Method for making magnetic components with M-phase coupling, and related inductor structures

• US 9,019,064 B2
• Filed: 10/29/2012
• Issued: 04/28/2015
• Est. Priority Date: 12/13/2002
• Status: Expired due to Term

• Current Assignee: Volterra Semiconductor Corporation (Analog Devices, Inc.)
• Original Assignee: Volterra Semiconductor Corporation (Analog Devices, Inc.)
• Inventors: Ikriannikov, Alexandr, Stratakos, Anthony J., Sullivan, Charles R., Schultz, Aaron M., Li, Jieli
• Primary Examiner(s): NGUYEN, TUYEN T
• Application Number:
  US13/662,821
• Publication Number:
  US 20130069755A1
• Time in Patent Office: 911 Days
• Field of Search: 336/200, 336/212, 336/232, 336214-215, 336170-173
• US Class Current: 336/212
• CPC Class Codes: H01F 17/0006 Printed inductances printed coils for dynamo-electric machines H02K3/26; printed circuits H05K
• CPC Class Codes: H01F 17/06 with core substantially closed in itself, e.g. toroid
• CPC Class Codes: H01F 2017/067 Core with two or more holes to lead through conductor
• CPC Class Codes: H01F 27/006 with special arrangement or spacing of turns of the winding(s), e.g. to produce desired self-resonance
• CPC Class Codes: H01F 27/24 Magnetic cores
• CPC Class Codes: H01F 3/10 Composite arrangements of magnetic circuits
• CPC Class Codes: H01F 30/12 Two-phase, three-phase or polyphase transformers
• CPC Class Codes: H01F 5/00 Coils superconducting coils H01F6/06; fixed inductances of the signal type H01F17/00

Abstract

An M phase coupled inductor includes a magnetic core including a first end magnetic element, a second end magnetic element, and M legs disposed between and connecting the first and second end magnetic elements. M is an integer greater than one. The coupled inductor further includes M windings, where each winding has a substantially rectangular cross section. Each one of the M windings is at least partially wound about a respective leg.

Claims

1. A coupled inductor having length and width, the coupled inductor comprising:

a ladder magnetic core including at least two rails extending in the lengthwise direction and a plurality of rungs, each of the plurality of rungs connecting the at least two rails in the widthwise direction; and

a single-turn winding wound around each of the plurality of rungs such that (1) the winding includes three rectangular sections facing the rung and (2) opposing ends of the winding form respective solder tabs partially under the rung and extending away from the rung in the widthwise direction;

each single-turn winding having width and thickness along its respective rung, the thickness of the winding being orthogonal to an inner surface of the winding facing the rung, and the width of the winding being greater than the thickness of the winding.

2. The coupled inductor of claim 1, wherein a pre-wound flattened shape of each single-turn winding is irregular, and has more than four sides.

3. The coupled inductor of claim 2, wherein the pre-wound flattened shape has at least eight sides.

4. The coupled inductor of claim 2, wherein the pre-wound flattened shape has at least twelve sides.

5. The coupled inductor of claim 2, wherein the pre-wound flattened shape is a zigzag.