Magnetic core structures and construction techniques therefor
First Claim
1. A magnetic device, comprising:
- a first core-portion composed of a magnetic material and having first and second legs associated therewith, said first leg having a first end face and a predetermined first cross-sectional area, said second leg having a second end face and a predetermined second cross-sectional area different from said first cross-sectional area;
a winding assembly having first and second windings associated therewith and disposed about first and second winding apertures, respectively, said first and second legs passing through said first and second winding apertures, respectively, to couple said first and second windings magnetically to said first and second legs, respectively;
a second core-portion composed of said magnetic material and adapted to mate with said first and second legs of said first core-portion; and
an interstitial non-magnetic material of a predetermined uniform thickness disposed on said first and second end faces and joining said first and second core-portions to form a core for said magnetic device, said non-magnetic material forming a uniform air gap in said first and second legs.
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Abstract
A magnetic device, a method of manufacturing the magnetic device and a DC/DC converter employing the magnetic device. The magnetic device comprises: (1) a first core-portion composed of a magnetic material and having first and second legs associated therewith, the first leg having a first end face and a predetermined first cross-sectional area, the second leg having a second end face and a predetermined second cross-sectional area different from the first cross-sectional area, (2) a winding assembly having first and second windings associated therewith and disposed about first and second winding apertures, respectively, the first and second legs passing through the first and second winding apertures, respectively, to couple the first and second windings magnetically to the first and second legs, respectively, (3) a second core-portion composed of the magnetic material and adapted to mate with the first and second legs of the first core-portion and (4) an interstitial non-magnetic material of a predetermined uniform thickness disposed on the first and second end faces and joining the first and second core-portions to form a core for the magnetic device, the non-magnetic material forming a uniform air gap in the first and second legs.
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Citations
20 Claims
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1. A magnetic device, comprising:
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a first core-portion composed of a magnetic material and having first and second legs associated therewith, said first leg having a first end face and a predetermined first cross-sectional area, said second leg having a second end face and a predetermined second cross-sectional area different from said first cross-sectional area; a winding assembly having first and second windings associated therewith and disposed about first and second winding apertures, respectively, said first and second legs passing through said first and second winding apertures, respectively, to couple said first and second windings magnetically to said first and second legs, respectively; a second core-portion composed of said magnetic material and adapted to mate with said first and second legs of said first core-portion; and an interstitial non-magnetic material of a predetermined uniform thickness disposed on said first and second end faces and joining said first and second core-portions to form a core for said magnetic device, said non-magnetic material forming a uniform air gap in said first and second legs. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A method of manufacturing a magnetic device, comprising the steps of:
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providing a first core-portion composed of a magnetic material and having first and second legs associated therewith, said first leg having a first end face and a predetermined first cross-sectional area, said second leg having a second end face and a predetermined second cross-sectional area different from said first cross-sectional area; fitting a winding assembly onto said first core-portion, said winding assembly having first and second windings associated therewith and disposed about first and second winding apertures, respectively, said first and second legs passing through said first and second winding apertures, respectively, to couple said first and second windings magnetically to said first and second legs, respectively; disposing an interstitial non-magnetic material of a predetermined uniform thickness on said first and second end faces; and
;joining a second core-portion composed of said magnetic material to said non-magnetic material, said second core-portion adapted to mate with said first and second legs of said first core-portion, said non-magnetic material forming a uniform air gap in said first and second legs. - View Dependent Claims (9, 10, 11, 12, 13, 14)
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15. A DC/DC converter, comprising:
a power train having a DC input, a DC output and power conversion circuitry coupling said DC input to said DC output, said power conversion circuitry including an isolation transformer, comprising; a first core-portion composed of a magnetic material and having first and second legs associated therewith, said first leg having a first end face and a predetermined first cross-sectional area, said second leg having a second end face and a predetermined second cross-sectional area different from said first cross-sectional area, a winding assembly having first and second windings associated therewith and disposed about first and second winding apertures, respectively, said first and second legs passing through said first and second winding apertures, respectively, to couple said first and second windings magnetically to said first and second legs, respectively, a second core-portion composed of said magnetic material and adapted to mate with said first and second legs of said first core-portion, and an interstitial non-magnetic material of a predetermined uniform thickness disposed on said first and second end faces and joining said first and second core-portions to form a core for said magnetic device, said non-magnetic material forming a uniform air gap in said first and second legs. - View Dependent Claims (16, 17, 18, 19, 20)
Specification