Magnetic element for power supply and dc-to-dc converter

• US 5,583,424 A
• Filed: 03/15/1994
• Issued: 12/10/1996
• Est. Priority Date: 03/15/1993
• Status: Expired due to Term

• Current Assignee: Kabushiki Kaisha Toshiba (Toshiba Corporation)
• Original Assignee: Kabushiki Kaisha Toshiba (Toshiba Corporation)
• Inventors: Yamaguchi, Yoshihiko, Ide, Yuji, Sato, Toshiro, Yanase, Isamu, Iseki, Yuji, Iwamoto, Yasunori, Matsukura, Kunio, Mizoguchi, Tetsuhiko, Hasegawa, Michio
• Primary Examiner(s): Wong, Peter S.
• Assistant Examiner(s): BERHANE, ADOLF D
• Application Number:
  US08/212,797
• Time in Patent Office: 1,001 Days
• Field of Search: 336/200, 336/232, 336/65, 336/105, 336/221, 361/87, 323/282, 323/285, 323/290, 323/294, 323/249
• US Class Current: 323/282
• CPC Class Codes: G05F 1/575 characterised by the feedback circuit
• CPC Class Codes: H01F 17/0006 Printed inductances printed coils for dynamo-electric machines H02K3/26; printed circuits H05K
• CPC Class Codes: H01F 2017/0066 with a magnetic layer
• CPC Class Codes: H01F 2017/0086 on semiconductor substrate
• CPC Class Codes: H02M 1/0009 Devices or circuits for detecting current in a converter
• CPC Class Codes: H02M 3/28 using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac

Abstract

Disclosed is a dc-to-dc converter comprising a switching transistor, a pulse-width modulation controller, a sandwich-type planar inductor, which accumulates an electromagnetic energy at ON state and releases the accumulated electromagnetic energy at OFF state of the switching transistor, a smoothing capacitor, a rectifying element, and a planar search coil for detecting an overcurrent flowing the planar coil, disposed on one of the outer surfaces of the soft magnetic layers constituting the planar inductor.

Claims

1. A magnetic element for use in a power supply comprising:

a planar inductor comprising a planar coil, insulating layers disposed on the both surfaces of the planar coil and soft magnetic layers disposed on the outer surfaces of the insulating layers; and

a search coil for detecting an overcurrent flowing said planar coil, disposed on at least one of the outer surfaces of said soft magnetic layers.

2. The magnetic element according to claim 1, wherein said search coil is a planar search coil stacked on at least one of the outer surfaces of said soft magnetic layers through on insulating layer.

3. A magnetic element for use in a power supply comprising:

a planar inductor comprising a planar coil, insulating layers disposed on the both surfaces of the planar coil and soft magnetic layers disposed on the outer surfaces of the insulating layers; and

auxiliary planar coils disposed on the outer surfaces of said soft magnetic layers.

4. A magnetic element for use in a power supply comprising:

a planar transformer comprising a planar primary coil and a planar secondary coil disposed through an insulating layer, insulating layers disposed on the surfaces of the primary and secondary coils and soft magnetic layers disposed on the outer surfaces of the insulating layers; and

a search coil for detecting an overcurrent flowing said planar coil, disposed on at least one of the outer surfaces of said soft magnetic layers.

5. The magnetic element according to claim 4, wherein said search coil is a planar search coil stacked on at least one of the outer surfaces of said soft magnetic layers through an insulating layer.

6. A dc-to-dc converter comprising:

a switching means for generating a rectangular wave from an input signal;

a means for modulating a pulse width of the rectangular wave generated by the switching means;

a planar inductor comprising a planar coil, insulating layers disposed on the both surfaces of the planar coil and soft magnetic layers disposed on the outer surfaces of the insulating layers, which accumulates an electromagnetic energy at ON state and releases the accumulated electromagnetic energy at OFF state of the switching means;

a capacitor for smoothing the wave generated by the switching means;

a rectifying element; and

a search coil for detecting an overcurrent flowing said planar coil, disposed on at least one of the outer surfaces of said soft magnetic layers constituting said planar inductor.

7. The dc-to-dc converter according to claim 6, wherein said search coil is a planar search coil stacked on at least one of the outer surfaces of said soft magnetic layers constituting said planer inductor through an insulating layer.

8. The dc-to-dc converter according to claim 6, wherein said rectifying element serves as regenerating the electromagnetic energy accumulated in the planar inductor.

9. The dc-to-dc converter according to claim 6, wherein the switching means, the planar inductor, and the capacitor are arranged such that they generate an output voltage lower than an input voltage.

10. The dc-to-dc converter according to claim 6, wherein the switching means, the planar inductor, and the capacitor are arranged such that they generate an output voltage higher than an input voltage.

11. The dc-to-dc converter according to claim 6, further comprising a highly heat-conductive insulating substrate having a recessed portion, wherein the planar inductor, the search coil and the capacitor are buried in the recessed portion, and the switching means, means for modulating the pulse width and the rectifying element are mounted on the insulating substrate.

12. The dc-to-dc converter according to claim 6, wherein said switching means is fabricated on a semiconductor substrate, and said search coil and said planar inductor are formed on the semiconductor substrate with being insulated.

13. The dc-to-dc converter according to claim 6, wherein said rectifying element is a p-n junction diode.

14. The dc-to-dc converter according to claim 6, wherein said rectifying element is an MOSFET diode.

15. The dc-to-dc converter according to claim 14, further comprising a Schottky diode having an ON voltage lower than the ON voltage of a parasitic p-n junction diode of said MOSFET diode.

16. The dc-to-dc converter according to claim 6, wherein said capacitor is a multilayered ceramic capacitor.

17. A dc-to-dc converter comprising:

a switching means for generating a rectangular wave from an input signal;

a means for modulating a pulse width of the rectangular wave generated by the switching means;

a planar transformer comprising a planar primary coil and a planar secondary coil disposed through an insulating layer, insulating layers disposed on the surfaces of the primary and secondary coils and soft magnetic layers disposed on the outer surfaces of the insulating layers, which accumulates an electromagnetic energy in the planar primary coil at ON state and releases the accumulated electromagnetic energy via the planar secondary coil at OFF state of the switching means;

a capacitor for smoothing the wave generated by the switching means;

a rectifying element; and

a search coil for detecting an overcurrent flowing said planar coil, disposed on at least one of the surfaces of said soft magnetic layers constituting said planar transformer.

18. The dc-to-dc converter according to claim 17, wherein said search coil is a planar search coil stacked on at least one of the outer surfaces of said soft magnetic layers constituting said planar transformer through an insulating layer.

19. The dc-to-dc converter according to claim 17, wherein said rectifying element serves as regenerating the electromagnetic energy accumulated in the planar transformer.

20. A magnetic element for use in a power supply comprising:

a planar inductor comprising a planar coil, insulating layers disposed on both surfaces of the planar coil, and soft magnetic layers disposed on surfaces of the insulating layers;

a search coil for detecting an overcurrent flowing through said planar coil, disposed on at least one of outer surfaces of said soft magnetic layers; and

a means for controlling a load current supplied to said planar inductor based on an overcurrent signal fed back from said search coil.