Extended E Matrix Integrated Magnetics (MIM) Core

• US 20100091522A1
• Filed: 12/14/2009
• Published: 04/15/2010
• Est. Priority Date: 04/18/2002
• Status: Active Grant

• Current Assignee: Flextronics International USA Incorporated (Flex, Ltd.)
• Original Assignee: Flextronics International USA Incorporated (Flex, Ltd.)
• Inventors: Chandrasekaran, Sriram, Mehrotra, Vivek
• Granted Patent: US 8,134,443 B2
• Time in Patent Office: Days
• US Class Current: 363/17
• CPC Class Codes: H01F 17/04 with magnetic core
• CPC Class Codes: H01F 2038/006 matrix transformer consisting of several interconnected individual transformers working as a whole
• CPC Class Codes: H01F 27/24 Magnetic cores
• CPC Class Codes: H01F 27/255 made from particles H01F27/26 takes precedence
• 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
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

Abstract

A matrix integrated magnetics (MIM) “Extended E” core in which a plurality of outer legs are disposed on a base and separated along a first outer edge to define windows therebetween. A center leg is disposed on the top region of the base and separated from the outer legs to define a center window. The center leg is suitably positioned along a second outer edge opposite the first or between outer legs positioned along opposing outer edges. A plate is disposed on the outer legs opposite the base.

Claims

1. A matrix integrated magnetic (MIM) core, comprising:

a base having first and second outer edges separated by a top region;

a plurality of outer legs on top region of said base along said first outer edge; and

a center leg on said top region of said base along said second outer edge that spans said plurality of outer legs and separated therefrom to define a center window.

2. The MIM core as recited in claim 1 further comprising a plate opposite said base that covers said plurality of outer legs and said center leg.

3. The MIM core as recited in claim 1 wherein said center leg is shorter than said plurality of outer legs and forms an air gap between said center leg and a plate opposite said base that covers said plurality of outer legs and said center leg two.

4. The MIM core as recited in claim 1 wherein said plurality of outer legs exceeds

5. The MIM core as recited in claim 1 wherein said plurality of outer legs are disposed parallel to each other and perpendicular to said center leg.

6. The MIM core as recited in claim 1 wherein a width of said center window is constant between said center leg and each of said plurality of outer legs.

7. The MIM core as recited in claim 1 wherein ones of said plurality of outer legs have a winding coupled thereto.

8. The MIM core as recited in claim 1 wherein said plurality of outer legs have primary and second windings coupled thereto.

9. The MIM core as recited in claim 1 wherein said center leg has a winding coupled thereto.

10. The MIM core as recited in claim 1 wherein said center leg is one piece.

11. A method of forming a matrix integrated magnetic (MIM) core, comprising:

forming a base having first and second outer edges separated by a top region;

forming a plurality of outer legs on top region of said base along said first outer edge; and

forming a center leg on said top region of said base along said second outer edge that spans said plurality of outer legs and separated therefrom to define a center window.

12. The method as recited in claim 11 further comprising placing a plate opposite said base that covers said plurality of outer legs and said center leg.

13. The method as recited in claim 11 further comprising placing a plate opposite said base that covers said plurality of outer legs and said center leg and wherein said center leg is shorter than said plurality of outer legs and forms an air gap between said center leg and said plate.

14. The method as recited in claim 11 wherein said plurality of outer legs exceeds two.

15. The method as recited in claim 11 wherein ones of said plurality of outer legs and said center leg have a winding coupled thereto.

16. A power converter comprising:

a first current doubler rectifier, including;

at least one switch coupled to an input of said power converter, and

a first matrix integrated magnetic (MIM) core, coupled to said at least one switch, including;

a base having first and second outer edges separated by a top region,

a plurality of outer legs on top region of said base along said first outer edge, and

a center leg on said top region of said base along said second outer edge that spans said plurality of outer legs and separated therefrom to define a center window; and

a second current doubler rectifier, including;

at least one switch coupled to said input of said power converter, and

a second matrix integrated magnetic (MIM) core, coupled to said at least one switch, including;

a base having first and second outer edges separated by a top region,

a plurality of outer legs on top region of said base along said first outer edge, and

a center leg on said top region of said base along said second outer edge that spans said plurality of outer legs and separated therefrom to define a center window.

17. The power converter as recited in claim 16 wherein said first and second MIM cores further comprise a plate opposite said base that covers said plurality of outer legs and said center leg.

18. The power converter as recited in claim 16 wherein said first and second MIM cores further comprise a plate opposite said base that covers said plurality of outer legs and said center leg and wherein said center leg is shorter than said plurality of outer legs and forms an air gap between said center leg and said plate.

19. The power converter as recited in claim 16 wherein said plurality of outer legs of at least one of said first and second MIM cores exceeds two.

20. The power converter as recited in claim 16 wherein ones of said plurality of outer legs and said center leg of said first and second MIM cores have a winding coupled thereto.