Magnetic Device Formed with U-Shaped Core Pieces and Power Converter Employing the Same

• US 20100254168A1
• Filed: 03/31/2010
• Published: 10/07/2010
• Est. Priority Date: 03/31/2009
• Status: Active Grant

• Current Assignee: Power Systems Technologies Company Limited (Flex, Ltd.)
• Original Assignee: Power Systems Technologies Company Limited (Flex, Ltd.)
• Inventors: Chandrasekaran, Sriram
• Granted Patent: US 9,019,061 B2
• Time in Patent Office: Days
• US Class Current: 363/37
• CPC Class Codes: H01F 2038/026 non-linear inductive arrangements for converters, e.g. with additional windings
• CPC Class Codes: H01F 27/263 Fastening parts of the core together
• CPC Class Codes: H01F 3/10 Composite arrangements of magnetic circuits
• CPC Class Codes: H01F 3/12 Magnetic shunt paths
• CPC Class Codes: H01F 3/14 Constrictions; Gaps, e.g. air-gaps in magnetic shunt paths H01F3/12
• CPC Class Codes: H01F 30/06 characterised by the structure
• CPC Class Codes: H01F 37/00 Fixed inductances not covered by group H01F17/00
• CPC Class Codes: H01F 41/02 for manufacturing cores, coils, or magnets H01F41/14 takes precedence; for dynamo-electric machines H02K15/00
• CPC Class Codes: H02M 1/4208 Arrangements for improving power factor of AC input
• CPC Class Codes: H02M 3/1582 Buck-boost converters H02M3/1584 takes precedence
• CPC Class Codes: H02M 3/1586 switched with a phase shift, i.e. interleaved
• 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
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

Abstract

A magnetic device formed with U-shaped core pieces employable in a power converter, and a method of forming the same. In one embodiment, the magnetic device includes a rectilinear core piece formed of a magnetic material, and first and second U-shaped core pieces positioned on the rectilinear core piece. The magnetic device also includes first and second conductive windings formed about the first and second U-shaped core pieces, respectively.

Claims

1. A magnetic device, comprising:

a rectilinear core piece formed of a magnetic material;

first and second U-shaped core pieces positioned on said rectilinear core piece; and

first and second conductive windings formed about said first and second U-shaped core pieces, respectively.

2. The magnetic device as recited in claim 1 wherein said first and second conductive windings are formed over substantially an entire curved length of said first and second U-shaped core pieces, respectively.

3. The magnetic device as recited in claim 1 wherein said first and second U-shaped core pieces are positioned on a common surface of said rectilinear core piece.

4. The magnetic device as recited in claim 1 further comprising a nonmagnetic spacer positioned between at least one of said first and second U-shaped core pieces and a surface of said rectilinear core piece.

5. The magnetic device as recited in claim 1 further comprising a third conductive winding formed about said rectilinear core piece.

6. The magnetic device as recited in claim 5 wherein said third conductive winding is formed as a staple.

7. The magnetic device as recited in claim 5 wherein said third conductive winding is electrically coupled to said first and second conductive windings.

8. The magnetic device as recited in claim 1 wherein said rectilinear core piece is formed with a distributed gap.

9. The magnetic device as recited in claim 1 wherein a relative permeability of said rectilinear core piece is substantially lower than a relative permeability of said first and second U-shaped core pieces.

10. The magnetic device as recited in claim 1 wherein said first and the second U-shaped core pieces are each formed as a portion of a toroidal core.

11. A method of forming a magnetic device, comprising:

providing a rectilinear core piece of a magnetic material;

positioning first and second U-shaped core pieces on said rectilinear core piece; and

forming first and second conductive windings about said first and second U-shaped core pieces, respectively.

12. The method as recited in claim 11 wherein said first and second conductive windings are formed over substantially an entire curved length of said first and second U-shaped core pieces, respectively.

13. The method as recited in claim 11 wherein said first and second U-shaped core pieces are positioned on a common surface of said rectilinear core piece.

14. The method as recited in claim 11 further comprising positioning a nonmagnetic spacer between at least one of said first and second U-shaped core pieces and a surface of said rectilinear core piece.

15. The method as recited in claim 11 further comprising forming a third conductive winding about said rectilinear core piece.

16. The method as recited in claim 15 wherein said third conductive winding is formed as a staple.

17. The method as recited in claim 15 wherein said third conductive winding is electrically coupled to said first and second conductive windings.

18. The method as recited in claim 11 wherein said rectilinear core piece is formed with a distributed gap.

19. The method as recited in claim 11 wherein a relative permeability of said rectilinear core piece is substantially lower than a relative permeability of said first and second U-shaped core pieces.

20. The method as recited in claim 11 wherein said first and the second U-shaped core pieces are each formed as a portion of a toroidal core.

21. A power converter, comprising:

a magnetic device, including;

a rectilinear core piece formed of a magnetic material,

first and second U-shaped core pieces positioned on said rectilinear core piece, and

first and second conductive windings formed about said first and second U-shaped core pieces, respectively;

a first power switch coupled to said first conductive winding;

a second power switch coupled to said second conductive winding; and

a controller configured to provide control signals to said first and second power switches.

22. The power converter as recited in claim 21 wherein said first and second conductive windings are formed over substantially an entire curved length of said first and second U-shaped core pieces, respectively.

23. The power converter as recited in claim 21 wherein said first and second U-shaped core pieces are positioned on a common surface of said rectilinear core piece.

24. The power converter as recited in claim 21 wherein said magnetic device further includes a nonmagnetic spacer positioned between at least one of said first and second U-shaped core pieces and a surface of said rectilinear core piece.

25. The power converter as recited in claim 21 wherein said magnetic device further includes a third conductive winding formed about said rectilinear core piece.

26. The power converter as recited in claim 25 wherein said third conductive winding is formed as a staple.

27. The power converter as recited in claim 25 wherein said third conductive winding is electrically coupled to said first and second conductive windings.

28. The power converter as recited in claim 21 wherein said rectilinear core piece is formed with a distributed gap.

29. The power converter as recited in claim 21 wherein a relative permeability of said rectilinear core piece is substantially lower than a relative permeability of said first and second U-shaped core pieces.

30. The power converter as recited in claim 21 wherein said first and the second U-shaped core pieces are each formed as a portion of a toroidal core.