Fractional matrix transformer

Abstract

The disclosed concept relates to a fractional matrix transformer comprising a plurality of ferromagnetic core posts, a plurality of primary windings, and a plurality of secondary windings. Each secondary winding is wound around each stem a same number of times. For each core column, the sum of the number of turns formed by the plurality of primary windings around the respective core column is the same. In addition, the total number of turns formed around the plurality of stems by each respective primary winding is not equal to an integer multiple of the number of stems. Thus, for a given / target number of stems (e.g., due to form factor requirements), and for a given number of turns of the secondary winding (e.g., only one turn to minimize conduction loss), a greater turn ratio between the primary winding and the secondary winding is possible because the limitation that the number of turns of each primary winding is equal to an integer multiple of the number of stems is eliminated.

Description

Fractional matrix transformer Technical Field

[0001] This disclosure generally relates to matrix transformers and methods for manufacturing matrix transformers. Background Technology

[0002] A matrix transformer is equivalent to a single transformer divided into multiple independent transformers. To convert a conventional transformer into a matrix transformer, the transformer's core is divided into the required number of cores. The primary winding of a single transformer is assigned to the new cores. For example, a primary winding with two turns assigned to two cores will be wound one turn around each core. The secondary winding is then repeated in each core. The primary windings are then connected in series, and the secondary windings are connected in parallel.

[0003] The advantage of using a matrix transformer lies in the fact that the output current is distributed across each parallel secondary winding, resulting in reduced total resistance and leakage inductance. In particular, using a matrix transformer in a DC-DC converter offers several benefits. Typically, this enables higher power density and efficiency compared to conventional transformer designs. This is due to improved magnetic coupling and reduced leakage inductance, which allows for better energy transfer and reduced power losses. In a matrix transformer, the magnetic circuit is segmented along with the windings, facilitating better current propagation through the windings.

[0004] The form factor of a matrix transformer typically depends on the number of cores. In many applications, a specific form factor (e.g., a specific length and width) may be desired. However, in a typical matrix transformer, for a given number of cores, the number of turns in the primary winding needs to be an integer multiple of the number of cores.

[0005] Therefore, a matrix transformer with a given shape factor and an adjustable turns ratio is required. Summary of the Invention

[0006] According to one aspect, a matrix transformer is provided.

[0007] A matrix transformer comprises multiple ferromagnetic core columns, multiple primary windings, and multiple secondary windings, with each core column including one secondary winding. For each core column, the sum of the number of turns formed by the multiple primary windings around that corresponding core column is the same. Furthermore, the total number of turns formed by each corresponding primary winding around the multiple core columns is not an integer multiple of the number of core columns. The number of primary windings equals the number of core columns. Each secondary winding is wound around each core column the same number of times.

[0008] According to another aspect of this disclosure, a hybrid switched capacitor including the matrix transformer described above is provided.

[0009] According to another aspect of this disclosure, a hybrid switched capacitor converter including the hybrid switched capacitor as described above is provided.

[0010] According to another aspect of this disclosure, a method for manufacturing a matrix autotransformer is provided. The method includes: providing a plurality of ferromagnetic core posts; and winding each of a plurality of primary windings around the plurality of ferromagnetic core posts, wherein: for each core post, the sum of the number of turns formed by the plurality of primary windings around the corresponding core post is the same, and the total number of turns formed by each corresponding primary winding around the plurality of core posts is not an integer multiple of the number of core posts. The number of primary windings is equal to the number of core posts. The method further includes winding each of a plurality of secondary windings around the plurality of core posts, wherein the plurality of secondary windings includes one secondary winding for each of the plurality of core posts, and each secondary winding is wound around each core post the same number of times.

[0011] Those skilled in the art will recognize additional features and advantages upon reading the following detailed description and accompanying drawings. Attached Figure Description

[0012] The invention will now be described by way of example with reference to the accompanying drawings, in which:

[0013] Figure 1 shows a circuit diagram of a hybrid switched capacitor (HSC) converter including a matrix transformer;

[0014] Figure 2 shows the connection and wiring of the primary and secondary windings surrounding the core of the matrix transformer included in the HSC converter of Figure 1.

[0015] Figure 3 shows a conventional transformer and its known equivalent matrix transformer;

[0016] Figure 4 illustrates a matrix transformer and an equivalent conventional transformer according to an embodiment of the present invention;

[0017] Figure 5 illustrates another matrix transformer and an equivalent conventional transformer according to an embodiment of the present invention;

[0018] Figure 6 illustrates yet another matrix transformer and an equivalent conventional transformer according to an embodiment of the present invention;

[0019] Figure 7 shows a flowchart of a method for manufacturing a matrix transformer according to an embodiment of the present invention.

[0020] It should be noted that these figures are schematic diagrams and not drawn to scale. For clarity and convenience, the relative dimensions and proportions of the parts in these figures have been enlarged or reduced. Detailed Implementation

[0021] The following description illustrates exemplary aspects of this disclosure. However, it should be understood that such description is not intended to limit the scope of this disclosure. Rather, the description also covers combinations and modifications of those exemplary aspects described herein.

[0022] The disclosed concept relates to a matrix transformer with multiple core posts, primary windings, and secondary windings. The proposed scheme is that, for each core post, the sum of the number of turns formed by the multiple primary windings around the corresponding core post is the same, and for at least two of the multiple primary windings, the total number of turns formed by each corresponding primary winding around the multiple core posts is not an integer multiple of the number of core posts. In other words, compared to a typical matrix transformer, some of the primary windings are not wound (i.e., turned) the same number of times around each core post. However, the sum of the number of turns formed by the primary windings around each core post is the same. Therefore, balancing operation of the matrix transformer is possible, but the number of turns formed by a single primary winding does not have to be an integer multiple of the number of core posts. Thus, more choices of the transformation ratio of the matrix transformer are possible.

[0023] In other words, the proposed concept relates to a matrix transformer comprising multiple ferromagnetic core posts, multiple primary windings, and multiple secondary windings. Each secondary winding is wound around each core post the same number of times. For each core post, the sum of the number of turns formed by the multiple primary windings around the corresponding core post is the same. Furthermore, the total number of turns of each corresponding primary winding around the multiple core posts is not an integer multiple of the number of core posts. Therefore, for a given / target number of core posts (e.g., due to form factor requirements) and for a given number of secondary winding turns (e.g., only one turn to minimize conduction losses), a larger turns ratio between the primary and secondary windings is possible because the restriction that the number of turns of each primary winding must be an integer multiple of the number of core posts is eliminated.

[0024] It's important to clarify that a specific number of core posts is typically required when designing matrix transformers, as the number of core posts (and their layout, dimensions, etc.) is a major parameter determining the form factor of the matrix transformer. Therefore, in many cases, for example, two or three core posts are desirable. Furthermore, it's desirable to minimize the number of turns per secondary winding around the associated core post, as the secondary winding carries very high currents. This is especially true for high-power applications. Therefore, it's convenient to choose the minimum number of secondary winding turns to minimize conduction losses. Finally, it's generally advisable that the total number of turns per primary winding around all core posts is an integer multiple of the number of core posts.

[0025] In summary, the situation is that a matrix transformer requires a predetermined number of cores (to provide a given form factor), and each secondary winding has only one turn (to minimize conduction losses). The only parameter that can be changed is the number of turns formed in the primary winding. However, because this parameter is restricted to an integer multiple of the number of cores, the transformation ratio of the matrix transformer may only be equal to some discrete values.

[0026] Therefore, this disclosure proposes that the number of times each primary winding is wound around a core post is not an integer multiple of the number of core posts. For example, the first primary winding may be wound once around the first core post and twice around the second core post, for a total of 3 turns. To provide balancing operation, the second primary winding may be wound twice around the first core post and once around the second core post, for a total of 3 turns, while also ensuring that the sum of the total number of turns formed by all primary windings around each core post is the same (3 times in the example case). Of course, different numbers of core posts and turns are possible, as long as the following conditions are met:

[0027] (i) For each core post, the sum of the number of turns of the multiple primary windings around the corresponding core post is the same; and

[0028] (ii) The total number of turns of each corresponding primary winding around multiple core posts is not an integer multiple of the number of core posts.

[0029] Provided that (i) and (ii) are satisfied, a greater number of transformation ratios are possible with a fixed number of core posts and secondary winding turns, while also having the balanced operation of a matrix transformer.

[0030] To best understand this disclosure, it is first important to understand the function of a matrix transformer, its applications, and how an equivalent matrix transformer is typically derived from a single transformer.

[0031] A matrix transformer is formed by dividing a single conventional transformer into an array of independent transformers connected in series on the primary side and in parallel on the secondary side. The advantage of using a matrix transformer is that the output current is distributed across each parallel secondary winding, resulting in reduced total resistance and leakage inductance. When a certain form factor is favorable (e.g., a long and thin converter), a slender matrix transformer can be the optimal choice.

[0032] In one implementation, a matrix transformer can be used in a DC-DC converter. Integrating a matrix transformer into a DC-DC converter offers several benefits. Typically, higher power density and efficiency can be achieved compared to conventional transformer designs. This is due to improved magnetic coupling and reduced leakage inductance, enabling better energy transfer and lower power losses. In a matrix transformer, the magnetic circuit is segmented along with the windings, allowing for better propagation of winding current.

[0033] Figure 1 illustrates an exemplary DC-DC converter. The matrix transformer 100 can be used in a hybrid switched capacitor converter (HSC) 10. The HSC includes a 2-column matrix transformer 100 having two primary windings 120 and two secondary windings 130.

[0034] As shown in the figure, the matrix transformer 100 is implemented as an autotransformer, which has a single winding shared by both the primary winding 120 and the secondary winding 130.

[0035] Figure 2 illustrates the arrangement of the windings around the core post 110 of the matrix transformer 100, the wiring of the two primary windings 120 and the two secondary windings 130, and an example of their interconnection. As shown, the first primary winding is connected between the first phase input ph1 and the first input in1. The second primary winding is connected between the second phase input ph2 and the second input in2. Both the first and second primary windings are wound once around each of the two core posts 110 and connected in series. The first primary winding is connected between the first phase input ph1 and the second input in2. out Between the outputs. The second-stage winding is connected between the second-phase input ph2 and the output v. out Between. The first-stage winding and the second-stage winding are each wound once around the two core posts 110 and connected in parallel.

[0036] Of course, it should be noted that HSC can be implemented with more core posts 110 and more primary and secondary windings (120, 130). In addition, the primary and secondary windings (120, 130) can be wound around the core post 110 more times than shown in Figure 2.

[0037] It is known that when the HSC shown in Figure 1 is implemented, the transformation ratio C is given by the following formula:

[0038] [1]

[0039] Where V in It is the input voltage, V out N1 is the output voltage, N2 is the number of turns in each primary winding, and N2 is the number of turns in each secondary winding.

[0040] In high-power applications, the secondary winding 130 carries very high current amplitudes. Therefore, as a design rule, the minimum N2 is typically chosen to minimize conduction losses. Some typical turns ratio combinations for HSC converters with matrix transformer 100 are shown in the table below.

[0041] N1N2C=V in / V out 31102181160.515 surface

[0042] It should be noted that HSC converters typically offer a conversion ratio C between 5:1 and 10:1. Ratios below 5:1 require more turns in the secondary winding, thus significantly increasing conduction losses. Ratios above 10:1, with the primary winding 120 delivering only a negligible fraction of the current to the output, no longer justify the complexity of this approach.

[0043] As mentioned above, it is desirable for the secondary winding 130 to have the minimum number of turns (i.e., per turn), so N2 is typically set to 1. Furthermore, the number of turns in the primary winding 120 must be proportional to the desired number of cores 110 (i.e., it must be an integer multiple of the number of cores 110). Therefore, only certain transformation ratios C are possible.

[0044] Figure 3 depicts a simplified example of a matrix transformer 100 for an HSC converter with an 8:1 conversion ratio C. A conventional transformer including windings is shown on the left, with two primary windings 120, each wound twice around a single core post (i.e., N1=2). Two identical secondary windings 130 (only one shown for clarity) are wound once around a single core post (i.e., N2=1). Note that this is an exploded view (i.e., each winding is represented around a different core post) to make the windings clearly visible. In practice, all windings are provided around the same core post. Furthermore, note that these windings can be implemented on different layers and can be connected in parallel multiple times.

[0045] The equivalent matrix transformer 100 of the conventional transformer on the left is depicted on the right side of Figure 3. As shown, the core column is divided into a desired number of core columns N. legs In this configuration, there are two ferromagnetic core posts 110. Each of the primary windings 120 is assigned to a new core post 110. Therefore, the two turns of the first primary winding around a single core post become one turn of the first primary winding around both the first and second core posts. Similarly, the two turns of the second primary winding around a single core post also become one turn around both the first and second core posts. The secondary windings 130 are repeated on each core post and connected in parallel at the HSC converter level. Thus, a matrix transformer 100 is provided with two core posts 110, two primary windings 120, and two secondary windings 130, where the primary windings are two turns and the secondary windings 130 are one turn. Referring to the table above, if this matrix transformer 100 is provided in an HSC converter, an 8:1 conversion ratio C is achieved.

[0046] As can be seen from the process described, when the number of primary turns is an integer multiple of the number of core posts 110 (i.e., (where K=1, 2, 3, etc.), the conversion from a conventional transformer to a matrix transformer 100 is straightforward. However, when the desired primary number of turns is a non-integer multiple of the number of core posts 110 (i.e., For example, this method cannot be followed when a 2-core matrix transformer 100 is expected to have a transformation ratio C of 10:1.

[0047] Therefore, it is proposed that at least some of the primary windings 120 are not wound the same number of times around all the core posts 110. For example, the first primary winding may be wound once around the first core post and twice around the second core post. The second primary winding may be wound once around the second core post and twice around the first core post. This would give N1=3, N legs =2, and therefore Therefore, in this example, a transformation ratio C of 10 can be achieved. The resulting matrix transformer 100 can be referred to as a fractional matrix transformer 100.

[0048] More specifically, an equal number of primary windings 120, secondary windings 130, and core posts 110 are provided. The sum of the number of turns formed by the multiple primary windings 120 around their respective core posts is the same. The total number of turns formed by each corresponding primary winding around the multiple core posts 110 is not an integer multiple of the number of core posts 110. In other words, although the total number of turns formed by the primary windings 120 is the same, each primary winding is wound around a given core post a different number of times. The process for the secondary windings 130 remains unchanged. That is, each secondary winding is wound around each core post the same number of times (typically once around each core post).

[0049] The proposed winding arrangement can be used when employing a symmetrical converter, meaning the transformer has two equal primary windings 120, as in the case of an HSC converter, for example. The secondary windings 130 are connected in parallel, following a classic matrix arrangement (i.e., repetition and parallel).

[0050] In some embodiments, multiple primary windings 120 are wound around the core post 110 in a consistent clockwise or counterclockwise winding direction. That is, each primary winding is wound either clockwise or counterclockwise around the core post 110, rather than winding clockwise around some core posts 110 and counterclockwise around others. It should be clarified that some of the primary windings 120 may be wound / turned in a consistent clockwise direction around the core post 110, while other primary windings 120 may be wound / turned in a consistent counterclockwise direction around the core post 110.

[0051] Furthermore, it should be noted that in application, multiple primary windings 120 are connected in series. That is, the end of one primary winding can be connected to the end of another primary winding, and so on. Additionally, multiple secondary windings 130 are connected in parallel. Therefore, one end of each secondary winding 130 is connected to a node, and the opposite end of each secondary winding 130 is connected to another node.

[0052] In an exemplary embodiment, each secondary winding is wound one turn around each post. In other words, the first secondary winding may be wound once around the first post and once around the second post, the second secondary winding may be wound once around the first post and once around the second post, and so on. As mentioned above, this is ideal for minimizing resistive losses on the secondary side. However, it should be understood that some configurations may require each secondary winding to be wound more than one turn around each post. In any case, each secondary winding is wound the same number of times around each post.

[0053] An exemplary matrix transformer 100 with two core posts 110 and an equivalent conventional transformer are depicted in Figure 4. More specifically, the figure depicts a simplified example of a matrix transformer 100 for an HSC converter with a 10:1 conversion ratio. Similar to Figure 3, a conventional transformer including windings is again shown on the left, where each of the two primary windings 120 is wound three times around a single core post (i.e., N1=3). Two identical secondary windings 130 (only one is shown for clarity) are wound once around a single core post (i.e., N2=1).

[0054] The equivalent matrix transformer 100 of the conventional transformer on the left is depicted on the right. The core column is divided into a desired number of core columns 110. In this case, there are two ferromagnetic core columns 110. Each of the primary windings 120 is then assigned to a new core column 110.

[0055] Specifically, a first ferromagnetic core post and a second ferromagnetic core post are provided, as well as a first primary winding and a second primary winding, and a first secondary winding and a second secondary winding. The first primary winding is wound around the first core post for a first number of turns, and the second primary winding is wound around the second core post for a first number of turns. The first primary winding is also wound around the second core post for a second number of turns, and the second primary winding is wound around the first core post for a second number of turns. As shown, each primary winding is wound in a consistent clockwise and / or counterclockwise direction. Typically, the first number is not equal to the second number. In this case, the first number is one, and the second number is two. Of course, in other examples, these numbers can be reversed. In other examples, these numbers can be completely changed. In any case, at least one of the first number and the second number is not an integer multiple of the number of core posts 110.

[0056] Furthermore, the first-stage winding is wound a third time around the first and second core posts, and the second-stage winding is wound a third time around the first and second core posts. In this case, the third number is one. However, the third number can be greater than one.

[0057] In other words, the total number of turns N1 of each primary winding must be formed using any available core post and with a consistent winding direction (e.g., clockwise or counterclockwise). As shown, the first primary winding must form three turns, with one turn around the first core post and two turns around the second core post. In other words, the first primary winding is wound once around the first core post 110 and once around the second core post 110, and then wound once more around the second core post. Similarly, the second primary winding must form three turns, with two turns around the first core post and one turn around the second core post. It is important to note that the wiring of the second primary winding must be symmetrical to that of the first primary winding. This is to ensure that the total number of turns formed around each core post is the same.

[0058] As before, the secondary winding 130 repeats around each core post and is connected in parallel at the HSC converter level. Therefore, a matrix transformer 100 is provided with two core posts 110, two primary windings 120, and two secondary windings 130, where the primary windings 120 are three turns and the secondary windings 130 are one turn. Referring to the table above, if this matrix transformer 100 is provided in an HSC converter, a conversion ratio C of 10:1 is achieved. Consistency can be checked by calculating the ampere-turns experienced by each core post. If all core posts 110 have the same primary winding ampere-turns, the design is correct.

[0059] As a further example, Figure 5 depicts another example matrix transformer 100 with two core posts 110, as well as an equivalent conventional transformer. More specifically, the figure depicts a simplified example of a matrix transformer 100 according to an HSC converter with a 6:1 transformation ratio. Similar to Figure 3, a conventional transformer including windings is again shown on the left, where two primary windings 120 are each wound once around a single core post (i.e., N1=1). Two identical secondary windings 130 (only one is shown for clarity) are wound once around a single core post (i.e., N2=1).

[0060] The equivalent matrix transformer 100 of the conventional transformer on the left is depicted on the right. The core column is divided into a desired number of core columns 110. In this case, there are two ferromagnetic core columns 110. Each of the primary windings 120 is then assigned to a new core column 110.

[0061] Specifically, a first ferromagnetic core post and a second ferromagnetic core post are provided, as well as a first primary winding and a second primary winding, and a first secondary winding and a second secondary winding. The first primary winding is wound around the first core post for a first number of turns, and the second primary winding is wound around the second core post for a first number of turns. The first primary winding is also wound around the second core post for a second number of turns, and the second primary winding is wound around the first core post for a second number of turns. As shown, each primary winding is wound in a consistent clockwise and / or counterclockwise direction. Typically, the first number is not equal to the second number. In this case, the first number is zero, and the second number is one. Of course, in other examples, these numbers can be reversed.

[0062] Furthermore, as described above, the first-stage winding is wound a third time around the first and second core posts, and the second-stage winding is wound a third time around the first and second core posts. In this case, the third number is one. However, the third number can be greater than one.

[0063] Therefore, the matrix transformer 100 is configured with two cores 110, two primary windings 120, and two secondary windings 130, wherein the primary windings 120 are one turn and the secondary windings 130 are one turn. Referring to the table above, if this matrix transformer 100 is provided in an HSC converter, a conversion ratio C of 6:1 is achieved.

[0064] As illustrated in the examples in Figures 4 and 5, this disclosure enables a higher transformation ratio with a fixed number of cores 110 and secondary winding turns. This is achieved by ensuring that the number of turns in the primary winding 120 is not an integer multiple of the number of cores 110.

[0065] To provide yet another example, Figure 6 depicts another example of a matrix transformer 100 and its equivalent conventional transformer. In this example, the matrix transformer 100 has three core posts 110. Similar to Figures 3 through 5, a conventional transformer including windings is again shown on the left, where each of the three primary windings 120 is wound four times around a single core post (i.e., N1=4). Three identical secondary windings 130 (only one is shown for clarity) are wound once around a single core post (i.e., N2=1).

[0066] The equivalent matrix transformer 100 of the conventional transformer on the left is depicted on the right. The core column is divided into a desired number of core columns 110. In this case, there are three ferromagnetic core columns 110. Each of the primary windings 120 is then assigned to a new core column 110.

[0067] Specifically, a first ferromagnetic core post, a second ferromagnetic core post, and a third ferromagnetic core post are provided, as well as a first primary winding, a second primary winding, and a third primary winding. Each of the first, second, and third primary windings is wound once around the core post 110. However, this leaves one extra turn. Therefore, each of the first, second, and third primary windings is wound one more turn around a different core post 110. Thus, the first primary winding is wound one more turn around the third core post, the second primary winding is wound one more turn around the second core post, and the third primary winding is wound one more turn around the first core post. Of course, as long as the total number of turns around each core post is equal (in this case, four turns around each core post), each of the first to third primary windings 120 can be wound one more turn around an alternative core post 110.

[0068] Furthermore, as described above, the first-stage winding is wound a third number around the first, second, and third core posts; the second-stage winding is wound a third number around the first, second, and third core posts; and the third-stage winding is wound a third number around the first, second, and third core posts. In this case, the third number is one. However, the third number can be greater than one.

[0069] Although not depicted, it should be understood that the number of times each primary winding is wound exceeds [a certain number]. In the case where N legs When >2 (e.g., every five times or N1=5, where N legs If N1 = 3, then the additional turns required after all primary windings 120 are formed (in the example case, two more turns are needed) must be allocated equally. When N1 = 5 and N... legs When the number of turns is 3, two additional turns are formed for each primary winding. Therefore, the first primary winding can be wound around the first and second core posts an additional number of times, the second primary winding can be wound around the second and third core posts an additional number of times, and the third primary winding can be wound around the first and third core posts an additional number of times. This means that the following conditions must be met: (i) for each core post, the sum of the number of turns formed by the multiple primary windings 120 around the corresponding core post is the same; and (ii) the total number of turns formed by each corresponding primary winding around the multiple core posts 110 is not equal to an integer multiple of the number of core posts 110.

[0070] Of course, other combinations of the number of cores 110 and the number of turns of the primary winding 120 and the secondary winding 130 are possible. How to apply the above principles to different combinations of cores 110 and turns to provide a balanced matrix transformer 100 without much effort will be obvious to those skilled in the art.

[0071] Turning now to Figure 7, a method for manufacturing a matrix transformer 100 according to an embodiment of the present invention is depicted.

[0072] In step 210, a plurality of ferromagnetic core columns are provided. The ferromagnetic core columns can be prefabricated or manufactured using any known process for producing ferromagnetic cores suitable for transformers. Additionally, a plurality of primary windings and a plurality of secondary windings can be provided. The number of primary windings and the number of secondary windings must equal the number of core columns.

[0073] In step 220, each of the plurality of primary windings 120 is wound around a plurality of ferromagnetic core posts (i.e., twisted). Each of the primary windings is wound around a core post. That is, the total number of turns formed by each primary winding around the plurality of core posts is not an integer multiple of the number of core posts.

[0074] Therefore, for example, if there are two core posts, each primary winding will wrap around a single core post an odd number of times (i.e., a number not a multiple of two). More generally, given N... legs Let K be the number of core posts, K be any positive integer, and N1 be the number of turns in each primary winding. .

[0075] In addition, the sum of the number of turns formed by multiple primary windings around the corresponding core post must be the same. That is, for each core post, the total number of turns formed by all primary windings around the corresponding core post must be the same number.

[0076] In some implementations, each corresponding primary winding turn comprises winding the winding around the core in a consistent clockwise or counterclockwise direction. That is, each turn of a separate primary winding may have the same orientation around the core.

[0077] In step 230, and similar to the standard process for manufacturing a matrix transformer, each of the multiple secondary windings is wound around a plurality of core posts. Each secondary winding is wound around each core post the same number of times. Typically, each secondary winding may be wound around each core post once. However, in some cases, each secondary winding may be wound around each core post more than once.

[0078] In some implementations, winding each corresponding secondary winding includes winding the winding around the core in a consistent clockwise or counterclockwise direction. That is, each turn of a separate secondary winding may have the same orientation around the core.

[0079] Then, in step 240, each of the multiple primary windings can be connected in series. In step 250, each of the multiple secondary windings can be connected in parallel.

[0080] Therefore, a method for manufacturing a matrix transformer is provided that does not require the primary winding to have a number of turns equal to an integer multiple of the number of cores. From another perspective, for a given number of cores (e.g., determined by form factor, manufacturing, or cost requirements) and a given number of turns in the secondary winding (e.g., determined by the need to reduce secondary-side resistance losses), a wider range of turns ratios between the primary and secondary windings is possible.

[0081] While specific examples have been shown and described herein, those skilled in the art will understand that various alternatives and / or equivalent implementations may be used instead of the specific examples shown and described without departing from the scope of this disclosure. This application is intended to cover any changes or variations to the specific examples discussed herein. Therefore, this disclosure is intended to be limited only by the claims and their equivalents.

[0082] It should be noted that the methods and apparatus (including their preferred embodiments) outlined in this document can be used alone or in combination with other methods and apparatus disclosed in this document. Furthermore, features outlined in the context of the apparatus also apply to the corresponding methods, and vice versa. Moreover, all aspects of the methods and apparatus outlined in this document can be combined arbitrarily. In particular, the features of the claims can be combined with each other in any manner.

[0083] It should be noted that the description and accompanying drawings only illustrate the principles of the proposed methods and systems. Those skilled in the art will be able to implement various arrangements, which, while not explicitly described or shown herein, embody the principles of the invention and are included within its spirit and scope. Furthermore, all examples and embodiments outlined in this document are primarily and explicitly intended for illustrative purposes only to aid the reader in understanding the principles of the proposed methods and systems. Moreover, all statements and specific examples of the principles, aspects, and embodiments of the invention provided herein are intended to cover their equivalents.

[0084] The following implementation methods are disclosed:

[0085] 1. A matrix transformer, comprising:

[0086] Multiple ferromagnetic core pillars;

[0087] Multiple primary windings, of which:

[0088] For each core post, the sum of the number of turns formed by the plurality of primary windings around the corresponding core post is the same.

[0089] The total number of turns of each corresponding primary winding around the plurality of core posts is not an integer multiple of the number of core posts.

[0090] The number of primary windings is equal to the number of core posts; and

[0091] Multiple secondary windings, wherein the number of secondary windings is equal to the number of core posts, and each secondary winding is wound around each core post the same number of times.

[0092] 2. The matrix transformer according to embodiment 1, wherein each of the plurality of primary windings is wound around the core post in a consistent clockwise or counterclockwise turning direction.

[0093] 3. The matrix transformer according to any one of embodiments 1 or 2, wherein the plurality of primary windings are connected in series.

[0094] 4. The matrix transformer according to any one of embodiments 1 to 3, wherein the plurality of secondary windings are connected in parallel.

[0095] 5. The matrix transformer according to any one of embodiments 1 to 4, wherein each secondary winding is wound one turn around each core post.

[0096] 6. The matrix transformer according to any one of embodiments 1 to 5, comprising:

[0097] First ferromagnetic core column and second ferromagnetic core column;

[0098] First primary winding and second primary winding, wherein:

[0099] The first primary winding is wound around the first core post for the first number of times, and the second primary winding is wound around the second core post for the first number of times.

[0100] The first primary winding is wound around the second core post a second time, and the second primary winding is wound around the first core post a second time.

[0101] Wherein, the first number is not equal to the second number; and

[0102] The first-stage winding and the second-stage winding, wherein the first-stage winding is wound a third time around the first core post and the second core post, and the second-stage winding is wound the third time around the first core post and the second core post.

[0103] 7. The matrix transformer according to embodiment 6, wherein the first number is equal to two and the second number is equal to three.

[0104] 8. The matrix transformer according to embodiment 6, wherein the first number is equal to one and the second number is equal to zero.

[0105] 9. The matrix transformer according to any one of embodiments 6 to 8, wherein the third number is equal to one.

[0106] 10. A hybrid switched capacitor HSC converter, comprising a matrix transformer according to any one of embodiments 1 to 9.

[0107] 11. A method for manufacturing a matrix transformer, the method comprising:

[0108] Multiple ferromagnetic core posts are available;

[0109] Each of the plurality of primary windings is wound around the plurality of ferromagnetic core pillars, wherein:

[0110] For each core post, the sum of the number of turns of the plurality of primary windings around the corresponding core post is the same, and

[0111] The total number of turns formed by each corresponding primary winding around the plurality of core posts is not an integer multiple of the number of core posts, and

[0112] The number of primary windings is equal to the number of core posts; and

[0113] Each of a plurality of secondary windings is wound around the plurality of core posts, wherein the number of secondary windings is equal to the number of core posts, and each secondary winding is wound around each core post the same number of times.

[0114] 12. The method according to embodiment 11, wherein, for each of the plurality of primary windings and the plurality of secondary windings, winding the corresponding primary winding or the corresponding secondary winding includes winding the winding around the core post in a consistent clockwise or counterclockwise winding direction.

[0115] 13. The method according to embodiment 11 or 12 further includes connecting the plurality of primary windings in series.

[0116] 14. The method according to any one of embodiments 11 to 13 further includes connecting the plurality of secondary windings in parallel.

Claims

1. A matrix transformer (100), comprising: Multiple ferromagnetic core pillars (110); Multiple primary windings (120), wherein: for each ferromagnetic core post, the sum of the number of turns formed by the multiple primary windings around the corresponding ferromagnetic core post is the same, the total number of turns formed by each corresponding primary winding around the multiple ferromagnetic core posts is not an integer multiple of the number of ferromagnetic core posts, and the number of primary windings is equal to the number of ferromagnetic core posts; and multiple secondary windings (130), wherein the number of secondary windings is equal to the number of ferromagnetic core posts, and each secondary winding is wound around each ferromagnetic core post the same number of times.

2. The matrix transformer according to claim 1, wherein, Each of the plurality of primary windings (120) is wound around the ferromagnetic core post (110) in a consistent clockwise or counterclockwise winding direction.

3. The matrix transformer according to any one of claims 1 to 2, wherein, The multiple primary windings (120) are connected in series.

4. The matrix transformer according to any one of claims 1 to 3, wherein, The multiple secondary windings (130) are connected in parallel.

5. The matrix transformer according to any one of claims 1 to 4, wherein, Each secondary winding is wound one turn around each ferromagnetic core post.

6. The matrix transformer according to any one of claims 1 to 5, comprising: First ferromagnetic core column and second ferromagnetic core column; A first primary winding and a second primary winding, wherein: the first primary winding is wound around the first ferromagnetic core post for a first number of times, and the second primary winding is wound around the second ferromagnetic core post for the first number of times, and the first primary winding is wound around the second ferromagnetic core post for a second number of times, and the second primary winding is wound around the first ferromagnetic core post for the second number of times, and wherein the first number of times is not equal to the second number of times; and a first primary winding and a second primary winding, wherein the first primary winding is wound around the first ferromagnetic core post and the second ferromagnetic core post for a third number of times, and the second primary winding is wound around the first ferromagnetic core post and the second ferromagnetic core post for the third number of times.

7. The matrix transformer according to claim 6, wherein, The first number of times is two, and the second number of times is three.

8. The matrix transformer according to claim 6, wherein, The first number is equal to one, and the second number is equal to zero.

9. The matrix transformer according to any one of claims 6 to 8, wherein, The third number is equal to one.

10. A hybrid switched capacitor HSC converter (10) comprising a matrix transformer (100) according to any one of claims 1 to 9.

11. A method for manufacturing a matrix transformer, the method comprising: Provide (210) multiple ferromagnetic core posts; Each of a plurality of primary windings is wound around the plurality of ferromagnetic core posts (220 turns), wherein: for each ferromagnetic core post, the sum of the number of turns formed by the plurality of primary windings around the corresponding ferromagnetic core post is the same, and the total number of turns formed by each corresponding primary winding around the plurality of ferromagnetic core posts is not an integer multiple of the number of ferromagnetic core posts, and the number of primary windings is equal to the number of ferromagnetic core posts; and each of a plurality of secondary windings is wound around the plurality of ferromagnetic core posts (230 turns), wherein the number of secondary windings is equal to the number of ferromagnetic core posts, and each secondary winding is wound around each ferromagnetic core post the same number of times.

12. The method according to claim 11, wherein, For each of the plurality of primary windings and the plurality of secondary windings, winding the corresponding primary winding (220) or winding the corresponding secondary winding (230) includes winding the winding around the ferromagnetic core in a consistent clockwise or counterclockwise winding direction.

13. The method according to claim 11 or 12, further comprising connecting the plurality of primary windings in series (240).

14. The method according to any one of claims 11 to 13, further comprising connecting the plurality of secondary windings in parallel (250).

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