Magnetic configuration for high efficiency power processing

• US 9,196,417 B2
• Filed: 05/05/2013
• Issued: 11/24/2015
• Est. Priority Date: 05/04/2012
• Status: Active Grant

• Current Assignee: Delta Electronics Thailand Public Company Limited (Delta Electronics Incorporated)
• Original Assignee: DET International Holding Limited (Delta Electronics Incorporated)
• Inventors: Jitaru, Ionel, Davila, Marco Antonio, Savu, Andrei, Radulescu, Andrei Ion
• Primary Examiner(s): Enad, Elvin G
• Assistant Examiner(s): BAISA, JOSELITO SASIS
• Application Number:
  US13/887,346
• Publication Number:
  US 20130314197A1
• Time in Patent Office: 933 Days
• Field of Search: 336/105, 336/177, 336/178, 336/212, 336/221, 336/214, 336/215, 336/222, 296/021
• US Class Current: 1/1
• CPC Class Codes: H01F 27/24 Magnetic cores
• CPC Class Codes: H01F 27/346 Preventing or reducing leakage fields using magnetic shields H01F27/36; using auxiliary windings H01F27/38
• CPC Class Codes: H01F 38/14 Inductive couplings for wireless supply or distribution of electric power using inductive coupling H02J50/10

Abstract

Several new and useful features for a magnetic structure are provided. One feature is that the magnetic structures are configured to help minimize the winding'"'"'s AC losses, improving the system'"'"'s efficiency. Another feature is that the combination of different magnetic hats creates a shaping path for the magnetic field. Still another feature is that a magnetic hat concept can be applied to a variety of magnetic core shapes.

Claims

1. A circular magnetic structure comprising:

a magnetic core made of solid magnetic material comprising;

a magnetic plate having an inner portion and an outer portion, said outer portion defining outer periphery of the magnetic core and said inner portion defining inner periphery of the magnetic core,

an outer edge having a bottom surface disposed on the outer portion of the magnetic plate and a top surface elevated from the inner portion of the magnetic plate;

a post made of said solid magnetic material having a bottom surface disposed within the inner portion of the magnetic plate at a distance from the outer edge and a top surface elevated from the inner portion of the magnet plate;

wherein either the top surface of the post or the top surface of the outer edge or the top surface of the post and the top surface of the outer edge is larger than the bottom surface of the post or the bottom surface of outer edge respectively such that, when one or more conductive windings are disposed between the post and the outer edge, the distance between the post and the outer edge comprises a magnetic leakage line path that is in parallel with the one or more conductive windings.

2. The magnetic structure in claim 1, wherein the post is positioned at the center of the inner portion of the magnetic plate.

3. The magnetic structure in claim 1, wherein the post has a shape of solid cylinder.

4. The magnetic structure in claim 1, wherein a cross section of the post has an inverted trapezoidal shape.

5. The magnetic structure in claim 1, wherein a cross section of the post has a hat shape.

6. The magnetic structure in claim 1, wherein a cross section of the center post has a t-shape.

7. The magnetic structure in claim 1, wherein a cross section of the outer edge has an inverted trapezoidal shape.

8. The magnetic structure in claim 1, wherein a cross section of the outer edge has a hat shape.

9. The magnetic structure in claim 1, wherein a cross section of the outer edge has a t-shape.

10. The magnetic structure in claim 1, wherein the conductive winding comprises a regular copper wire or litz wire.

11. The magnetic structure in claim 1, wherein the conductive winding comprises a planar winding configuration.

12. The magnetic structure in claim 11, wherein the planar winding configuration has a constant width per each turn.

13. The magnetic structure in claim 11, wherein the planar winding configuration has a variable width per each turn.

14. A transformer comprising:

circular primary and circular secondary magnetic cores made of solid magnetic material, each one of the primary and secondary magnetic cores comprising;

a magnetic plate having an inner portion and an outer portion, said outer portion defining outer periphery of the magnetic core and said inner portion defining inner periphery of the magnetic core,

an outer edge having a bottom surface disposed on the outer portion of the magnetic plate a top surface that is elevated from the inner portion of the magnetic plate;

a post having a bottom surface disposed within the inner portion of the magnetic plate at a distance from the outer edge and a top surface that is elevated from the inner portion of the magnet plate; and

wherein either the top surface of the post of the primary magnetic core or the top surface of the outer edge of the primary magnetic core or the top surface of the post of the primary magnetic core and the top surface of the outer edge of the primary magnetic core is larger than the bottom surface of the post of the primary magnetic core or the bottom surface of the outer edge of the primary magnetic core respectively such that, when one or more primary conductive windings are disposed between the post and the outer edge of the primary magnetic core, the distance between the post and the outer edge of the primary magnetic core comprises a primary magnetic leakage line path that is in parallel with the one or more primary conductive windings; and

wherein either the top surface of the post of the secondary magnetic core or the top surface of the outer edge of the secondary magnetic core or the top surface of the post of the secondary magnetic core and the to surface of the outer edge of the secondary magnetic core is larger than the bottom surface of the post of the secondary magnetic core or the bottom surface of the outer edge of the secondary magnetic core respectively such that, when one or more secondary conductive windings are disposed between the post and the outer edge of the secondary magnetic core, the distance between the post and the outer edge of the secondary magnetic core comprises a magnetic leakage line path that is in parallel with the one or more secondary conductive windings.

15. The transformer of claim 14, wherein the primary and secondary magnetic cores are positioned opposite each other with their corresponding top surface of their corresponding posts facing each other.

16. The transformer of claim 15, wherein there is an air gap between the primary and secondary magnetic cores.