Core structure

• US 20030197585A1
• Filed: 04/18/2002
• Published: 10/23/2003
• Est. Priority Date: 04/18/2002
• Status: Active Grant

• Current Assignee: MyPAQ Holdings Ltd. (Transpacific IP Group Limited)
• Original Assignee: Innovative Technology Licensing LLC (Teledyne Technologies Incorporated)
• Inventors: Sun, Jian, Chandrasekaran, Sriram, Mehrotra, Vivek
• Granted Patent: US 6,873,237 B2
• Time in Patent Office: Days
• US Class Current: 336/178
• CPC Class Codes: H01F 17/04 with magnetic core
• CPC Class Codes: H01F 3/08 made from powder powder coatings on sheets H01F3/02; on strips or ribbons H01F3/04; on wires H01F3/06
• CPC Class Codes: H01F 30/06 characterised by the structure
• CPC Class Codes: H02M 7/043 using transformers or inductors only

Abstract

There is disclosed a core structure with a very low profile, high power density and lower losses. Higher core surface area and improved core utilization in terms of flux density are other desirable feature in the disclosed design. The disclosed design also allowed for a larger core area where the DC fluxes are added, thereby reducing the air-gap requirements in the cores derived from low saturation density materials such as ferrites. The cellular nature of the design can also be effectively employed in vertically packaged power converters and modules.

Claims

1. A core comprising:

a base having an outer edge and a top region,

a first post disposed on the top region of the base at the outer edge,

a second post disposed on the top region of the base at the outer edge,

a third post disposed on the top region of the base at the outer edge,

a shared common center portion disposed on the base, and

a top disposed on the posts and opposite the base,

wherein the first post and the center portion are separated on the base to thereby define a first window, the second post and the center portion are separated on the base to thereby define a second window, the third post and the center portion are separated on the base to thereby define a third window, and the top and center portions are spaced apart to thereby define an air gap.

2. The core of claim 1, further comprising a fourth post disposed on the top region of the base at the outer edge, with the fourth post and the center portion separated on the base to thereby define a fourth window.

3. The core of claim 2, wherein the first post, the second post, the third post, the fourth post are disposed on the base in a rectangular matrix.

4. The core of claim 3, wherein the rectangular matrix is square.

5. The core of claim 2, wherein the base has a square shape and the posts are each disposed at a different corner of the square.

6. The core of claim 5, wherein the center portion has plural legs in a plus shape.

7. The core of claim 1, wherein the center portion has plural legs between the posts and separating the posts.

8. The core of claim 7, wherein the legs are disposed on the base in a radial pattern.

9. The core of claim 8, wherein the center portion comprises a round portion disposed centrally of the legs.

10. The core of claim 1, wherein the posts are disposed on the base in a symmetrical pattern.

11. The core of claim 1, wherein the posts are disposed on the base in an asymmetrical pattern.

12. The core of claim 1, further comprising windings around the posts.

13. The core of claim 12, wherein the windings have respective directions, and the directions provide for additive flux in the center portion when the windings are energized as inductors.

14. The core of claim 1, wherein the base, the posts and the center portion are an integrated unit.

15. The core of claim 1, wherein the base has a round cross-section with a perimeter and the posts are each disposed on the perimeter.

16. The core of claim 15, wherein the center portion has a central portion with a round shape and the legs extend radially from the central portion.

17. The core of claim 1, wherein the base, the posts and the center portion are formed of a single material.

18. The core of claim 1, wherein the posts have a common height measured from the base, and the center portion has a height which is less than the common height of the posts.

19. The core of claim 1, wherein the posts have a common shape.

20. The core of claim 1, wherein the posts have a rectangular shape.

21. A power module comprising the core of claim 1.

22. A power converter comprising the core of claim 1.

23. A power converting apparatus having at least two cells, the power converting apparatus comprising:

a core having a base, a top, a center portion and a first post, a second post and a third post,

first and second windings around the first post,

a third winding around the second post,

a fourth winding around the third post, and

a control circuit connected to said windings and having a first phase and a second phase adapted to provide current,

wherein a first cell is defined by the first winding, the first post, the third winding, the second post, the base and the center portion, and a second cell is defined by the second winding, the first post, the fourth winding, the third post, the base and the center portion.

24. The power converting apparatus of claim 23, wherein the center portion comprises plural legs.

25. The power converting apparatus of claim 24, wherein the legs are disposed between the posts.

26. The power converting apparatus of claim 23, wherein the posts are disposed on the base in a rectangular matrix.

27. The power converting apparatus of claim 23, wherein the posts are disposed on the base in a radial pattern.

28. The power converting apparatus of claim 23, wherein the posts are disposed on the base in a symmetrical pattern.

29. The power converting apparatus of claim 23, further comprising a fourth post, wherein the base has a square cross-section and the posts are each disposed at different corners of the square.

30. The power converting apparatus of claim 23, wherein the center portion has a plus shape.

31. The power converting apparatus of claim 23, wherein the base has a round shape with a perimeter and the posts are each disposed on the perimeter.

32. The power converting apparatus of claim 23, wherein the center portion has a central area with a round shape and legs which extend radially from the central area.

33. The power converting apparatus of claim 23, wherein the base, the posts and the center portion are formed of a single material.

34. The power converting apparatus of claim 23, wherein the posts have a common cross-sectional area.

35. A power module comprising the power converting apparatus of claim 23.

36. A power converter comprising the power converting apparatus of claim 23.

37. A power converter, comprising:

a core having eight primary windings and eight secondary windings in an arrangement on the core, the arrangement defining four cells each comprising two primary windings and two secondary windings, and

a control circuit having an output connected to the primary windings, the control circuit having at least two phases in which current runs from the output in a first direction during a first phase and a second direction in a second phase, two of the cells being powered by the control circuit during the first phase and the other two cells being powered by the control circuit during the second phase.