DC-DC converter and transformer

• US 7,889,520 B2
• Filed: 10/16/2007
• Issued: 02/15/2011
• Est. Priority Date: 10/16/2006
• Status: Expired due to Fees

• Current Assignee: Kabushiki Kaisha Toyota Jidoshokki (Toyota Motor Corporation)
• Original Assignee: Kabushiki Kaisha Toyota Jidoshokki (Toyota Motor Corporation)
• Inventors: Moiseev, Sergey
• Primary Examiner(s): Laxton; Gary L
• Assistant Examiner(s): Mehari; Yemane
• Application Number:
  US11/872,795
• Publication Number:
  US 20080212341A1
• Time in Patent Office: 1,218 Days
• Field of Search: 363/21.01, 363/21.02, 363/21.04, 363/21.12, 336/178
• US Class Current: 363/21.04
• CPC Class Codes: H01F 27/2866 Combination of wires and sheets
• CPC Class Codes: H01F 27/34 Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
• CPC Class Codes: H01F 27/345 using auxiliary conductors
• CPC Class Codes: H01F 3/14 Constrictions; Gaps, e.g. air-gaps in magnetic shunt paths H01F3/12
• CPC Class Codes: H01F 30/04 having two or more secondary windings, each supplying a separate load, e.g. for radio set power supplies
• CPC Class Codes: H02M 1/0048 Circuits or arrangements for reducing losses using snubbers H02M1/34
• CPC Class Codes: H02M 1/0064 Magnetic structures combining different functions, e.g. storage, filtering or transformation
• CPC Class Codes: H02M 3/33569 having several active switching elements H02M3/3353 takes precedence
• 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

A DC-DC converter using a plurality of transformers capable of decreasing the loss, preventing heat generation of transformers, and improving the heat transfer property of the core, and an integrated type transformer used in this DC-DC converter. A terminal T1 in which a negative electromotive force is generated and a terminal TR2 in which a positive electromotive force is generated, while a switching element Q1 is conducting, are connected at a node N1. An output coil L1 and output terminals TO1 and TO2 are provided on a current route shared by transformers T1 and T2. Diodes D1 and D2 are respectively inserted in a forward direction from a node N3 toward a terminal TR3 and in a forward direction from the node N3 toward a terminal TR4. An operation of a first transformer and an operation of a second transformer are respectively assigned to a flyback operation and a forward operation.

Claims

1. A DC-DC converter comprising:

a first transformer provided with a first core having a gap, the first core being wound around with a first core primary winding and a first core secondary winding;

a second transformer provided with a second core having a gap narrower than the gap of the first core or no gap, the second core being wound around with a second core primary winding and a second core secondary winding;

a first switching element serially connected to the first core primary winding and the second core primary winding, the first switching element being set in conducting/non -conductive state in a predetermined period;

a first rectifier element in which a first polarity terminal is connected to a first terminal of the first core secondary winding that generates an electromotive force of first polarity when the first switching element conducts, the first rectifier element being biased in a reverse bias condition;

a second rectifier element in which the first polarity terminal is connected to a second terminal of the second core secondary winding that generates an electromotive force of second polarity when the first switching element conducts, the second rectifier element being biased in a forward bias condition;

a secondary winding connection point to which a third terminal and a fourth terminal are connected, the third terminal being provided at an opposite side of the first terminal of the first core secondary winding and the fourth terminal being provided at an opposite side of the second terminal of the second core secondary winding;

a connection point which connects the secondary polarity terminal of the first rectifier element and the second polarity terminal of the second rectifier element;

a common current path in common with a current path which includes the first core secondary winding and the first rectifier element and a current path which includes the second core secondary winding and the second rectifier element, the common current path connecting the secondary winding connection point and the connection point;

an output terminal provided on the common current path; and

an output coil provided on the common current path.

2. The DC-DC converter according to claim 1, comprising:

a second switching element provided in a closed circuit including the first core primary winding and the second core primary winding, the second switching element being made to conduct during a period when the first switching element is set in non-conductive state; and

a second capacitor element provided in the closed circuit.

3. The DC-DC converter according to claim 1, comprising:

a first capacitor element of which one end is connected to a negative pole of an input direct-current power source;

a first core primary auxiliary winding wound on the first core in a same number of turns and a same winding direction as the first core primary winding;

a second core primary auxiliary winding wound on the second core in a same number of turns and a same winding direction as the second core primary winding, and wherein

one end of the first core primary winding is connected to one end of the second core primary winding;

an other end of the first core primary winding is connected to a positive pole of the input direct-current power source;

an other end of the second core primary winding is connected to the first switching element at a first connection point;

the first core primary auxiliary winding is wound in a winding direction that generates magnetic flux in an opposite direction to a magnetic flux generating at the first core primary winding when the first switching element is not conducting, the first core primary auxiliary winding being arranged on a connection path between the first connection point and the first capacitor element; and

the second core primary auxiliary winding is wound in a winding direction that generates magnetic flux in an opposite direction to a magnetic flux generating at the second core primary winding when the first switching element is not conducting, the second core primary auxiliary winding being arranged on a connection path between the first connection point and the first capacitor element.

4. The DC-DC converter according to claim 1 further comprising:

a transformer which is either one of an EE-type and an EI-type, the transformer comprising an E-shaped core which is provided with a first external magnetic lead, a central magnetic lead, a second external magnetic lead disposed in parallel on a flat bottom plate, the E-shaped core being arranged in such a manner that a height of the first external magnetic lead is set lower than heights of the central magnetic lead and the second external magnetic lead,

wherein;

a first magnetic flux loop circulates around the first core through the central magnetic lead and the first external magnetic lead,

a second magnetic flux loop circulates around the second core through the central magnetic lead and the second external magnetic lead,

the first core primary winding and the second core primary winding are wound on the central magnetic lead,

the first core secondary winding passes through between the central magnetic lead and the first external magnetic lead,

the second core secondary winding passes through between the central magnetic lead and the second external magnetic lead, and

together with the first core secondary winding and the second core secondary winding, the output coil forms a third magnetic flux loop which circulates around the first external magnetic lead and the second external magnetic lead.

5. The DC-DC converter according to claim 3, comprising

a transformer resetting circuit provided with a second switching element which conducts when the first switching element is in non-conductive state and a second capacitor element which is serially connected to the second switching element, and wherein

the transformer resetting circuit is connected in parallel to the first core primary auxiliary winding and the second core primary auxiliary winding which are serially connected with each other.

6. A transformer comprising:

an E-shaped core which is provided with a first external magnetic lead, a central magnetic lead, a second external magnetic lead disposed in parallel on a flat bottom plate, the E-shaped core being arranged in such a manner that a height of the first external magnetic lead is set lower than heights of the central magnetic lead and the second external magnetic lead;

a first core, around which a first magnetic flux loop circulates through the central magnetic lead and the first external magnetic lead;

a second core around which a second magnetic flux loop circulates through the central magnetic lead and the second external magnetic lead;

a first winding which is wound on the central magnetic lead;

a second winding which is wound on the first core, and together with the first winding, forms a first transformer having the first core as a magnetic core; and

a third winding which is wound on the second core, and together with the first winding, forms a second transformer having the second core as a magnetic core,

wherein the transformer comprises either one of an EE-type and an EI-type core.