Integrated power-converting module

Abstract

An integrated power-converting module includes a bobbin, a primary coil, a magnetic core assembly, and a plurality of power-converting units. The bobbin includes a main body, a plurality of winding portions and a plurality of receiving portions, and the winding portions and the and the receiving portion are arranged in a staggered manner. The primary coil is wound on the winding portions and the magnetic core assembly is assembled with the bobbin. Each power-converting unit includes a circuit board, a rectifier, and a filter, the rectifier and the filter are placed on a base portion of the circuit board and electrically connected thereto. An extending portion of the circuit board connect to the base portion is inserted into a slot formed within the receiving portion, and a penetrating hole formed on the extending portion is aligned with and communicated with a first channel formed on the main body.

What is claimed is: 
     
       1. An integrated power-converting module electrically connected to a direct current electric power, the integrated power-converting module comprising:
 a bobbin comprising a main body, a plurality of winding portions, and a plurality of receiving portions, the main body having a first channel and a second channel communicating with the first channel and perpendicular to the first channel, the winding parts portions and the receiving portion portions arranged in a staggered manner, each receiving portion having a slot communicating with the first channel; 
 a primary coil wound on the winding portions; 
 a magnetic core assembly assembled with the bobbin and partially received in the first channel; and 
 a plurality of power-converting units arranged in a parallel manner and each of the power-converting units comprising:
 a circuit board having a base portion and an expending extending portion connected to the base portion, a penetrating hole and a secondary winding formed on the expending extending portion, wherein the extending portions are portion is respectively inserted into the slots slot, and the penetrating hole is corresponding to and communicating with the first channel; 
 a rectifier placed on one of surfaces of the base portion and electrically connected to the circuit board; and 
 a filter placed on the other surface of the base portion opposite to where the rectifier placed on and electrically connected to the rectifier, 
 
 wherein when the direct current electric power is conducted to the primary coil, the magnetic core assembly generates electromagnetic induction, and a converted power is generated on by the secondary windings of the power-converting units, wherein the filters of two power-converting units disposed on two opposite sides of and most close to the second channel face each other. 
 
     
     
       2. The integrated power-converting module in  claim 1 , wherein the main body further comprising second channel communicating with the first channel and perpendicular to the first channel, wherein the filters of two power-converting units disposed two opposite sides of and most close to the second channel faces each other. 
     
     
       3. The integrated power-converting module in claim  2  1, wherein the magnetic core assembly comprises two magnetic cores, each magnetic core comprising a central leg, the central legs are leg is inserted into the second channel, and an air gap is formed between top surfaces of the central cores legs and within the second channel, and a plurality of gas passages are formed between the magnetic core assembly, the main body, and the primary coil wound on the winding portions. 
     
     
       4. The integrated power-converting module in claim  2  1, wherein the winding portions arranged on the opposites sides of the second cannel channel by a prescribed amount, and the receiving portions arranged in the opposite sides of the second channel by the prescribed amount, and the winding portions and the receiving portions are arranged in a staggered manner. 
     
     
       5. The integrated power-converting module in  claim 4 , wherein the rectifiers of two adjacent power-converting units arranged at one side of the second channel face each other. 
     
     
       6. The integrated power-converting module in  claim 1 , wherein each of the converting power-converting unit further comprises an electrically conductive plate placed on the base portion of the circuit board, the electrically conductive plate and the rectifier are placed on the same side of the base portion. 
     
     
       7. The integrated power-converting module in claim  2  1, further comprising a plurality of spacers arranged between the second channel and the receiving portions and parallel to the receiving portions. 
     
     
       8. The integrated power-converting module in  claim 1 , wherein each of the receiving portion further comprises a side-wall disposed opposite to the power-converting unit and enclosing the slot. 
     
     
       9. The integrated power-converting module in  claim 1 , further comprising a plurality of fixing members disposed on a bottom of the receiving portions. 
     
     
       10. The integrated power-converting module in  claim 1 , further comprising an electrically conductive sheet attached on the extending portion of the circuit board.