Coil device and switching power supply apparatus using the same

• US 20010020886A1
• Filed: 05/15/2001
• Published: 09/13/2001
• Est. Priority Date: 03/11/1999
• Status: Active Grant

• Current Assignee: Murata Manufacturing Co Limited
• Original Assignee: Murata Manufacturing Co Limited
• Inventors: Nagai, Jun, Matsumoto, Tadahiko
• Granted Patent: US 6,380,836 B2
• Time in Patent Office: Days
• US Class Current: 336/200
• CPC Class Codes: H01F 19/04 Transformers or mutual inductances suitable for handling frequencies considerably beyond the audio range resonant circuits H03H
• CPC Class Codes: H01F 27/2804 Printed windings
• CPC Class Codes: H02M 1/0064 Magnetic structures combining different functions, e.g. storage, filtering or transformation
• CPC Class Codes: H02M 3/335 using semiconductor devices only
• CPC Class Codes: H02M 3/33576 having at least one active switching element at the secondary side of an isolation transformer
• CPC Class Codes: H02M 3/33592 having a synchronous rectifier circuit or a synchronous freewheeling circuit at the secondary side of an isolation transformer
• CPC Class Codes: H05K 1/144 Stacked arrangements of planar printed circuit boards
• CPC Class Codes: H05K 1/165 incorporating printed inductors
• CPC Class Codes: Y02B 70/10 Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes

Abstract

further comprising a fourth printed coil provided on a fourth substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the fourth printed coil including a pair of external printed coils which are connected in series and are respectively wound around the pair of the external holes and each having the same number of turns but having wound in the opposite directions, whereby the second printed coil is magnetically coupled with the fourth printed coil to form a second transformer.

Claims

1. A switching power supply apparatus comprising a transformer for power transmission having a primary coil and a secondary coil, a main switch to control the current flowing from an input power supply into the primary coil, a rectifying and smoothing circuit which includes a choke coil and rectifies and smoothes an output of the secondary coil of the transformer for power transmission, and a control circuit to control the action of the main switch, wherein there is provided:

a core having an intermediate leg and at least a pair of external legs arranged at equal intervals from the intermediate leg;

a first printed coil provided on a first substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the first printed coil being wound around the intermediate hole; and

a second printed coil provided on a second substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the second printed coil including a pair of external printed coils which are connected in series and are respectively wound around the pair of the external holes and each having the same number of turns but wound in opposite directions;

wherein the pair of external printed coils of the second printed coil generate magnetic fields in opposite directions to each other in the intermediate leg such that the magnetic fields in the intermediate leg cancel each other and induce no induction voltage in the first printed coil, and induction voltages induced in the external printed coils of the second printed coil by magnetic flux generated by the first printed coil are substantially canceled, whereby the first printed coil and the second printed coil form separate inductors which are not magnetically coupled, further comprising

a third printed coil provided on a third substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the third printed coil being wound around the intermediate hole, whereby the first printed coil is magnetically coupled with the third printed coil to form a first transformer;

and further wherein the transformer for power transmission comprises the first transformer.

3. The switching power supply apparatus of

claim 1

, wherein the choke coil comprises the first printed coil.

4. The switching power supply apparatus of

claim 1

, wherein the choke coil comprises the second printed coil.

5. The switching power supply apparatus of

claim 1

, further comprising a fourth printed coil provided on a fourth substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the fourth printed coil including a pair of external printed coils which are connected in series and are respectively wound around the pair of the external holes and each having the same number of turns but being wound in opposite directions, whereby the second printed coil is magnetically coupled with the fourth printed coil to form a second transformer, and wherein the choke coil comprises the first printed coil.

6. The switching power supply apparatus of

claim 1

, further comprising a fourth printed coil provided on a fourth substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the fourth printed coil including a pair of external printed coils which are connected in series and are respectively wound around the pair of the external holes and each having the same number of turns but being wound in opposite directions, whereby the second printed coil is magnetically coupled with the fourth printed coil to form a second transformer, and wherein the choke coil comprises the second printed coil.

2. A switching power supply apparatus comprising a transformer for power transmission having a primary coil and a secondary coil, a main switch to control the current flowing from an input power supply into the primary coil, a rectifying and smoothing circuit which includes a choke coil and rectifies and smoothes an output of the secondary coil of the transformer for power transmission, and a control circuit to control the action of the main switch, wherein there is provided:

a core having an intermediate leg and at least a pair of external legs arranged at equal intervals from the intermediate leg;

a first printed coil provided on a first substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the first printed coil being wound around the intermediate hole; and

a second printed coil provided on a second substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the second printed coil including a pair of external printed coils which are connected in series and are respectively wound around the pair of the external holes and each having the same number of turns but wound in opposite directions;

wherein the pair of external printed coils of the second printed coil generate magnetic fields in opposite directions to each other in the intermediate leg such that the magnetic fields in the intermediate leg cancel each other and induce no induction voltage in the first printed coil, and induction voltages induced in the external printed coils of the second printed coil by magnetic flux generated by the first printed coil are substantially canceled, whereby the first printed coil and the second printed coil form separate inductors which are not magnetically coupled, further comprising

a fourth printed coil provided on a fourth substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the fourth printed coil including a pair of external printed coils which are connected in series and are respectively wound around the pair of the external holes and each having the same number of turns but being wound in opposite directions, whereby the second printed coil is magnetically coupled with the fourth printed coil to form a second transformer,

and further wherein the transformer for power transmission comprises the second transformer.

7. The switching power supply apparatus of

claim 2

, further comprising a third printed coil provided on a third substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the third printed coil being wound around the intermediate hole, whereby the first printed coil is magnetically coupled with the third printed coil to form a first transformer, and wherein the choke coil comprises the first printed coil.

8. The switching power supply apparatus of

claim 2

, further comprising a third printed coil provided on a third substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the third printed coil being wound around the intermediate hole, whereby the first printed coil is magnetically coupled with the third printed coil to form a first transformer, and wherein the choke coil comprises the second printed coil.

9. The switching power supply apparatus of

claim 2

, wherein the choke coil comprises the first printed coil.

10. The switching power supply apparatus of

claim 2

, herein the choke coil comprises the second printed coil.

11. A switching power supply apparatus including a transformer for power transmission having a primary coil and a secondary coil, a main switch to control the current flowing from an input power supply into the primary coil, a rectifying and smoothing circuit which includes a choke coil and rectifies and smoothes the output of the secondary coil of the transformer for power transmission and a current transformer to detect the current flowing in the main switch and to output it to the control circuit, wherein there is provided:

a core having an intermediate leg and at least a pair of external legs arranged at equal intervals from the intermediate leg;

a first printed coil provided on a first substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the first printed coil being wound around the intermediate hole; and

a second printed coil provided on a second substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the second printed coil including a pair of external printed coils which are connected in series and are respectively wound around the pair of the external holes and each having the same number of turns but wound in opposite directions,

wherein the pair of external printed coils of the second printed coil generate magnetic fields in opposite directions to each other in the intermediate leg such that the magnetic fields in the intermediate leg cancel each other and induce no induction voltage in the first printed coil, and induction voltages induced in the external printed coils of the second printed coil by magnetic flux generated by the first printed coil are substantially canceled, whereby the first printed coil and the second printed coil form separate inductors which are not magnetically coupled,

further comprising a third printed coil provided on a third substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the third printed coil being wound around the intermediate hole, whereby the first printed coil is magnetically coupled with the third printed coil to form a first transformer,

wherein the transformer for power transmission comprises the first transformer.

12. A switching power supply apparatus including a transformer for power transmission having a primary coil and a secondary coil, a main switch to control the current flowing from an input power supply into the primary coil, a rectifying and smoothing circuit which includes a choke coil and rectifies and smoothes the output of the secondary coil of the transformer for power transmission and a current transformer to detect the current flowing in the main switch and to output it to the control circuit, wherein there is provided:

a core having an intermediate leg and at least a pair of external legs arranged at equal intervals from the intermediate leg;

a first printed coil provided on a first substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the first printed coil being wound around the intermediate hole; and

a second printed coil provided on a second substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the second printed coil including a pair of external printed coils which are connected in series and are respectively wound around the pair of the external holes and each having the same number of turns but wound in opposite directions,

wherein the pair of external printed coils of the second printed coil generate magnetic fields in opposite directions to each other in the intermediate leg such that the magnetic fields in the intermediate leg cancel each other and induce no induction voltage in the first printed coil, and induction voltages induced in the external printed coils of the second printed coil by magnetic flux generated by the first printed coil are substantially canceled, whereby the first printed coil and the second printed coil form separate inductors which are not magnetically coupled,

further comprising a third printed coil provided on a third substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the third printed coil being wound around the intermediate hole, whereby the first printed coil is magnetically coupled with the third printed coil to form a first transformer, wherein the current transformer comprises the first transformer.

13. A switching power supply apparatus including a transformer for power transmission having a primary coil and a secondary coil, a main switch to control the current flowing from an input power supply into the primary coil, a rectifying and smoothing circuit which includes a choke coil and rectifies and smoothes the output of the secondary coil of the transformer for power transmission and a current transformer to detect the current flowing in the main switch and to output it to the control circuit, wherein there is provided:

a core having an intermediate leg and at least a pair of external legs arranged at equal intervals from the intermediate leg;

a first printed coil provided on a first substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the first printed coil being wound around the intermediate hole; and

a second printed coil provided on a second substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the second printed coil including a pair of external printed coils which are connected in series and are respectively wound around the pair of the external holes and each having the same number of turns but wound in opposite directions,

wherein the pair of external printed coils of the second printed coil generate magnetic fields in opposite directions to each other in the intermediate leg such that the magnetic fields in the intermediate leg cancel each other and induce no induction voltage in the first printed coil, and induction voltages induced in the external printed coils of the second printed coil by magnetic flux generated by the first printed coil are substantially canceled, whereby the first printed coil and the second printed coil form separate inductors which are not magnetically coupled,

further comprising a third printed coil provided on a third substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the third printed coil being wound around the intermediate hole, whereby the first printed coil is magnetically coupled with the third printed coil to form a first transformer,

further comprising a fourth printed coil provided on a fourth substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the fourth printed coil including a pair of external printed coils which are connected in series and are respectively wound around the pair of the external holes and each having the same number of turns but having wound in the opposite directions, whereby the second printed coil is magnetically coupled with the fourth printed coil to form a second transformer,

wherein the current transformer comprises the second transformer.

14. A switching power supply apparatus including a transformer for power transmission having a primary coil and a secondary coil, a main switch to control the current flowing from an input power supply into the primary coil, a rectifying and smoothing circuit which includes a choke coil and rectifies and smoothes the output of the secondary coil of the transformer for power transmission and a current transformer to detect the current flowing in the main switch and to output it to the control circuit, wherein there is provided:

a core having an intermediate leg and at least a pair of external legs arranged at equal intervals from the intermediate leg;

a first printed coil provided on a first substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the first printed coil being wound around the intermediate hole; and

a second printed coil provided on a second substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the second printed coil including a pair of external printed coils which are connected in series and are respectively wound around the pair of the external holes and each having the same number of turns but wound in opposite directions,

wherein the pair of external printed coils of the second printed coil generate magnetic fields in opposite directions to each other in the intermediate leg such that the magnetic fields in the intermediate leg cancel each other and induce no induction voltage in the first printed coil, and induction voltages induced in the external printed coils of the second printed coil by magnetic flux generated by the first printed coil are substantially canceled, whereby the first printed coil and the second printed coil form separate inductors which are not magnetically coupled,

further comprising a third printed coil provided on a third substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the third printed coil being wound around the intermediate hole, whereby the first printed coil is magnetically coupled with the third printed coil to form a first transformer,

further comprising a fourth printed coil provided on a fourth substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the fourth printed coil including a pair of external printed coils which are connected in series and are respectively wound around the pair of the external holes and each having the same number of turns but having wound in the opposite directions, whereby the second printed coil is magnetically coupled with the fourth printed coil to form a second transformer,

wherein the transformer for power transmission comprises the second transformer.

15. A switching power supply apparatus including a transformer for power transmission having a primary coil and a secondary coil, a main switch to control the current flowing from an input power supply into the primary coil, a rectifying and smoothing circuit which includes a choke coil and has a rectifier to rectify and smooth the output of the secondary coil of the transformer for power transmission, a control circuit to control the action of the main switch, a drive transformer to transmit the drive signal from a control circuit and drive one of a high-side switch, a synchronous commutator and a secondary side switch, wherein there is provided:

a core having an intermediate leg and at least a pair of external legs arranged at equal intervals from the intermediate leg;

a first printed coil provided on a first substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the first printed coil being wound around the intermediate hole; and

a second printed coil provided on a second substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the second printed coil including a pair of external printed coils which are connected in series and are respectively wound around the pair of the external holes and each having the same number of turns but wound in opposite directions,

wherein the pair of external printed coils of the second printed coil generate magnetic fields in opposite directions to each other in the intermediate leg such that the magnetic fields in the intermediate leg cancel each other and induce no induction voltage in the first printed coil, and induction voltages induced in the external printed coils of the second printed coil by magnetic flux generated by the first printed coil are substantially canceled, whereby the first printed coil and the second printed coil form separate inductors which are not magnetically coupled,

further comprising a third printed coil provided on a third substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the third printed coil being wound around the intermediate hole, whereby the first printed coil is magnetically coupled with the third printed coil to form a first transformer,

wherein the transformer for power transmission comprises the first transformer.

16. A switching power supply apparatus including a transformer for power transmission having a primary coil and a secondary coil, a main switch to control the current flowing from an input power supply into the primary coil, a rectifying and smoothing circuit which includes a choke coil and has a rectifier to rectify and smooth the output of the secondary coil of the transformer for power transmission, a control circuit to control the action of the main switch, a drive transformer to transmit the drive signal from a control circuit and drive one of a high-side switch, a synchronous commutator and a secondary side switch, wherein there is provided:

a core having an intermediate leg and at least a pair of external legs arranged at equal intervals from the intermediate leg;

a first printed coil provided on a first substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the first printed coil being wound around the intermediate hole; and

a second printed coil provided on a second substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the second printed coil including a pair of external printed coils which are connected in series and are respectively wound around the pair of the external holes and each having the same number of turns but wound in opposite directions,

wherein the pair of external printed coils of the second printed coil generate magnetic fields in opposite directions to each other in the intermediate leg such that the magnetic fields in the intermediate leg cancel each other and induce no induction voltage in the first printed coil, and induction voltages induced in the external printed coils of the second printed coil by magnetic flux generated by the first printed coil are substantially canceled, whereby the first printed coil and the second printed coil form separate inductors which are not magnetically coupled,

further comprising a third printed coil provided on a third substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the third printed coil being wound around the intermediate hole, whereby the first printed coil is magnetically coupled with the third printed coil to form a first transformer,

wherein the drive transformer comprises the first transformer.

17. A switching power supply apparatus including a transformer for power transmission having a primary coil and a secondary coil, a main switch to control the current flowing from an input power supply into the primary coil, a rectifying and smoothing circuit which includes a choke coil and has a rectifier to rectify and smooth the output of the secondary coil of the transformer for power transmission, a control circuit to control the action of the main switch, a drive transformer to transmit the drive signal from a control circuit and drive one of a high-side switch, a synchronous commutator and a secondary side switch, wherein there is provided:

a core having an intermediate leg and at least a pair of external legs arranged at equal intervals from the intermediate leg;

a first printed coil provided on a first substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the first printed coil being wound around the intermediate hole; and

a second printed coil provided on a second substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the second printed coil including a pair of external printed coils which are connected in series and are respectively wound around the pair of the external holes and each having the same number of turns but wound in opposite directions,

wherein the pair of external printed coils of the second printed coil generate magnetic fields in opposite directions to each other in the intermediate leg such that the magnetic fields in the intermediate leg cancel each other and induce no induction voltage in the first printed coil, and induction voltages induced in the external printed coils of the second printed coil by magnetic flux generated by the first printed coil are substantially canceled, whereby the first printed coil and the second printed coil form separate inductors which are not magnetically coupled,

further comprising a fourth printed coil provided on a fourth substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the fourth printed coil including a pair of external printed coils which are connected in series and are respectively wound around the pair of the external holes and each having the same number of turns but having wound in the opposite directions, whereby the second printed coil is magnetically coupled with the fourth printed coil to form a second transformer;

wherein the transformer for power transmission comprises the second transformer.

18. A switching power supply apparatus including a transformer for power transmission having a primary coil and a secondary coil, a main switch to control the current flowing from an input power supply into the primary coil, a rectifying and smoothing circuit which includes a choke coil and has a rectifier to rectify and smooth the output of the secondary coil of the transformer for power transmission, a control circuit to control the action of the main switch, a drive transformer to transmit the drive signal from a control circuit and drive one of a high-side switch, a synchronous commutator and a secondary side switch, wherein there is provided:

a core having an intermediate leg and at least a pair of external legs arranged at equal intervals from the intermediate leg;

a first printed coil provided on a first substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the first printed coil being wound around the intermediate hole; and

a second printed coil provided on a second substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the second printed coil including a pair of external printed coils which are connected in series and are respectively wound around the pair of the external holes and each having the same number of turns but wound in opposite directions,

wherein the pair of external printed coils of the second printed coil generate magnetic fields in opposite directions to each other in the intermediate leg such that the magnetic fields in the intermediate leg cancel each other and induce no induction voltage in the first printed coil, and induction voltages induced in the external printed coils of the second printed coil by magnetic flux generated by the first printed coil are substantially canceled, whereby the first printed coil and the second printed coil form separate inductors which are not magnetically coupled,

further comprising a fourth printed coil provided on a fourth substrate which has an intermediate hole and a pair of external holes respectively inserted in the intermediate leg and the pair of external legs of the core, the fourth printed coil including a pair of external printed coils which are connected in series and are respectively wound around the pair of the external holes and each having the same number of turns but having wound in the opposite directions, whereby the second printed coil is magnetically coupled with the fourth printed coil to form a second transformer;

wherein the drive transformer comprises the second transformer.