Power converter using orthogonal secondary windings

• US 9,224,531 B2
• Filed: 03/31/2011
• Issued: 12/29/2015
• Est. Priority Date: 03/31/2011
• Status: Active Grant

• Current Assignee: Bose Corporation
• Original Assignee: Bose Corporation
• Inventors: Nussbaum, Michael
• Primary Examiner(s): Berhane, Adolf
• Assistant Examiner(s): DEMISSE, AFEWORK S
• Application Number:
  US13/076,923
• Publication Number:
  US 20120249105A1
• Time in Patent Office: 1,734 Days
• Field of Search: 323/213, 323/222, 323/232, 323/247, 323/250, 323/262, 323/172, 323/282, 323/301, 323/332, 323/334, 336/200, 336/214, 336/221, 336/232, 336/233
• US Class Current: 1/1
• CPC Class Codes: H01F 2027/2819 Planar transformers with printed windings, e.g. surrounded by two cores and to be mounted on printed circuit
• CPC Class Codes: H01F 27/2804 Printed windings
• CPC Class Codes: H02M 1/0032 Control circuits allowing low power mode operation, e.g. in standby mode
• CPC Class Codes: H02M 1/0064 Magnetic structures combining different functions, e.g. storage, filtering or transformation
• CPC Class Codes: H02M 3/1584 with a plurality of power processing stages connected in parallel
• CPC Class Codes: H02M 3/1586 switched with a phase shift, i.e. interleaved
• CPC Class Codes: H02M 3/33523 with galvanic isolation between input and output of both the power stage and the feedback loop
• 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 power conversion device includes a magnetic core; and a plurality of windings surrounding portions of the magnetic core, including a first set of windings defining a first magnetic flux path, a second set of windings defining a second magnetic flux path magnetically orthogonal to the first magnetic flux path, and a third set of windings. Each winding of the third set of windings is configured to be excitable via both the first flux path and the second flux path.

Claims

1. A power conversion device comprising:

a magnetic core having first, second, and third legs, the first leg being between the second and third legs; and

a plurality of windings surrounding portions of the magnetic core, including a first set of windings around the first leg and defining a first magnetic flux path, a second set of windings around the second and third legs and defining a second magnetic flux path, and a third set of windings around the second and third legs;

wherein magnetic flux in both the first magnetic flux path and the second magnetic flux path induces a current in each winding of the third set of windings, and

the first set of windings are magnetically orthogonal to the second set of windings, such that magnetic flux in the first magnetic flux path does not induce current in the second set of windings and magnetic flux in the second magnetic flux path does not induce current in the first set of windings.

2. The power conversion device of claim 1 operable in a plurality of modes, including a first mode in which power is transferred from one or more windings of the first set of windings to the windings of the third set of windings, and in a second mode in which power is transferred from windings of the second set of windings to the windings of the third set of windings.

3. The power conversion device of claim 2 further comprising circuitry to form a first power supply using the first set of windings operable only in the first mode, and circuitry to form a second power supply for providing power via the third set of windings operable in both the first mode and the second mode.

4. The power conversion device of claim 3 wherein the first mode comprises a primary operating mode and the second mode comprises a standby operating mode.

5. The power conversion device of claim 3 wherein the first power supply has a power capacity at least ten times greater than the second power supply.

6. The power conversion device of claim 3 wherein the first power supply has a power capacity of at least 0.2 kW.

7. The power conversion device of claim 3 wherein the first power supply comprises a boost converter.

8. The power conversion device of claim 7 wherein the first set of windings comprises a plurality of windings coupled by the magnetic core, and wherein the boost converter comprises an interleaved boost converter.

9. The power conversion device of claim 3, wherein the circuitry further comprises a rectifier coupled to each of the windings of the third set of windings.

10. The power conversion device of claim 3, wherein the circuitry further comprises a charge pump coupled to each of the windings of the third set of windings.

11. The power conversion device of claim 1 wherein the second set of windings comprises a plurality of windings arranged in a serial connection, and the third set of windings comprises a plurality of windings, each winding of the third set of windings correspond to a different one of the windings of the second set of windings.

12. The power conversion device of claim 1, wherein each of the windings of the first set of magnetic windings is coupled to a MOSFET having a first current rating, and wherein each winding of the second set of windings is coupled to a MOSFET having a second current rating less than the first current rating.

13. The power conversion device of claim 1, wherein each winding of the first set of windings is disposed on a substrate of a set of one or more substrates, the first leg of the magnetic core passing through openings in the substrates on which the first set of windings is disposed.

14. A method for power conversion comprising:

in a first operating mode,

providing current through windings of a first set of windings surrounding a first leg of a magnetic core, forming a first magnetic flux path,

wherein the first magnetic flux path couples power from the first set of windings to a third set of windings surrounding second and third legs of the magnetic core and magnetically coupled to the first set of windings via the magnetic core, causing a first power output from the third set of windings; and

in a second operating mode,

providing current through windings of a second set of windings surrounding the second and third legs of the magnetic core, forming a second magnetic flux path, the second set of windings being magnetically orthogonal to the first set of windings,

wherein the second magnetic flux path couples power from the second set of windings to the third set of windings magnetically coupled to the second set of windings via the magnetic core, causing a second power output from the third set of windings.

15. The method of claim 14, wherein the first operating mode comprises a primary operating mode and the second operating mode comprises a standby operating mode.

16. The method of claim 14, wherein the first set of windings form part of a first power supply and the second set of windings form part of a second power supply.

17. The method of claim 16, wherein the first power supply has a power capacity at least ten times greater than the second power supply.