Magnetic device and power converter employing the same

• US 9,106,130 B2
• Filed: 07/16/2012
• Issued: 08/11/2015
• Est. Priority Date: 07/16/2012
• Status: Active Grant

• Current Assignee: Power Systems Technologies Company Limited (Flex, Ltd.)
• Original Assignee: Power Systems Technologies Company Limited (Flex, Ltd.)
• Inventors: Chandrasekaran, Sriram
• Primary Examiner(s): Lian, Mangtin
• Application Number:
  US13/550,396
• Publication Number:
  US 20140016368A1
• Time in Patent Office: 1,121 Days
• Field of Search: 336/182, 336/221, 336/222, 336/170, 336/150, 336/145, 336/183, 336/212, 363/21.12
• US Class Current: 1/1
• CPC Class Codes: H01F 27/38 Auxiliary core members; Auxiliary coils or windings
• CPC Class Codes: H01F 3/10 Composite arrangements of magnetic circuits
• CPC Class Codes: H02M 1/4225 using a non-isolated boost converter
• CPC Class Codes: H02M 3/156 with automatic control of output voltage or current, e.g. switching regulators
• CPC Class Codes: H02M 3/1586 switched with a phase shift, i.e. interleaved
• CPC Class Codes: H02M 3/285 Single converters with a plurality of output stages connected in parallel parallel operation of a plurality of converters in dc distribution networks H02J1/10
• CPC Class Codes: H02M 3/33592 having a synchronous rectifier circuit or a synchronous freewheeling circuit at the secondary side of an isolation transformer
• CPC Class Codes: H02M 3/3376 with automatic control of output voltage or current
• 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 magnetic device and power converter employing the same. In one embodiment, the magnetic device includes a first L-core segment including a first leg and a second leg extending therefrom, and an opposing second L-core segment including a first leg and a second leg extending therefrom. The magnetic device also includes a winding formed around at least one of the first leg and the second leg of the first L-core segment or the second L-core segment.

Claims

1. A magnetic device, comprising:

a first L-core segment including a first leg and a second leg extending therefrom;

a discrete, opposing second L-core segment including a first leg and a second leg extending therefrom, said first leg of said first L-core segment being mated with said second leg of said second L-core segment and said second leg of said first L-core segment being mated with said first leg of said second L-core segment;

a primary winding formed from wire and wound around at least one of said first leg and said second leg of said first L-core segment or said second L-core segment; and

a center-tapped secondary winding formed with a single layer first secondary winding and a single layer second secondary winding discrete from said first secondary winding, said first and second secondary windings being stamped and rectangularly formed sheets of metal positioned over said primary winding.

2. The magnetic device as recited in claim 1 wherein said second leg of said first L-core segment is substantially perpendicular to said first leg of said first L-core segment, and said second leg of said second L-core segment is substantially perpendicular to said first leg of said second L-core segment.

3. The magnetic device as recited in claim 1 wherein a length of said first leg of said first L-core segment is elongated with respect to a length of said second leg of said first L-core segment, and a length of said first leg of said second L-core segment is elongated with respect to a length of said second leg of said second L-core segment.

4. The magnetic device as recited in claim 1 wherein a thickness of said first leg and said second leg of said first L-core segment is substantially equal and a thickness of said first leg and said second leg of said second L-core segment is substantially equal.

5. The magnetic device as recited in claim 1 wherein said primary winding, and said first and second secondary windings are formed around said first leg of said second L-core segment.

6. The magnetic device as recited in claim 1 wherein said first secondary winding comprises a tab.

7. The magnetic device as recited in claim 6 wherein said tab of said first secondary winding is mated with a portion of said second secondary winding.

8. The magnetic device as recited in claim 1 wherein said first and second secondary windings slide over said primary winding.

9. The magnetic device as recited in claim 1 comprising a first primary winding formed around said first leg of said first L-core segment and a second primary winding formed around said first leg of said second L-core segment.

10. The magnetic device as recited in claim 9 wherein said first secondary winding is formed over said first primary winding around said first leg of said first L-core segment and said second secondary winding is formed over said second primary winding around said first leg of said second L-core segment.

11. A power converter, comprising:

a main switch coupled to an input of said power converter;

a magnetic device coupled to said main switch, comprising;

a first L-core segment including a first leg and a second leg extending therefrom,

a discrete, opposing second L-core segment including a first leg and a second leg extending therefrom, said first leg of said first L-core segment being mated with said second leg of said second L-core segment and said second leg of said first L-core segment being mated with said first leg of said second L-core segment,

a primary winding formed from wire and wound around at least one of said first leg and said second leg of said first L-core segment or said second L-core segment, and

a center-tapped secondary winding formed with a single layer first secondary winding and a single layer second secondary winding discrete from said first secondary winding, said first and second secondary windings being stamped and rectangularly formed sheets of metal positioned over said primary winding;

an auxiliary switch coupled to said magnetic device; and

an output filter capacitor coupled to said auxiliary switch and an output of said power converter.

12. The power converter as recited in claim 11 wherein said second leg of said first L-core segment is substantially perpendicular to said first leg of said first L-core segment, and said second leg of said second L-core segment is substantially perpendicular to said first leg of said second L-core segment.

13. The power converter as recited in claim 11 wherein a length of said first leg of said first L-core segment is elongated with respect to a length of said second leg of said first L-core segment, and a length of said first leg of said second L-core segment is elongated with respect to a length of said second leg of said second L-core segment.

14. The power converter as recited in claim 11 wherein a thickness of said first leg and said second leg of said first L-core segment is substantially equal and a thickness of said first leg and said second leg of said second L-core segment is substantially equal.

15. The power converter as recited in claim 11 wherein said primary winding, and said first and second secondary windings are formed around said first leg of said second L-core segment.

16. The power converter as recited in claim 11 wherein said first secondary winding comprises a tab.

17. The power converter as recited in claim 16 wherein said tab of said first secondary winding is mated with a portion of said second secondary winding.

18. The power converter as recited in claim 11 wherein said first and second secondary windings slide over said primary winding.

19. The power converter as recited in claim 11 wherein said magnetic device comprises a first primary winding formed around said first leg of said first L-core segment and a second primary winding formed around said first leg of said second L-core segment.

20. The power converter as recited in claim 19 wherein said first secondary winding is formed over said first primary winding around said first leg of said first L-core segment and said second secondary winding is formed over said second primary winding around said first leg of said second L-core segment.