the rest bridge arms are electrically connected with the second end of the power grid. As shown in fig. 11, the two switching tubes SW11 and SW13 of the first arm are provided at the upper and lower ends of the first winding connection pin, and the two switching tubes SW12 and SW14 of the second arm are provided at the upper and lower ends of the second winding connection pin. In some embodiments, in order to reduce the length of the circuit substrate, a bridge arm directly connected to the power grid may also be provided on the main board. In addition, the connection pins in fig. 11 and 13 are only schematic, and are only for explaining the positional relationship between the connection pins and the switch tube, and the shape and structure of the connection pins are not limited in the present invention.

The power module is applied to the front-stage PFC, the inductor, the switching tube SW and the filter capacitor 301 are arranged as shown in the figures 1-2, the path among the inductor, the switching tube and the power grid is shortened, the loss on the path is reduced, and the rectification efficiency is improved. The front-stage PFC is integrated on the circuit substrate 10, so that the structure is compact, and the power density is favorably improved. And the winding of the magnetic element is exposed in the air in a large area, and is favorable for heat dissipation in the environment with high power density.

Further, in some embodiments, the winding 111 may be a litz wire, and the winding 111 may be formed by winding a plurality of wires in parallel according to the magnitude of the load current. For example, in fig. 1, i.e., two litz wire windings are used for each winding 111, and each winding 111 forms 4 connection pins 1110.

Fig. 14 is a perspective view of a magnetic element according to an embodiment of the present invention, and fig. 15 is a schematic view of a magnetic element and a circuit board according to an embodiment of the present invention. As shown in fig. 14, the magnetic element 11 is further provided with a positioning plate 113, the positioning plate 113 is provided with a positioning hole 1130, and the connection pin 1110 of the winding 111 passes through the positioning hole 1130 for positioning. In mounting, as shown in fig. 15, the positioning plate 113 is attached to the circuit substrate 10, and the connecting pins 1110 are fixed and electrically connected to the circuit substrate 10. The positioning plate 113 enables the connecting pin 1110 not to shake, and the stability of the structure is increased. The connection pins 1110 can be soldered on the circuit substrate 10, thereby reducing the length of the winding pin leads and reducing the line loss and the leakage inductance.

Further, as shown in fig. 14 and fig. 15, the magnetic element 11 further includes a bobbin 114, the winding 111 is wound on the bobbin 114, and the bobbin 114 is sleeved on the winding post (such as the winding post shown in fig. 4); the frame 114 is provided with a positioning element 1140, and the positioning element 1140 is engaged with the positioning hole 1130 of the positioning plate 113. In some embodiments, the frame 114 and the positioning plate 113 are fixed by dispensing.

Referring to fig. 1, the power module 1 further includes a main board (not shown), the circuit substrate 10 is vertically disposed on the main board, a plurality of lead terminals 101 (e.g., output terminals, GND terminals, signal terminals) are disposed on a lower edge of the circuit substrate 10, and the lead terminals 101 are inserted on the main board and electrically connected to the main board. In some embodiments, the lower cover plate 1101 of the magnetic element 11 is flush with the lower edge of the circuit substrate 10. And the primary winding 111 includes at least two primary connection pins 1110, and the primary connection pins 1110 are electrically connected to the main board. The circuit substrate 10 is vertically disposed and flush with the lower cover plate 1102 of the magnetic element 11, so that the structure is compact, the vertical height utilization rate and the space utilization rate of the power module are improved, and the power density of the rectifier module is improved.

To sum up, the winding of the magnetic element of the power module of the present invention is wound on the winding post and exposed in the air, which is beneficial to heat dissipation in the environment of high power density; in addition, the connection pin of the winding of the magnetic element, the switch tube and the filter capacitor are arranged close to each other, so that the path of the rectification loop is reduced to the maximum extent, and the line loss is reduced; the circuit structures are approximately distributed in a bilateral symmetry manner, which is beneficial to natural current sharing; furthermore, the circuit substrate is vertically inserted on the mainboard, and the three-dimensional layout is adopted, so that the space is saved and the power density is improved compared with the planar layout.

It should be noted that the above-mentioned embodiments illustrate only preferred embodiments of the disclosure, and the disclosure is not limited to the described embodiments, as the scope of the disclosure is determined by the claims. And that this disclosure will be modified by those skilled in the art as deemed to be within the scope and spirit of the appended claims.

Claims (22)

1. A power module, comprising:

a circuit substrate including a first side and an opposing second side;

a magnetic element disposed on the first side of the circuit substrate; the magnetic element comprises a magnetic core and a winding, the magnetic core comprises an upper cover plate, a lower cover plate and two winding posts, and the upper cover plate and the lower cover plate are connected with the two winding posts to form a magnetic circuit; the winding comprises a plurality of connecting pins, and the connecting pins are fixed with the circuit substrate and are electrically connected with the circuit substrate; the winding is wound on the winding post and at least partially exposed out of the magnetic core;

at least one rectifying unit including a plurality of switching tubes disposed at the first side and/or the second side of the circuit substrate and disposed adjacent to connection pins of the respective windings;

and the filter circuit comprises a plurality of filter capacitors and is arranged on the first side and/or the second side of the circuit substrate.

2. The power module of claim 1 wherein the magnetic element is a transformer including a primary winding and a secondary winding.

3. The power supply module according to claim 2, wherein the rectifying unit is a full bridge circuit connected to the secondary winding.

4. The power module of claim 3, wherein the full bridge circuit comprises two bridge legs, each of the bridge legs comprises an upper bridge leg and a lower bridge leg connected in series, the upper bridge leg comprises a plurality of the switching tubes connected in parallel, and the lower bridge leg comprises a plurality of the switching tubes connected in parallel.

5. The power supply module according to claim 2, wherein the secondary winding is a center-tapped winding, and the rectifying unit is a full-wave rectifying circuit connected to the secondary winding.

6. The power module of claim 5, wherein the full-wave rectification circuit comprises a first branch and a second branch, the first branch comprising a plurality of the switching tubes connected in parallel, and the second branch comprising a plurality of the switching tubes connected in parallel.

7. The power module of claim 1, wherein the magnetic element is a coupled inductor comprising a first winding and a second winding.

8. The power supply module of claim 7, wherein the rectifying unit is a full bridge circuit.

9. The power supply module of claim 8, wherein the full bridge circuit comprises a first leg and a second leg, each leg comprising two switching tubes connected in series; the middle point of the first bridge arm is electrically connected with the first end of the power grid through the first winding, and the middle point of the second bridge arm is electrically connected with the second end of the power grid through the second winding.

10. The power supply module of claim 8, wherein the full bridge circuit comprises three legs, each of the legs comprising two switching tubes connected in series; the middle points of the two bridge arms are respectively and electrically connected with the first end of the power grid through corresponding windings in the first winding and the second winding, and the middle point of the remaining bridge arm is electrically connected with the second end of the power grid.

11. The power module of claim 1, wherein the switching tubes are disposed at upper and lower sides of the connection pins, respectively.

12. The power supply module of claim 1 or 11, wherein at least a portion of the filter capacitor is disposed proximate to the upper and lower edges of the circuit substrate.

13. The power module as claimed in claim 1, wherein the magnetic element is provided with a positioning plate, and the positioning plate is attached to the circuit substrate; the positioning plate is provided with a positioning hole, and the connecting pin of the magnetic element penetrates through the positioning hole and then is fixed and electrically connected with the circuit substrate.

14. The power module as claimed in claim 13, wherein the magnetic element further comprises a bobbin, the bobbin is sleeved on the winding post, and the winding is wound on the bobbin; the framework is provided with a positioning piece which is clamped in the positioning hole of the positioning plate.

15. The power module of claim 14, wherein the frame and the positioning plate are fixed by dispensing.

16. The power module of claim 1, wherein the magnetic core comprises a first magnetic core and a second magnetic core spliced to each other, the first magnetic core and the second magnetic core each having a U-shape; or the first magnetic core and the second magnetic core are respectively in a U shape and an I shape.

17. The power module of claim 1 or 16, wherein said magnetic core further comprises two side legs disposed between said upper cover plate and said lower cover plate; and the axes of the two side columns are perpendicular to the axes of the two winding columns.

18. The power module of claim 1 wherein said winding is litz wire.

19. The power module as claimed in claim 1, wherein the circuit substrate is vertically disposed on a main board; the lower edge of the circuit substrate is provided with a lead terminal, and the lead terminal is inserted on the mainboard and is electrically connected with the mainboard.

20. The power module of claim 1 or 19, wherein the lower cover plate of the magnetic element is flush with a lower edge of the circuit substrate.

21. The power module of claim 2, wherein the primary winding includes at least two primary connection pins, the primary connection pins being electrically connected to a motherboard.

22. The power supply module of claim 1 wherein said winding is formed by winding a plurality of wire windings in parallel.

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