Magnetic device and power converter comprising such a magnetic device

Abstract

Magnetic device comprising: a first L-core segment with a first leg and a second leg extending from it; a different, opposing second L-core segment with a first leg and a second leg extending therefrom, wherein the first leg of the first L-core segment is connected to the second leg of the second L-core segment and the second leg of the first L-core segment is connected to the first leg of the second L-core segment; a primary winding that is wound around the first leg of the second L-core segment; and a secondary winding provided with a central tap, comprising a first secondary winding and a second secondary winding formed around the first leg of the second L-core segment, wherein the first secondary winding and the second secondary winding are formed above the primary winding around the first leg of the second L-core segment.

Description

Technical field

[0001] The present invention relates generally to power electronics and in particular to a magnetic device and a power converter comprising such a magnetic device. background

[0002] A switched-mode power supply (also known as a "power converter" or "regulated power supply") is a power supply circuit that converts an input voltage waveform into a defined output voltage waveform. Magnetic devices, such as transformers and inductors, are often used in power converters to store and / or transfer electrical energy. Because these magnetic devices typically occupy a significant amount of space on the power converter's substrate and consume a disproportionate amount of manufacturing time, it is advantageous to use a compact magnetic device that allows for flexible design. Therefore, there is a need in the field for a component for a less complex magnetic core that can be integrated into compact magnetic devices.

[0003] US Patent 5,283,728 A describes a voltage control system consisting of a pair of coils nested clockwise and counterclockwise on a portion of a transformer core. The coils have multiple spaced turns forming sets of coplanar, alternating electrical contact pairs. These extend linearly to form a tap system for varying the transformer's output voltage.

[0004] US 2001 / 0043135A1 describes how an inductive resistor is manufactured from a conductor and a flexible, plate-shaped support element.

[0005] US 2011 / 0148559A1 describes a coil with multiple windings comprising a first foil winding and a second foil winding. One end of the first foil winding extends from a first side of the core and is wrapped under the core to form a solder lug beneath the core.

[0006] US Patent 7,675,764 B2 describes a power converter with input and output nodes and a method for its operation. The power converter includes a switching circuit with a first, a second, and a third active phase line. Each of the first, second, and third active phase lines comprises a first switch coupled to one of the input nodes and a second switch coupled to another of the input nodes, with a common switching node between them. The power converter further comprises a magnetic device with a first, a second, and a third primary winding, and a first, a second, and a third secondary winding. The first, second, and third primary windings are each coupled to the common switching node of the first, second, and third active phase lines, respectively.The power converter further comprises a rectifier with a first, a second and a third rectifier element, each of which is arranged between the first, the second and the third secondary winding and one of the output nodes.

[0007] CN 2 01 196 897 Y describes an improved transformer comprising a magnetic core and primary and secondary windings mounted on this core. The magnetic core consists of stacked silicon steel sheets arranged in a hollow square structure. This design eliminates waste and saves material, as the sheets are made entirely of sheet metal. The structure simplifies the stamping process, reduces production costs, and is both economical and environmentally friendly.

[0008] US Patent 2008 / 0024261A1 describes a high-voltage transformer with an optimized arrangement of the primary winding relative to the secondary winding. This achieves close electromagnetic coupling and improved ease of assembly. Both windings are wound around a coil former, in the cavity of which a magnetic core is inserted. The primary winding consists of resin-coated conductive laminated coils and is arranged around the secondary winding. A positioning device allows for flexible and optimal arrangement of the primary winding, thereby modulating the electromagnetic coupling. Summary of the invention

[0009] Advantageous embodiments of the present invention, which include a magnetic device and a power converter comprising such a magnetic device, generally offer technical advantages. In one embodiment, the magnetic device comprises a first L-core segment with a first leg and a second leg extending therefrom, and a different, opposing second L-core segment with a first leg and a second leg extending therefrom, wherein the first leg of the first L-core segment is connected to the second leg of the second L-core segment, and the second leg of the first L-core segment is connected to the first leg of the second L-core segment. a primary winding which is wound around the first leg of the second L-core segment, a secondary winding provided with a central tap, comprising a first secondary winding and a second secondary winding which are formed around the first leg of the second L-core segment, wherein the first secondary winding and the second secondary winding are formed above the primary winding around the first leg of the second L-core segment. Brief description of the drawing

[0010] For a more comprehensive understanding of the present invention, reference is now made to the following description, which has been made in connection with the accompanying drawing, wherein: Fig. 1 shows a block diagram of an embodiment of a power converter; Fig. 2 and Fig. Three circuit diagrams of exemplary power transformers of a power converter are shown, which uses a boost converter; Fig. 4 and Fig. 5 circuit diagrams of embodiments of sections of power converters are shown; Fig. Figure 6 shows a time sequence diagram illustrating the operation of the power converter. Fig. 4 and Fig. 5 shows; Fig. 7 and Fig. 8 Circuit diagrams of alternative embodiments of power converter sections are shown; Fig. Figure 9 shows a circuit diagram of an alternative embodiment of a power converter; Fig. Figure 10 shows a circuit diagram of an alternative embodiment of a power converter; Fig. Figure 11 shows a perspective view of an embodiment of an L-core segment of a magnetic device; Fig. Figure 12 shows a side view of an embodiment of an L-core segment of a magnetic device; and Fig. Figures 13 to 20 and 24 to 49 show views of embodiments of magnetic devices not belonging to the invention; Fig. Figures 21 to 23 show views of embodiments of magnetic devices belonging to the invention.

[0011] Matching numbers and symbols in the various figures generally refer to corresponding parts, unless otherwise stated, and are not described again after their first occurrence for the sake of brevity. The figures serve to illustrate the key aspects of exemplary embodiments. Detailed description of illustrative embodiments

[0012] The following section discusses in detail the manufacture and use of the previous embodiments.

[0013] First, to Fig. Figure 1, showing a block diagram of an embodiment of a power converter. The power converter is coupled to a source of electrical power providing an input AC voltage V. in supplies, for example, an AC power grid. The power converter has a power transformer 105, which is controlled by a controller 110. The controller 110 generally measures an operating characteristic of the power converter, such as an output voltage V. outThe power transformer controls, in response to the measured operating characteristic, a duty cycle (generally denoted by "D") of a switch within it to regulate the characteristic. The power transformer can form part of a power supply and supply power to other subsystems of it, such as a galvanically isolated DC-DC converter coupled to its output, which supplies a load with a constant voltage. The power transformer 105 can use a converter (e.g., a boost or buck converter) as described here. The power transformer 105 of the power converter generally has a variety of switches coupled to reactive circuit elements to provide the power conversion function.

[0014] Now to Fig. 2 and Fig. 3, which show circuit diagrams of exemplary power transformers of a power converter that uses a boost converter. First to Fig. Figure 2 shows a power transformer 200 that uses a boost converter. The power converter accepts an input voltage V at its input. in (e.g. an unregulated input AC voltage) from a source of electrical power such as an AC mains supply and provides a regulated output voltage V at one output of the power converter. out ready. According to the principles of a boost converter topology, the output voltage V out generally higher than the input voltage V in , so that one switching operation of this results in the output voltage V out can regulate. A main switch S1 (e.g., an "active" n-channel metal-oxide-semiconductor switch) of the boost converter is set to a conducting state for a first interval D by a gate driver signal GD, so that it controls the input voltage V. in via a rectifier bridge 205 to an inductive boost converter component L boostcouples. During the first interval D, a rectified input current or input current i flows. in through the inductive boost converter component L boost to the local ground of the circuit.

[0015] The duty cycle of the power transformer 200 in steady state, with continuous current in the inductive boost converter element L boost depends on the ratio of the input and output voltages V in and V out from, namely according to the following equation: D=1−VinVout.

[0016] During a complementary interval 1-D, the main switch S1 is set to a non-conducting state, and an auxiliary switch (e.g., a diode D1) conducts. In an alternative circuit arrangement, the auxiliary switch can contain a second active switching element that is controlled to conduct by a complementary gate driver signal. The diode D1 provides a path to maintain the continuity of the input current i. in , which is through the inductive boost converter component L boost flows. During the complementary interval 1-D, the inductive boost converter L takes on boost flowing input current i in from and can become zero and remain zero for a period of time, resulting in a "discontinuous line operating mode".

[0017] During the complementary interval 1-D, the current flows through the inductive boost converter element L. boostCurrent flows through diode D1 into an output filter capacitor C. In general, the duty cycle of the main switch S1 (and the complementary duty cycle of diode D1) can be adjusted to regulate the output voltage V. out the power converter is obtained. To regulate the output voltage V outTo maintain the efficiency of the power transformer, the conduction periods of the main and auxiliary switches can be essentially the same or different. However, it is understood by those skilled in the art that the conduction periods of the main and auxiliary switches can be separated by a short time interval, either by using "voltage-limiting" circuit elements (not shown) or by sequence control via the control circuit, in order to avoid cross-currents between them and advantageously reduce the switching losses associated with the power transformer. Circuit and control techniques for avoiding cross-currents between switches are well known to those skilled in the art and are not described in detail here for the sake of brevity.

[0018] Now to Fig. 3, in which an exemplary power transformer 300 of a power converter is shown, which uses a first boost converter connected to a first inductive boost converter element L boost1is coupled, and a second boost converter, which is coupled to a second inductive boost converter element L boost2 The two converters are coupled. The first boost converter contains a first main switch S1 and a first auxiliary switch (e.g., a first diode D1). The second boost converter contains a second main switch S2 and a second auxiliary switch (e.g., a second diode D2). The first main switch S1 receives a first gate driver signal GD. S1 , and the second main switch S2 receives a second gate driver signal GD S2The driver signals are generally controlled to be phase-shifted by approximately 180 degrees relative to each other. Phase-shifted operation of the boost converters produces a superposition effect that doubles the ripple frequency and reduces the absolute value of the ripple for an AC input current delivered to a rectifier bridge 305. The rectifier bridge 305 provides a rectified input current, or input current i. inA similar effect is achieved for the current supplied to an output filter capacitor C. Reducing the switching ripple of the input AC current helps to lower the requirements for an input filter (not shown) to attenuate unwanted high-frequency components. Although significant advantages can arise from the superposition effects of two boost converters, the design problems described earlier in the implementation of efficient inductive boost converter devices remain unresolved. The remaining circuit elements in Fig. 3 and in the following figures are those of Fig. 2 are similar; therefore, for the sake of brevity, they are generally not described again.

[0019] Now to Fig. 4 and Fig. 5, which show circuit diagrams of embodiments of power converter components. More precisely, they illustrate Fig. 4 a power transformer that incorporates a boost converter topology with two nested boost converters (e.g., a first and second boost converter) and a coupled inductive boost converter device L boost used. However, it is understood that other topologies, such as a buck converter topology with nested converters (e.g., a first and second converter) and a coupled inductive component, as described here, also fall within the broad scope of application of the present invention. The coupled inductive buck converter component L boost has a common winding N ic (between nodes 1 and 2), a first winding N sc1 (between nodes 2 and 3) and a second winding N sc2 (between nodes 2 and 4). The first winding N sc1 and the second winding N sc2 are each electrically and magnetically connected to the common winding N iccoupled. In an advantageous embodiment, the first winding N has sc1 and the second winding N sc2 same number of turns; they are referred to below by the reference symbol N S represented. In the figure, points are drawn next to the windings, each indicating the direction of the winding (i.e., the winding direction and the direction of the magnetically induced voltage within it).

[0020] In an advantageous embodiment, the nested boost converters are controlled to supply an input current with a high power factor. The first boost converter includes a first main switch (e.g., a field-effect transistor) S1 and a first auxiliary switch (e.g., a first diode D1) and is coupled to a section of the coupled inductive boost converter device L. boost coupled, which the common winding N ic and the first winding N sc1The second boost converter contains a second main switch (e.g., a field-effect transistor) S2 and a second auxiliary switch (e.g., a second diode D2) and is connected to a section of the coupled inductive boost converter component L. boost coupled, which the common winding N ic and the second winding N sc2 The output currents from the boost converters of the power transformer are combined and flow through the first and second diodes, D1 and D2, into an output filter capacitor C. Similarly, the rectified input current, or input current i, is also... in interlocked in the boost converter and flows through the common winding N ic The first and second main switches S1, S2 are controlled by control signals GD. S1 or GD S2 The system is controlled in such a way that a duty cycle control is maintained for each of the two nested boost converters. The control signals are typically GD. S1, GD S2 The control signals are phase-shifted by approximately 180 degrees relative to each other, ensuring a common duty cycle (generally denoted by "D") for each boost converter. It is also possible to use the control signals GD S1 , GD S2 The two inductors are controlled independently to obtain two different duty cycles and ensure that the inductor currents i1 and i2 are equal. A load, represented as a current source CS, is connected to the output terminals of the power converter, drawing a current i. o pulls.

[0021] Around a common limb (e.g., a center limb) of a magnetic core of the coupled inductive boost converter device L boost can a common winding N ic be designed with preselected windings. In an alternative embodiment, the common winding N icwith preselected windings arranged around a common leg of a magnetic core, which, geometrically speaking, is not centered. Therefore, the term "common leg" encompasses a leg of a magnetic core that, geometrically speaking, need not be centered. (See, for example, US 8,125,205 B2 or US Patent No. 8,125,205 entitled "Power Converter Employing Regulators with a Coupled Inductor," granted to Chandrasekaran et al. on February 28, 2012.)

[0022] Continuing with reference to Fig. 5, in which a circuit diagram of an alternative embodiment of a power converter with a power transformer having two nested boost converters is shown, wherein a coupling inductive boost converter element L boostis used. Other topologies, such as a buck converter topology with nested converters (e.g., a first and second converter) and a coupled inductive component, as described here, also fall within the broad scope of application of the present invention. The coupling inductive boost converter component L boost has a common winding N between nodes 1A and 1B ic on, coupled to node 2 thereof in a feedback branch of the boost converter, which is connected to the source of electrical power for the supply of an input voltage V in is connected. A first winding N sc1 of the coupling inductive boost converter component L boost is connected between nodes 2 and 3, and a second winding N sc2 is connected between nodes 2 and 4. The first winding N sc1 and the second winding N sc2are each magnetically connected to the common winding N ic coupled and electrically connected to the common winding N ic coupled. The functionality of the in Fig. 4 and Fig. The power converter shown in section 5 is essentially the same. The remaining elements in Fig. 5, which bear reference marks that correspond to those in Fig. The four items are essentially the same and are therefore not described again for the sake of brevity.

[0023] In another alternative embodiment of the coupling inductive boost converter device L boost can the first and second windings, N sc1 and N sc2 , be electrically coupled to each other outside the magnetic device and form a section of the coupling inductive boost converter component L boost form. In another alternative embodiment of the coupling inductive boost converter device L boost can the common winding N icconsist of two separate winding parts, each part being, as in Fig. 4 and Fig. 5 is specified for the corresponding winding, which couples in the power converter.

[0024] Now to Fig. 6, which includes a time-lapse diagram to illustrate the operation of the power converter of Fig. 4 and Fig. Figure 5 shows the period of a switching cycle. This period is determined by the variable T. S The periods during which the first and second main switches S1 and S2 are in a conducting state are represented by the quantity DT. s represented, assuming the same time interval for both. The first main switch S1 and the second main switch S2 are delayed by 0.5·Ts, as shown in Fig. 6 shown, actuated with a 180-degree phase shift.

[0025] Now to Fig. 7 and Fig. 8, in which circuit diagrams of alternative embodiments of power converter sections are shown. In particular, it shows Fig. 7 a power converter that uses a step-down converter with a coupled inductive component. Fig. Figure 8 shows a power converter that uses boost / deflector converters with a coupled inductive component. Although the operating principle of the power converters of Fig. 7 and Fig. 8 differs in order to take account of the operation as a buck converter or boost / blow converter, the basic ideas of the present invention with regard to the nested converters and coupled inductive components are analogous to the basic ideas described above and are not repeated below.

[0026] Now to Fig. Figure 9 shows a circuit diagram of an alternative embodiment of a power converter. The power converters contain two nested half-bridges, so-called isolated current double rectifiers (labeled "CDR-I" and "CDR-II"). The power converter is operated by applying an input AC voltage from a source of electrical power via a bridge rectifier (not shown) to produce an input DC voltage V. dc to supply to the corresponding primary windings. The input DC voltage V dc is via a first pair of switches connected in series S 11 , S 12 and via a second pair of switches connected in series S 21 , S 22 installed. The first pair of switches connected in series S 11 , S 12 is interconnected in a first node N1, and the second pair of switches S are connected in series. 21 , S 22is interconnected in a second node N2. The first and second pairs of switches S are connected in series. 11 , S 12 , S 21 , S 22 These are preferably field-effect transistors, each with a parasitic diode connected in parallel. Furthermore, the input DC voltage V dc also applied to a pair of capacitors C1, C2, which are connected to a first common node N c1 are interconnected. The control of the first pair and the second pair of switches connected in series S 11 , S 12 , S 21 , S 22 This is done by means of a controller 910 such that between the first node N1 and the first common node N c1 a first control voltage V p1 is generated and between the second node N2 and the first common node N c1 A second control voltage N2 is generated.

[0027] The first nested half-bridge, the isolated current double rectifier CDR-I, has two primary windings PR connected in series. 11 , PR 12 on, which via the first node N1 and the first common node N c1 are switched, and is therefore connected to the first control voltage V p1 controlled. The two secondary windings SC 11 , SC 12 are in an output node N o interconnected and connected to the primary windings PR 11 or PR 12 magnetically coupled. The two series-connected synchronous rectifier switches SR 11 , SR 12 are connected in parallel to the secondary windings SC 11 or SC 12 and are in a second common node N c2 interconnected. Similarly, the second nested half-bridge, the CDR-II dual current rectifier, has two primary windings PR connected in series. 21 , PR 22on, which via the second node N2 and the first common node N c1 are switched, and is therefore connected to the second control voltage V p2 controlled. The two secondary windings SC 21 , SC 22 are in an output node N o interconnected and connected to the primary winding PR 21 or PR 22 magnetically coupled. The two series-connected synchronous rectifier switches SR 21 , SR 22 are connected in parallel to the secondary winding SC 21 and SC 22 and are at the second common node N c2 interconnected. The synchronous rectifier switches SR 11 , SR 12 , SR 21 , SR 22 These are preferably field-effect transistors, each with a parasitic diode connected in parallel. Alternatively, the synchronous rectifier switches SR can be used. 11 , SR 12 , SR 21 , SR 22are replaced by diodes and oriented in the same way as the parasitic diodes. Between the output node N o and the second common node N c2 An output filter capacitor C3 is connected, with an output voltage V o to be delivered to a load coupled to it.

[0028] The input AC voltages are generated according to the symmetrical modulation scheme. Accordingly, the control voltages applied to the respective current double rectifiers are offset from each other by T. s / (2*N) phase-shifted, where T s where N is the switching period of the control voltages and N is the number of current doubler rectifiers. In the illustrated power converter with N = 2, the controller 910 controls the switches S 11 , S 12 , S 21 , S 22 so that the first control voltage V p1 and the second control voltage V p2 by a quarter of the leap period Ts are phase-shifted, which ensures that the rectified output currents of the two current double rectifiers are interlaced. Furthermore, the 910 controller provides the signals necessary for controlling the SR synchronous rectifier switches. 11 , SR 12 , SR 21 , SR 22 The 910 controller controls the aforementioned switches according to the output voltage V. o of the power converter. (See, for example, US 7,046,523 B2 or US Patent No. 7,046,523 entitled "Core Structure and Interleaved DC-DC Converter Topology", granted to Sun et al. on May 16, 2006, and US 8,134,443 B2 or US Patent No. 8,134,443 entitled "Extended E Matrix Integrated Magnetic (MIM) Core", granted to Chandrasekaran et al. on March 13, 2012)

[0029] Now to Fig. Figure 10, which shows a circuit diagram of an alternative embodiment of a power converter. The power converter comprises a current double rectifier (“CDR”) and a controller. A double-terminated half-bridge topology is used for the current double rectifier, across which positive, negative, and zero voltages can be applied. The current double rectifier has a first and second capacitor C1, C2, and a first and second switch S1, S2. An input DC voltage V is applied across the first and second capacitors C1, C2 and the first and second switches S1, S2, respectively. in The first and second capacitors C1, C2 can be, for example, tantalum electrolytic capacitors, and the first and second switches S1, S2 can be metal oxide semiconductor field-effect transistors.

[0030] The current double rectifier has a magnetic device with a magnetic core MC, a primary winding (with “N”). p“” and a secondary winding (with “N” s “ denoted). Furthermore, the current double rectifier has an output filter capacitor C. out and a first and second rectifier diode D1, D2. The magnetic core MC has a center leg CL, a first outer leg OL1, and a second outer leg OL2. The first and second outer legs OL1, OL2 are arranged on opposite sides of the center leg. To the primary winding N p These include a first primary winding PR1, which is formed around the first outer leg OL1, and a second primary winding PR2, which is formed around the second outer leg OL2. The secondary winding N sThe circuit includes a first, second, and third secondary winding SC1, SC2, SC3, which are formed around the first outer leg OL1, the second outer leg OL2, and the middle leg CL, respectively. The duty cycle of the first and second switches S1 and S2 is controlled such that a deviation of an output voltage V o is reduced from a defined target value.

[0031] In addition to controlling the duty cycle of the first and second switches S1 and S2, a control unit can also control the output rectifiers if the first and second rectifier diodes D1 and D2 are replaced by active switching elements (e.g., synchronous rectifier switches). The control unit includes an isolation circuit (e.g., an isolation transformer) that provides galvanic isolation between the components on both sides of the magnetic device.

[0032] During operation, the input voltage V inThe current is applied to the first and second capacitors C1 and C2 and the first and second switches S1 and S2. The first and second switches S1 and S2 are controlled in a complementary manner by a driver control circuit of the controller. The first and second switches S1 and S2 are connected to the primary winding N. p an alternating voltage V ab This results in a first current i1 through the first secondary winding SC1, a second current i2 through the second secondary winding SC2, and a third current i3 through the third secondary winding SC3 (where i1 + i2 = i3). The first and second currents i1 and i2 are rectified by the first rectifier diode D1 and the second rectifier diode D2, respectively. The third current i3 charges the output filter capacitor C. outwhich then feeds a load that is coupled to the output of the power converter. (See, for example, US 6,549,436 B1 or US Patent No. 6,549,436 entitled "Integrated Magnetic Converter Circuit and Method with Improved Filtering," granted to Sun on April 15, 2003)

[0033] Now to Fig. Figure 11 shows a perspective view of an embodiment of a section of a magnetic device. In particular, an L-core segment is shown with a first leg LEG1 and a second leg LEG2. The first leg LEG1 has a length L1 and a thickness TH1, and the second leg LEG2 has a length L2 and a thickness TH2. In the embodiment shown, the length L1 of the first leg LEG1 is greater (i.e., extended or longer) than the length L2 of the second leg LEG2 (e.g., L1 ≠ L2), and the second leg LEG2 is substantially perpendicular to the first leg LEG1. However, it is understood that the first leg LEG1 and the second leg LEG2 may have substantially the same length (e.g., L1 = L2), and the second leg LEG2 may extend from the first leg LEG1 at other angles. Although the first and second legs, LEG1 and LEG2, are represented with the same thickness (e.g.When considering TH1 = TH2, it is taken into account that the thickness of the legs can differ (e.g., TH1 ≠ TH2). The L-core segment enables a less complex magnetic core that can be integrated into compact magnetic devices. Furthermore, the L-core segment creates a structure around which windings can be formed without an additional winding support. In addition, the L-core segment can be used as a building block for numerous magnetic core geometries and magnetic device assemblies.

[0034] Now to Fig. Figure 12, showing a side view of an embodiment of a section of a magnetic device. A magnetic core of the magnetic device comprises a first L-core segment LC1 and an opposing second L-core segment LC2. The first L-core segment LC1 has a first leg LEG1 and a second leg LEG2 extending therefrom. The second L-core segment LC2 has a first leg LEG1 and a second leg LEG2 extending therefrom. An end face ES of the second leg LEG2 of the first L-core segment LC1 is connected (e.g., glued, frictionally secured, or joined) to a section of an inner surface IS of the first leg LEG1 of the second L-core segment LC2. Furthermore, an end face ES of the second leg LEG2 of the second L-core segment LC2 is connected to a section of an inner surface IS of the first leg LEG1 of the first L-core segment LC1 (e.g. glued, frictionally secured or joined).The first and second L-core segments LC1, LC2 can be compared with the above with reference to . Fig. The flexibility described in section 11 can be designed.

[0035] Now to Fig. Figures 13 to 16, showing views of an embodiment of a magnetic device not belonging to the invention. Fig. 13 and Fig. Figure 14 shows a circuit diagram or a side view of the magnetic device with primary windings in series and secondary windings in parallel around a magnetic core. Fig. 15 and Fig. Figure 16 shows perspective partial views of the assembly of the magnetic device. The magnetic core of the magnetic device has a first L-core segment LC1 and an opposing second L-core segment LC2. The first L-core segment LC1 has a first leg LEG1 and a second leg LEG2 extending from it. The second L-core segment LC2 has a first leg LEG1 and a second leg LEG2 extending from it. The first and second L-core segments LC1 and LC2 can be connected using the above with reference to Fig. 11 and Fig. The flexibility described in section 12 can be designed.

[0036] The magnetic device has a first primary winding PR1 connected in series with a second primary winding PR2, and first, second, and third primary terminals p1, p2, p3 for connection to another circuit element of a power converter or the like. At the third primary terminal p3, one end of the first primary winding PR1 is connected to one end of the second primary winding PR2. The first primary winding PR1 is formed (e.g., wound) around the first leg LEG1 of the first L-core segment LC1, and the second primary winding PR2 is formed (e.g., wound) around the first leg LEG1 of the second L-core segment LC2.

[0037] The magnetic device has a first secondary winding SC1 connected in parallel with a second secondary winding SC2, and first and second secondary terminals s1, s2 for connection to another circuit element of a power converter or the like. One end of the first secondary winding SC1 is connected to one end of the second secondary winding SC2. The first secondary winding SC1 is formed around the first leg LEG1 of the first L-core segment LC1 (e.g., by wrapping it with stamped and formed sheet metal), and the second secondary winding SC2 is formed around the first leg LEG1 of the second L-core segment LC2 (e.g., by wrapping it with stamped and formed sheet metal).The first secondary winding SC1 is formed above the first primary winding PR1 around the first leg LEG1 of the first L-core segment LC1, and the second secondary winding SC2 is formed above the second primary winding PR2 around the first leg LEG1 of the second L-core segment LC2.

[0038] The primary windings PR1, PR2 can be dielectrically insulated from the respective secondary windings SC1, SC2 by an insulating layer (e.g., tape or winding support, not shown). Additionally, the primary windings PR1, PR2 and / or the secondary windings SC1, SC2 can be dielectrically insulated from the respective first or second L-core segment LC1, LC2 by an insulating layer (e.g., tape or winding support, not shown). Furthermore, the magnetic device can be encapsulated, individually or together with other circuit elements, as part of a power converter or the like, using a protective potting compound such as epoxy resin.

[0039] Now to Fig. Figures 17 to 20, showing views of an embodiment of a magnetic device not belonging to the invention. Fig. 17 and Fig. Figure 18 shows a circuit diagram or a side view of the magnetic device with parallel primary windings and parallel secondary windings around a magnetic core. Fig. 19 and Fig. Figure 20 shows perspective partial views of the magnetic device during assembly. The magnetic core of the magnetic device has a first L-core segment LC1 and an opposing second L-core segment LC2. The first L-core segment LC1 has a first leg LEG1 and a second leg LEG2 extending from it. The second L-core segment LC2 has a first leg LEG1 and a second leg LEG2 extending from it. The first and second L-core segments LC1 and LC2 can be connected using the above with reference to Fig. 11 and Fig. The flexibility described in section 12 can be designed.

[0040] The magnetic device has a first primary winding PR1, which is connected in parallel with a second primary winding PR2, and first and second primary terminals p1, p2 for connection to another circuit element of a power converter or the like. The ends of the first and second primary windings PR1, PR2 are connected together at the first and second primary terminals p1, p2. The first primary winding PR1 is formed (e.g., wound) around the first leg LEG1 of the first L-core segment LC1, and the second primary winding PR2 is formed (e.g., wound) around the first leg LEG1 of the second L-core segment LC2.

[0041] The magnetic device has a first secondary winding SC1 connected in parallel with a second secondary winding SC2, and first and second secondary terminals s1, s2 for connection to another circuit element of a power converter or the like. One end of the first secondary winding SC1 is connected to one end of the second secondary winding SC2. The first secondary winding SC1 is formed around the first leg LEG1 of the first L-core segment LC1 (e.g., by wrapping it with stamped and formed sheet metal), and the second secondary winding SC2 is formed around the first leg LEG1 of the second L-core segment LC2 (e.g., by wrapping it with stamped and formed sheet metal).The first secondary winding SC1 is formed above the first primary winding PR1 around the first leg LEG1 of the first L-core segment LC1, and the second secondary winding SC2 is formed above the second primary winding PR2 around the first leg LEG1 of the second L-core segment LC2.

[0042] The primary windings PR1, PR2 can be dielectrically insulated from the respective secondary windings SC1, SC2 by an insulating layer (e.g., tape or winding support, not shown). Additionally, the primary windings PR1, PR2 and / or the secondary windings SC1, SC2 can be dielectrically insulated from the respective first or second L-core segment LC1, LC2 by an insulating layer (e.g., tape or winding support, not shown). Furthermore, the magnetic device can be encapsulated, individually or together with other circuit elements, as part of a power converter or the like, using a protective potting compound such as epoxy resin.

[0043] Accordingly, a magnetic device, a method for forming it, and a power converter were presented here. In one embodiment, the magnetic device comprises a first L-core segment with a first leg and a second leg extending therefrom. The magnetic device also comprises an opposing second L-core segment with a first leg and a second leg extending therefrom. Furthermore, the magnetic device has a winding formed around the first leg and / or the second leg of the first L-core segment or the second L-core segment. In one embodiment, the second leg of the first L-core segment is substantially perpendicular to the first leg of the first L-core segment, and the second leg of the second L-core segment is substantially perpendicular to the first leg of the second L-core segment.Furthermore, the length of the first leg of the first L-core segment is greater than the length of the second leg of the first L-core segment, and the length of the first leg of the second L-core segment is greater than the length of the second leg of the second L-core segment. Additionally, the thickness of the first and second legs of the first L-core segment is essentially equal, and the thickness of the first and second legs of the second L-core segment is essentially equal.

[0044] In one embodiment, a primary winding is formed around the first leg of the first L-core segment, and a secondary winding is formed around the first leg of the first L-core segment and the first leg of the second L-core segment. In yet another embodiment, a first primary winding is formed around the first leg of the first L-core segment in series with a second primary winding formed around the first leg of the second L-core segment. Alternatively, a first primary winding is formed around the first leg of the first L-core segment in parallel with a second primary winding formed around the first leg of the second L-core segment.In a related embodiment, a first secondary winding is formed around the first leg of the first L-core segment in parallel with a second secondary winding formed around the first leg of the second L-core segment. Furthermore, a first secondary winding is formed above a first primary winding around the first leg of the first L-core segment, and a second secondary winding is formed above a second primary winding around the first leg of the second L-core segment. The first and second secondary windings are stamped and formed sheets.

[0045] Now to Fig. Figures 21 to 23 show views of an embodiment of a magnetic device. Fig. 21 and Fig. Figures 22 show a circuit diagram or a side view of the magnetic device, which has a primary winding and secondary windings with a central tap around a magnetic core. Fig. Figure 23 shows a perspective partial view of the assembly of the magnetic device. The magnetic core of the magnetic device has a first L-core segment LC1 and an opposing second L-core segment LC2. The first L-core segment LC1 has a first leg LEG1 and a second leg LEG2 extending from it. The second L-core segment LC2 has a first leg LEG1 and a second leg LEG2 extending from it. The first and second L-core segments LC1 and LC2 can be connected using the above with reference to Fig. 11 and Fig. The flexibility described in section 12 can be designed.

[0046] The magnetic device has a first primary winding PR with first and second primary terminals p1, p2 for connection to another circuit element of a power converter or the like. The first primary winding PR is formed (e.g., wound) around the first leg LEG1 of the second L-core segment LC2. The magnetic device has secondary windings with a center tap, namely a first secondary winding SC1 and a second secondary winding SC2, and first, second, and third secondary terminals s1, s2, and s3 for connection to another circuit element of a power converter or the like. The center tap of the secondary windings with a center tap is connected to the third secondary terminal s3. The first and second secondary windings SC1, SC2 are formed around the first leg LEG1 of the second L-core segment LC2 (e.g., by wrapping stamped and formed sheet metal around it).The first and second secondary windings SC1, SC2 are formed above the primary winding PR around the first leg LEG1 of the second L-core segment LC2.

[0047] The primary winding PR can be dielectrically insulated from the secondary windings SC1, SC2 by an insulating layer (e.g., tape or winding support, not shown). Additionally, the primary winding PR and / or the secondary windings SC1, SC2 can be dielectrically insulated from the second L-core segment LC2 by an insulating layer (e.g., tape or winding support, not shown). Furthermore, the magnetic device can be encapsulated, either individually or together with other circuit elements, as part of a power converter or similar device, using a protective potting compound such as epoxy resin.

[0048] Now to Fig. Figures 24 to 27, showing views of an embodiment of a magnetic device not belonging to the invention. Fig. 24 and Fig. Figure 25 shows a circuit diagram or a side view of the magnetic device, which has primary windings in series and secondary windings with a central tap around a magnetic core. Fig. 26 and Fig. Figure 27 shows perspective partial views of the assembly of the magnetic device. The magnetic core of the magnetic device has a first L-core segment LC1 and an opposing second L-core segment LC2. The first L-core segment LC1 has a first leg LEG1 and a second leg LEG2 extending from it. The second L-core segment LC2 has a first leg LEG1 and a second leg LEG2 extending from it. The first and second L-core segments LC1 and LC2 can be connected using the above with reference to Fig. 11 and Fig. The flexibility described in section 12 can be designed.

[0049] The magnetic device has a first primary winding PR1 connected in series with a second primary winding PR2, and first, second, and third primary terminals p1, p2, p3 for connection to another circuit element of a power converter or the like. At the third primary terminal p3, one end of the first primary winding PR1 is connected to one end of the second primary winding PR2. The first primary winding PR1 is formed (e.g., wound) around the first leg LEG1 of the first L-core segment LC1, and the second primary winding PR2 is formed (e.g., wound) around the first leg LEG1 of the second L-core segment LC2.

[0050] The magnetic device has secondary windings with a center tap, namely a first secondary winding SC1 and a second secondary winding SC2, and a first, second, and third secondary terminal s1, s2, s3 for connection to another circuit element of a power converter or the like. The center tap of the secondary windings with a center tap is connected to the third secondary terminal s3. The first secondary winding SC1 is formed around the first leg LEG1 of the first L-core segment LC1 (e.g., by wrapping it with stamped and formed sheet metal), and the second secondary winding SC2 is formed around the first leg LEG1 of the second L-core segment LC2 (e.g., by wrapping it with stamped and formed sheet metal).The first secondary winding SC1 is formed above the first primary winding PR1 around the first leg LEG1 of the first L-core segment LC1, and the second secondary winding SC2 is formed above the second primary winding PR2 around the first leg LEG1 of the second L-core segment LC2.

[0051] The primary windings PR1, PR2 can be dielectrically insulated from the respective secondary windings SC1, SC2 by an insulating layer (e.g., tape or winding support, not shown). Additionally, the primary windings PR1, PR2 and / or the secondary windings SC1, SC2 can be dielectrically insulated from the respective first or second L-core segment LC1, LC2 by an insulating layer (e.g., tape or winding support, not shown). Furthermore, the magnetic device can be encapsulated, individually or together with other circuit elements, as part of a power converter or the like, using a protective potting compound such as epoxy resin.

[0052] Now to Fig. Figures 28 to 31, showing views of an embodiment of a magnetic device not belonging to the invention. Fig. 28 and Fig. Figures 29 show a circuit diagram or a side view of the magnetic device, which has primary windings in parallel and secondary windings with a central tap arranged around a magnetic core. Fig. 30 and Fig. Figure 31 shows perspective partial views of the assembly of the magnetic device. The magnetic core of the magnetic device has a first L-core segment LC1 and an opposing second L-core segment LC2. The first L-core segment LC1 has a first leg LEG1 and a second leg LEG2 extending from it. The second L-core segment LC2 has a first leg LEG1 and a second leg LEG2 extending from it. The first and second L-core segments LC1, LC2 can be connected using the above with reference to Fig. 11 and Fig. The flexibility described in section 12 can be designed.

[0053] The magnetic device has a first primary winding PR1 connected in parallel to a second primary winding PR2, and first and second primary terminals p1, p2 for connection to another circuit element of a power converter or the like. The ends of the first and second primary windings PR1, PR2 are connected together at the first and second primary terminals p1, p2. The first primary winding PR1 is formed (e.g., wound) around the first leg LEG1 of the first L-core segment LC1, and the second primary winding PR2 is formed (e.g., wound) around the first leg LEG1 of the second L-core segment LC2.

[0054] The magnetic device has secondary windings with a center tap, namely a first secondary winding SC1 and a second secondary winding SC2, and a first, second, and third secondary terminal s1, s2, s3 for connection to another circuit element of a power converter or the like. The center tap of the secondary windings with a center tap is connected to the third secondary terminal s3. The first secondary winding SC1 is formed around the first leg LEG1 of the first L-core segment LC1 (e.g., by wrapping it with stamped and formed sheet metal), and the second secondary winding SC2 is formed around the first leg LEG1 of the second L-core segment LC2 (e.g., by wrapping it with stamped and formed sheet metal).The first secondary winding SC1 is formed above the first primary winding PR1 around the first leg LEG1 of the first L-core segment LC1, and the second secondary winding SC2 is formed above the second primary winding PR2 around the first leg LEG1 of the second L-core segment LC2.

[0055] The primary windings PR1, PR2 can be dielectrically insulated from the respective secondary windings SC1, SC2 by an insulating layer (e.g., tape or winding support, not shown). Additionally, the primary windings PR1, PR2 and / or the secondary windings SC1, SC2 can be dielectrically insulated from the respective first or second L-core segment LC1, LC2 by an insulating layer (e.g., tape or winding support, not shown). Furthermore, the magnetic device can be encapsulated, individually or together with other circuit elements, as part of a power converter or the like, using a protective potting compound such as epoxy resin.

[0056] Accordingly, a magnetic device, a method for forming it, and a power converter were presented here. In one embodiment, the magnetic device comprises a first L-core segment with a first leg and a second leg extending therefrom. Furthermore, the magnetic device comprises an opposing second L-core segment with a first leg and a second leg extending therefrom. The magnetic device also includes a secondary winding with a central tap, comprising a first secondary winding and a second secondary winding formed around the first leg and / or the second leg of the first L-core segment or the second L-core segment.In one embodiment, the second leg of the first L-core segment is substantially perpendicular to the first leg of the first L-core segment, and the second leg of the second L-core segment is substantially perpendicular to the first leg of the second L-core segment. Furthermore, the length of the first leg of the first L-core segment is greater than the length of the second leg of the first L-core segment, and the length of the first leg of the second L-core segment is greater than the length of the second leg of the second L-core segment. Additionally, the thickness of the first and second legs of the first L-core segment is substantially equal, and the thickness of the first and second legs of the second L-core segment is substantially equal.

[0057] In one embodiment, the first and second secondary windings are formed around the first leg of the second L-core segment. The magnetic device can also have a primary winding formed around the first leg and / or the second leg of the first or second L-core segment. In a related embodiment, the magnetic device can have a primary winding formed around the first leg of the second L-core segment, with the first and second secondary windings formed above the primary winding around the first leg of the second L-core segment. The first and second secondary windings are stamped and formed laminations.In a further embodiment, the magnetic device has a first primary winding formed around the first leg of the first L-core segment, and a second primary winding formed around the first leg of the second L-core segment. Accordingly, the first secondary winding is formed around the first leg of the first L-core segment above the first primary winding, and the second secondary winding is formed around the first leg of the second L-core segment above the second primary winding.

[0058] Now to Fig. Figures 32 to 35, showing views of an embodiment of a magnetic device not belonging to the invention. Fig. 32 and Fig. Figure 33 shows a circuit diagram or a side view of a magnetic device designed as an E-core type magnetic device, which has primary windings in series and secondary windings in parallel around a magnetic core. Fig. 34 and Fig. Figure 35 shows perspective assembly views of the E-core type magnetic device. The magnetic core of the E-core type magnetic device has a first core section comprising a first L-core segment LC11 and an opposing second L-core segment LC12. The first L-core segment LC11 has a first leg LEG1 and a second leg LEG2 extending from it. The second L-core segment LC12 has a first leg LEG1 and a second leg LEG2 extending from it. The magnetic core of the E-core type magnetic device has a second core section comprising a first L-core segment LC21 and an opposing second L-core segment LC22. The first L-core segment LC21 has a first leg LEG1 and a second leg LEG2 extending from it. The second L-core segment LC22 has a first leg LEG1 and a second leg LEG2 extending from it.In the illustrated embodiment, the outer surfaces EXS of the second leg LEG2 of the second L-core segments LC12, LC22 of the first and second core sections, respectively, are joined together (e.g., glued, frictionally secured, or combined). Furthermore, the end faces ES of the first leg LEG1 of the first L-core segments LC11, LC21 of the first and second core sections, respectively, are joined together (e.g., glued, frictionally secured, or combined). The first and second L-core segments LC11, LC12, LC21, LC22 can be connected to the above with reference to... Fig. 11 and Fig. The flexibility described in section 12 can be designed.

[0059] The magnetic device has a first primary winding PR1 connected in series with a second primary winding PR2, and first, second, and third primary terminals p1, p2, p3 for connection to another circuit element of a power converter or the like. At the third primary terminal p3, one end of the first primary winding PR1 is connected to one end of the second primary winding PR2. The first primary winding PR1 is formed (e.g., wound) around the first leg LEG1 of the second L-core segment LC12 of the first core section, and the second primary winding PR2 is formed (e.g., wound) around the first leg LEG1 of the second L-core segment LC22 of the second core section.

[0060] The magnetic device has a first secondary winding SC1 connected in parallel with a second secondary winding SC2, and first and second secondary terminals s1, s2 for connection to another circuit element of a power converter or the like. One end of the first secondary winding SC1 is connected to one end of the second secondary winding SC2. The first secondary winding SC1 is formed around the first leg LEG1 of the second L-core segment LC12 of the first core section (e.g., by wrapping it with stamped and formed sheet metal), and the second secondary winding SC2 is formed around the first leg LEG1 of the second L-core segment LC22 of the second core section (e.g., by wrapping it with stamped and formed sheet metal).The first secondary winding SC1 is formed above the first primary winding PR1 around the first leg LEG1 of the second L-core segment LC12 of the first core section, and the second secondary winding SC2 is formed above the second primary winding PR2 around the first leg LEG1 of the second L-core segment LC22 of the second core section.

[0061] The primary windings PR1, PR2 can be dielectrically insulated from the respective secondary windings SC1, SC2 by an insulating layer (e.g., tape or winding support, not shown). Additionally, the primary windings PR1, PR2 and / or the secondary windings SC1, SC2 can be dielectrically insulated from the respective second L-core segment, LC12 or LC22, by an insulating layer (e.g., tape or winding support, not shown). Furthermore, the magnetic device can be encapsulated, individually or together with other circuit elements, as part of a power converter or the like, using a protective potting compound such as epoxy resin.

[0062] Now to Fig. Figures 36 to 39 show views of an embodiment of a magnetic device not belonging to the invention. Fig. 36 and Fig. Figure 37 shows a circuit diagram or a side view of a magnetic device designed as an E-core type magnetic device, which has primary windings in parallel and secondary windings with a central tap around a magnetic core. Fig. 38 and Fig. Figure 39 shows perspective partial assembly views of the E-core type magnetic device. The magnetic core of the E-core type magnetic device has a first core section comprising a first L-core segment LC11 and an opposing second L-core segment LC12. The first L-core segment LC11 has a first leg LEG1 and a second leg LEG2 extending from it. The second L-core segment LC12 has a first leg LEG1 and a second leg LEG2 extending from it. The magnetic core of the E-core type magnetic device has a second core section comprising a first L-core segment LC21 and an opposing second L-core segment LC22. The first L-core segment LC21 has a first leg LEG1 and a second leg LEG2 extending from it. The second L-core segment LC22 has a first leg LEG1 and a second leg LEG2 extending from it.In the illustrated embodiment, the outer surfaces EXS of the first leg LEG1 of the second L-core segment LC12, LC22 of the first and second core sections, respectively, are joined (e.g., glued, frictionally secured, or combined). Furthermore, the end faces ES of the second leg LEG2 of the first L-core segments LC11, LC21 of the first and second core sections, respectively, are joined (e.g., glued, frictionally secured, or combined). The first and second L-core segments LC11, LC12, LC21, LC22 can be connected to the above with reference to... Fig. 11 and Fig. The flexibility described in section 12 can be designed.

[0063] The magnetic device has a first primary winding PR1 connected in parallel to a second primary winding PR2, and first and second primary terminals p1, p2 for connection to another circuit element of a power converter or the like. The ends of the first and second primary windings PR1, PR2 are connected together at the first and second primary terminals p1, p2. The first primary winding PR1 is formed (e.g., wound) around the first leg LEG1 of the first L-core segment LC11 of the first core section, and the second primary winding PR2 is formed (e.g., wound) around the first leg LEG1 of the first L-core segment LC21 of the second core section.

[0064] The magnetic device has secondary windings with a center tap, namely a first secondary winding SC1 and a second secondary winding SC2, and a first, second, and third secondary terminal s1, s2, s3 for connection to another circuit element of a power converter or the like. The center tap of the secondary windings with a center tap is connected to the third secondary terminal s3. The first secondary winding SC1 is formed around the first leg LEG1 of the first L-core segment LC11 of the first core section (e.g., by wrapping it with stamped and formed sheet metal), and the second secondary winding SC2 is formed around the first leg LEG1 of the first L-core segment LC21 of the second core section (e.g., by wrapping it with stamped and formed sheet metal).The first secondary winding SC1 is formed above the first primary winding PR1 around the first leg LEG1 of the first L-core segment LC11 of the first core section, and the second secondary winding SC2 is formed above the second primary winding PR2 around the first leg LEG1 of the first L-core segment LC21 of the second core section.

[0065] The primary windings PR1, PR2 can be dielectrically insulated from the respective secondary windings SC1, SC2 by an insulating layer (e.g., tape or winding support, not shown). Additionally, the primary windings PR1, PR2 and / or the secondary windings SC1, SC2 can be dielectrically insulated from the respective first L-core segments LC11, LC21 by an insulating layer (e.g., tape or winding support, not shown). Furthermore, the magnetic device can be encapsulated, individually or together with other circuit elements, as part of a power converter or the like, using a protective potting compound such as epoxy resin.

[0066] Accordingly, a magnetic device, a method for forming it, and a power converter were presented here. In one embodiment, the magnetic device comprises a first core section with a first L-core segment having a first leg and a second leg extending therefrom, and an opposing second L-core segment having a first leg and a second leg extending therefrom. Furthermore, the magnetic device comprises a second core section with a first L-core segment having a first leg and a second leg extending therefrom, and an opposing second L-core segment having a first leg and a second leg extending therefrom. A surface of the second core section is joined to a surface of the first core section (e.g., glued, frictionally secured, or joined).In one embodiment, the second leg of the first L-core segment of the first core section is substantially perpendicular to the first leg of the first L-core segment of the first core section, and the second leg of the second L-core segment of the first core section is substantially perpendicular to the first leg of the second L-core segment of the first core section. Furthermore, the length of the first leg of the first L-core segment of the first core section is greater than the length of the second leg of the first L-core segment of the first core section, and the length of the first leg of the second L-core segment of the first core section is greater than the length of the second leg of the second L-core segment of the first core section.Furthermore, the thickness of the first limb and the second limb of the first L-core segment of the first core section is essentially the same, and the thickness of the first limb and the second limb of the second L-core segment of the first core section is essentially the same.

[0067] In one embodiment, a winding is formed around the first leg and / or the second leg of the first L-core segment or the second L-core segment of the first core section, and a winding is formed around the first leg and / or the second leg of the first L-core segment or the second L-core segment of the second core section. Regarding the joining of the first and second core sections, an end face of the first leg of the first L-core segment of the first core section is joined to an end face of the first leg of the first L-core segment of the second core section, and an outer surface of the second leg of the second L-core segment of the first core section is joined to an outer surface of the second leg of the second L-core segment of the second core section.Alternatively, an end face of the second leg of the first L-core segment of the first core section is joined with an end face of the second leg of the first L-core segment of the second core section, and an outer surface of the first leg of the second L-core segment of the first core section is joined with an outer surface of the first leg of the second L-core segment of the second core section.

[0068] In one embodiment, the magnetic device has a first and second primary winding formed around the first leg of the second L-core segment of the first and second core sections, respectively, and a first and second secondary winding is formed around the first leg of the second L-core segment of the first and second core sections, respectively. Alternatively, the magnetic device has a first and second primary winding formed around the first leg of the first L-core segment of the first and second core sections, respectively, and a first and second secondary winding is formed around the first leg of the first L-core segment of the first and second core sections, respectively.

[0069] Now to Fig. Figures 40 to 41 show a circuit diagram and a side view, respectively, of a magnetic device not belonging to the invention, in the form of a coupled inductive component. The magnetic core of the coupled inductive component has a first core section comprising a first L-core segment LC11 and an opposing second L-core segment LC12. The first L-core segment LC11 has a first leg LEG1 and a second leg LEG2 extending therefrom. The second L-core segment LC12 has a first leg LEG1 and a second leg LEG2 extending therefrom. The magnetic core of the coupled inductive component has a second core section comprising a first L-core segment LC21 and an opposing second L-core segment LC22. The first L-core segment LC21 has a first leg LEG1 and a second leg LEG2 extending from it.The second L-core segment LC22 has a first leg LEG1 and a second leg LEG2 extending from it. In the illustrated embodiment, the outer surfaces EXS of the second leg LEG2 of the second L-core segments LC12, LC22 of the first and second core sections, respectively, are joined together (e.g., glued, frictionally secured, or combined). Furthermore, the end faces ES of the first leg LEG1 of the first L-core segments LC11, LC21 of the first and second core sections, respectively, are joined together (e.g., glued, frictionally secured, or combined). The first and second L-core segments LC11, LC12, LC21, LC22 can be connected to the above with reference to... Fig. 11 and Fig. The flexibility described in section 12 can be designed.

[0070] The magnetic device has secondary windings with a center tap, namely a first secondary winding SC1 and a second secondary winding SC2, and a first, second, and third secondary terminal s1, s2, s3 for connection to another circuit element of a power converter or the like. The center tap of the secondary windings with a center tap is connected to a transformer winding IC and to the third secondary terminal s3. The first secondary winding SC1 is formed around the first leg LEG1 of the second L-core segment LC12 of the first core section (e.g., by wrapping it with stamped and formed sheet metal), and the second secondary winding SC2 is formed around the first leg LEG1 of the second L-core segment LC22 of the second core section (e.g., by wrapping it with stamped and formed sheet metal).The transformer winding IC is formed around the second leg LEG2 of the second L-core segments LC12, LC22 of the first core section or the second core section.

[0071] The secondary windings SC1, SC2 and / or the transformer winding IC can be dielectrically insulated from the respective second L-core segments LC12, LC22 by an insulating layer (e.g., tape or winding support, not shown). Furthermore, the magnetic device can be encapsulated, individually or together with other circuit elements, as part of a power converter or similar device, using a protective potting compound such as epoxy resin. It should be noted that the coupled inductive component, including the formation of the secondary windings SC1, SC2 and / or the transformer winding IC, can be mounted around the first and second core sections as described above.

[0072] Now to Fig. Figure 42, showing a side view of an embodiment of a magnetic core of a magnetic device in the form of a coupled inductive component. The magnetic core of Fig. 42 is analogous to the magnetic core of Fig. Figure 41, but additionally features gaps. A first gap (labeled "a") enables energy storage, and a second gap (labeled "b") significantly prevents the circulation of the magnetic flux. The first gap "a" can be created by grinding down the second leg LEG2 of the second L-core segments LC12, LC22 of the first or second core section, respectively. The second gap "b" can be created by placing a spacer (partially shown and labeled "s") between the outer surfaces EXS of the second leg LEG2 of the second L-core segments LC12, LC22 of the first or second core section, respectively. The gaps "a" and "b" can contain, for example, air, a filler such as an epoxy resin, or a spacer "s". For the sake of simplicity, the second gap "b" is shown partially filled with air or another filler (in its upper section) and partially filled with the spacer "s".Consequently, the magnetic device has at least one gap between two adjacent legs. Naturally, windings can be formed around the magnetic core of the coupled inductive component as described above.

[0073] Now to Fig. Figures 43 to 44 show a circuit diagram and a side view, respectively, of a magnetic device in the form of a coupled inductive component. The magnetic core of the coupled inductive component has a first core section comprising a first L-core segment LC11 and an opposing second L-core segment LC12. The first L-core segment LC11 has a first leg LEG1 and a second leg LEG2 extending from it. The second L-core segment LC12 has a first leg LEG1 and a second leg LEG2 extending from it. The magnetic core of the coupled inductive component has a second core section comprising a first L-core segment LC21 and an opposing second L-core segment LC22. The first L-core segment LC21 has a first leg LEG1 and a second leg LEG2 extending from it.The second L-core segment LC22 has a first leg LEG1 and a second leg LEG2 extending from it. In the illustrated embodiment, the outer surfaces EXS of the first leg LEG1 of the second L-core segment LC12, LC22 of the first and second core sections, respectively, are joined (e.g., glued, frictionally secured, or combined). Furthermore, the end faces ES of the second leg LEG2 of the first L-core segments LC11, LC21 of the first and second core sections, respectively, are joined (e.g., glued, frictionally secured, or combined). The first and second L-core segments LC11, LC12, LC21, LC22 can be connected to the above with reference to... Fig. 11 and Fig. The flexibility described in section 12 can be designed.

[0074] The magnetic device has secondary windings with a center tap, namely a first secondary winding SC1 and a second secondary winding SC2, and a first, second, and third secondary terminal s1, s2, s3 for connection to another circuit element of a power converter or the like. The center tap of the secondary windings with a center tap is connected to a transformer winding IC and to the third secondary terminal s3. The first secondary winding SC1 is formed around the first leg LEG1 of the first L-core segment LC11 of the first core section (e.g., by wrapping it with stamped and formed sheet metal), and the second secondary winding SC2 is formed around the first leg LEG1 of the first L-core segment LC21 of the second core section (e.g., by wrapping it with stamped and formed sheet metal).The transformer winding IC is formed around the first leg LEG1 of the second L-core segments LC12, LC22 of the first core section or the second core section.

[0075] The secondary windings SC1, SC2 and / or the transformer winding IC can be dielectrically insulated from the respective first L-core segments LC11, LC21 and / or second L-core segments LC12, LC22 by an insulating layer (e.g., tape or winding support, not shown). Furthermore, the magnetic device can be encapsulated, individually or together with other circuit elements, as part of a power converter or the like, using a protective potting compound such as epoxy resin. It should be noted that the coupled inductive component, including the formation of the secondary windings SC1, SC2 and / or the transformer winding IC around the first and second core sections, can be mounted as described above.

[0076] Now to Fig. Figure 45, showing a side view of an embodiment of a magnetic core of a magnetic device in the form of a coupled inductive component. The magnetic core of Fig. 45 is analogous to the magnetic core of Fig. Figure 44, but additionally features gaps. A first gap (labeled "a") enables energy storage, and a second gap (labeled "b") significantly prevents the circulation of the magnetic flux. The first gap "a" can be created by grinding down the first leg LEG1 of the second L-core segment LC12, LC22 of the first or second core section, respectively. The second gap "b" can be created by placing a spacer (partially shown and labeled "s") between the outer surfaces EXS of the first leg LEG1 of the second L-core segments LC12, LC22 of the first or second core section, respectively. The gaps "a" and "b" can contain, for example, air, a filler such as an epoxy resin, or a spacer "s". For the sake of simplicity, the second gap "b" is shown partially filled with air or another filler (in its upper section) and partially filled with the spacer "s".Consequently, the magnetic device has at least one gap between two adjacent legs. Naturally, windings can be formed around the magnetic core of the coupled inductive component as described above.

[0077] Accordingly, a magnetic device, a method for forming it, and a power converter were presented here. In one embodiment, the magnetic device has a magnetic core comprising a first core section and a second core section. The first core section has a first L-shaped core segment with a first leg and a second leg extending therefrom, and an opposing second L-shaped core segment with a first leg and a second leg extending therefrom. The second core section has a first L-shaped core segment with a first leg and a second leg extending therefrom, and an opposing second L-shaped core segment with a first leg and a second leg extending therefrom. A surface of the second core section is joined to a surface of the first core section (e.g., glued, frictionally secured, or joined).Furthermore, the magnetic device has a secondary winding with a center tap, comprising a first secondary winding and a second secondary winding, which are formed around the first leg and / or the second leg of the first L-core segment or the second L-core segment of the first core section or the second core section. The magnetic device also has a transformer winding, which is formed around the first leg and / or the second leg of the first L-core segment or the second L-core segment of the first core section or the second core section. The transformer winding is coupled to a center tap between the first secondary winding and the second secondary winding.

[0078] In one embodiment, the second leg of the first L-core segment of the first core section is substantially perpendicular to the first leg of the first L-core segment of the first core section, and the second leg of the second L-core segment of the first core section is substantially perpendicular to the first leg of the second L-core segment of the first core section. Furthermore, the length of the first leg of the first L-core segment of the first core section is greater than the length of the second leg of the first L-core segment of the first core section, and the length of the first leg of the second L-core segment of the first core section is greater than the length of the second leg of the second L-core segment of the first core section.Furthermore, the thickness of the first limb and the second limb of the first L-core segment of the first core section is essentially the same, and the thickness of the first limb and the second limb of the second L-core segment of the first core section is essentially the same.

[0079] In one embodiment, the first secondary winding is formed around the first leg of the second L-core segment of the first core section, the second secondary winding is formed around the first leg of the second L-core segment of the second core section, and the transformer winding is formed around the second leg of the second L-core segments of the first core section and the second core section. Alternatively, the first secondary winding is formed around the first leg of the first L-core segment of the first core section, the second secondary winding is formed around the first leg of the first L-core segment of the second core section, and the transformer winding is formed around the first leg of the second L-core segments of the first core section and the second core section.

[0080] In one embodiment, an end face of the first leg of the first L-core segment of the first core section is joined to an end face of the first leg of the first L-core segment of the second core section, and an outer surface of the second leg of the second L-core segment of the first core section is joined to an outer surface of the second leg of the second L-core segment of the second core section. Alternatively, an end face of the second leg of the first L-core segment of the first core section is joined to an end face of the second leg of the first L-core segment of the second core section, and an outer surface of the first leg of the second L-core segment of the first core section is joined to an outer surface of the first leg of the second L-core segment of the second core section. Furthermore, the magnetic device may have a gap between two adjacent legs.

[0081] Now to Fig. Figures 46 to 47 show a circuit diagram and a side view, respectively, of a magnetic device in the form of an integrated magnetic device. The magnetic core of the integrated magnetic device has a first core section comprising a first L-core segment LC11 and an opposing second L-core segment LC12. The first L-core segment LC11 has a first leg LEG1 and a second leg LEG2 extending from it. The second L-core segment LC12 has a first leg LEG1 and a second leg LEG2 extending from it. The magnetic core of the integrated magnetic device has a second core section comprising a first L-core segment LC21 and an opposing second L-core segment LC22. The first L-core segment LC21 has a first leg LEG1 and a second leg LEG2 extending from it.The second L-core segment LC22 has a first leg LEG1 and a second leg LEG2 extending from it. In the illustrated embodiment, the outer surfaces EXS of the second leg LEG2 of the second L-core segments LC12, LC22 of the first and second core sections, respectively, are joined together (e.g., glued, frictionally secured, or combined). Furthermore, the end faces ES of the first leg LEG1 of the first L-core segments LC11, LC21 of the first and second core sections, respectively, are joined together (e.g., glued, frictionally secured, or combined). The first and second L-core segments LC11, LC12, LC21, LC22 can be connected to the above with reference to... Fig. 11 and Fig. The flexibility described in section 12 can be designed.

[0082] The magnetic device has a first primary winding PR1 connected in series with a second primary winding PR2, and first, second, and third primary terminals p1, p2, p3 for connection to another circuit element of a power converter or the like. At the third primary terminal p3, one end of the first primary winding PR1 is connected to one end of the second primary winding PR2. The first primary winding PR1 is formed (e.g., wound) around the first leg LEG1 of the second L-core segment LC12 of the first core section, and the second primary winding PR2 is formed (e.g., wound) around the first leg LEG1 of the second L-core segment LC22 of the second core section.

[0083] The magnetic device has secondary windings with a center tap, namely a first secondary winding SC1 and a second secondary winding SC2, and a first, second, and third secondary terminal s1, s2, s3 for connection to another circuit element of a power converter or the like. The center tap of the secondary windings with a center tap is connected to a transformer winding IC and to the third secondary terminal s3. The first secondary winding SC1 is formed around the first leg LEG1 of the second L-core segment LC12 of the first core section (e.g., by wrapping it with stamped and formed sheet metal), and the second secondary winding SC2 is formed around the first leg LEG1 of the second L-core segment LC22 of the second core section (e.g., by wrapping it with stamped and formed sheet metal).The transformer winding IC is formed around the second leg LEG2 of the second L-core segments LC12, LC22 of the first core section or the second core section.

[0084] The primary windings PR1, PR2 can be dielectrically insulated from the respective secondary windings SC1, SC2, or the transformer winding IC by an insulating layer (e.g., tape or winding support, not shown). Furthermore, the primary windings PR1, PR2, and / or the secondary windings SC1, SC2, and / or the transformer winding IC can be dielectrically insulated from the respective second L-core segments LC12, LC22 by an insulating layer (e.g., tape or winding support, not shown). Additionally, the magnetic device can be encapsulated, individually or together with other circuit elements, as part of a power converter or similar device, using a protective potting compound such as epoxy resin. It should be noted that the integrated magnetic device, including the formation of the primary windings PR1, PR2, the secondary windings SC1, SC2, and / or the transformer winding IC around the first and second core sections, can be mounted as described above.

[0085] Now to Fig. Figures 48 to 49 show a circuit diagram and a side view, respectively, of a magnetic device in the form of an integrated magnetic device. The magnetic core of the integrated magnetic device has a first core section comprising a first L-core segment LC11 and an opposing second L-core segment LC12. The first L-core segment LC11 has a first leg LEG1 and a second leg LEG2 extending from it. The second L-core segment LC12 has a first leg LEG1 and a second leg LEG2 extending from it. The magnetic core of the integrated magnetic device has a second core section comprising a first L-core segment LC21 and an opposing second L-core segment LC22. The first L-core segment LC21 has a first leg LEG1 and a second leg LEG2 extending from it.The second L-core segment LC22 has a first leg LEG1 and a second leg LEG2 extending from it. In the illustrated embodiment, the outer surfaces EXS of the first leg LEG1 of the second L-core segment LC12, LC22 of the first and second core sections, respectively, are joined (e.g., glued, frictionally secured, or combined). Furthermore, the end faces ES of the second leg LEG2 of the first L-core segments LC11, LC21 of the first and second core sections, respectively, are joined (e.g., glued, frictionally secured, or combined). The first and second L-core segments LC11, LC12, LC21, LC22 can be connected to the above with reference to... Fig. 11 and Fig. The flexibility described in section 12 can be designed.

[0086] The magnetic device has a first primary winding PR1 connected in series with a second primary winding PR2, and first, second, and third primary terminals p1, p2, p3 for connection to another circuit element of a power converter or the like. At the third primary terminal p3, one end of the first primary winding PR1 is connected to one end of the second primary winding PR2. The first primary winding PR1 is formed (e.g., wound) around the first leg LEG1 of the first L-core segment LC11 of the first core section, and the second primary winding PR2 is formed (e.g., wound) around the first leg LEG1 of the first L-core segment LC21 of the second core section.

[0087] The magnetic device has secondary windings with a center tap, namely a first secondary winding SC1 and a second secondary winding SC2, and a first, second, and third secondary terminal s1, s2, s3 for connection to another circuit element of a power converter or the like. The center tap of the secondary windings with a center tap is connected to a transformer winding IC and to the third secondary terminal s3. The first secondary winding SC1 is formed around the first leg LEG1 of the first L-core segment LC11 of the first core section (e.g., by wrapping it with stamped and formed sheet metal), and the second secondary winding SC2 is formed around the first leg LEG1 of the first L-core segment LC21 of the second core section (e.g., by wrapping it with stamped and formed sheet metal).The transformer winding IC is formed around the first leg LEG1 of the second L-core segments LC12, LC22 of the first core section or the second core section.

[0088] The primary windings PR1, PR2 can be dielectrically insulated from the respective secondary windings SC1, SC2, or the transformer winding IC by an insulating layer (e.g., tape or winding support, not shown). Furthermore, the primary windings PR1, PR2, and / or the secondary windings SC1, SC2, and / or the transformer winding IC can be dielectrically insulated from the respective first L-core segments LC11, LC21, and / or second L-core segments LC12, LC22 by an insulating layer (e.g., tape or winding support, not shown). Additionally, the magnetic device can be encapsulated, individually or together with other circuit elements, as part of a power converter or similar device, using a protective potting compound such as epoxy resin.It should be noted that the integrated magnetic device, including the formation of the primary windings PR1, PR2, the secondary windings SC1, SC2 and / or the transformer winding IC, can be mounted around the first and second core sections as described above.

[0089] Accordingly, a magnetic device, a method for forming it, and a power converter were presented here. In one embodiment, the magnetic device has a magnetic core comprising a first core section and a second core section. The first core section has a first L-shaped core segment with a first leg and a second leg extending therefrom, and an opposing second L-shaped core segment with a first leg and a second leg extending therefrom. The second core section has a first L-shaped core segment with a first leg and a second leg extending therefrom, and an opposing second L-shaped core segment with a first leg and a second leg extending therefrom. A surface of the second core section is joined to a surface of the first core section (e.g., glued, frictionally secured, or joined).The magnetic device comprises a first primary winding and a second primary winding formed around the first leg and / or the second leg of the first L-core segment or the second L-core segment of the first core section or the second core section. The magnetic device also comprises a secondary winding with a central tap, comprising a first secondary winding and a second secondary winding formed around the first leg and / or the second leg of the first L-core segment or the second L-core segment of the first core section or the second core section. Furthermore, the magnetic device comprises a transformer winding formed around the first leg and / or the second leg of the first L-core segment or the second L-core segment of the first core section or the second core section.The transformer winding is coupled to a center tap between the first secondary winding and the second secondary winding.

[0090] In one embodiment, the second leg of the first L-core segment of the first core section is substantially perpendicular to the first leg of the first L-core segment of the first core section, and the second leg of the second L-core segment of the first core section is substantially perpendicular to the first leg of the second L-core segment of the first core section. Furthermore, the length of the first leg of the first L-core segment of the first core section is greater than the length of the second leg of the first L-core segment of the first core section, and the length of the first leg of the second L-core segment of the first core section is greater than the length of the second leg of the second L-core segment of the first core section.Furthermore, the thickness of the first limb and the second limb of the first L-core segment of the first core section is essentially the same, and the thickness of the first limb and the second limb of the second L-core segment of the first core section is essentially the same.

[0091] In one embodiment, the first primary winding and the first secondary winding are formed around the first leg of the second L-core segment of the first core section, the second primary winding and the second secondary winding are formed around the first leg of the second L-core segment of the second core section, and the transformer winding is formed around the second leg of the second L-core segments of the first core section and the second core section. Alternatively, the first primary winding and the first secondary winding are formed around the first leg of the first L-core segment of the first core section, the second primary winding and the second secondary winding are formed around the first leg of the first L-core segment of the second core section, and the transformer winding is formed around the first leg of the second L-core segments of the first core section and the second core section.The first and second secondary windings can be stamped and formed sheets.

[0092] In one embodiment, an end face of the first leg of the first L-core segment of the first core section is joined to an end face of the first leg of the first L-core segment of the second core section, and an outer surface of the second leg of the second L-core segment of the first core section is joined to an outer surface of the second leg of the second L-core segment of the second core section. Alternatively, an end face of the second leg of the first L-core segment of the first core section is joined to an end face of the second leg of the first L-core segment of the second core section, and an outer surface of the first leg of the second L-core segment of the first core section is joined to an outer surface of the first leg of the second L-core segment of the second core section.

[0093] The control or associated method, as described above with reference to the power converters, can be implemented as hardware (embodied in one or more chips, including an integrated circuit, such as an application-specific integrated circuit) or can be implemented as software or firmware for execution by a processor (e.g., a digital signal processor) in a manner suitable for storage. In particular, in the case of firmware or software, the embodiment can be created as a computer program product comprising a computer-readable medium embodying computer program code (i.e., software or firmware) for execution by the processor.

[0094] The computer-readable medium can store program or code segments that represent different implementations. For example, a computer program product comprising program code stored on a computer-readable medium (e.g., a non-volatile computer-readable medium) can take different implementations. The "computer-readable medium" can be any medium capable of storing or transmitting information. Examples of computer-readable media include an electronic circuit, a semiconductor memory, a read-only memory ("ROM"), a flash memory, an erasable ROM ("EROM"), a floppy disk, a compact disc (CD) ROM, and the like.

[0095] It will be understood by those skilled in the art that the previously described embodiments of a power converter comprising an L-core segment, and the associated methods for forming it, were presented for illustrative purposes only. Although a magnetic device in the vicinity of a power converter has been described, this magnetic device can also be applied to other systems, in particular to a power amplifier and a motor controller.

[0096] For a better understanding of power converters, see “Modern DC-to-DC Power Switch-mode Power Converter Circuits”, by Rudolph P. Severns and Gordon Bloom, Van Nostrand Reinhold Company, New York, New York (1985) and “Principles of Power Electronics”, by JG Kassakian, MF Schlecht and GC Verghese, Addison-Wesley (1991).

Claims

[1] Magnetic device comprising: a first L-core segment with a first leg and a second leg extending from it; a different, opposing second L-core segment with a first leg and a second leg extending therefrom, wherein the first leg of the first L-core segment is connected to the second leg of the second L-core segment and the second leg of the first L-core segment is connected to the first leg of the second L-core segment; a primary winding that is wound around the first leg of the second L-core segment; and a secondary winding provided with a central tap, comprising a first secondary winding and a second secondary winding formed around the first leg of the second L-core segment, wherein the first secondary winding and the second secondary winding are formed above the primary winding around the first leg of the second L-core segment. [2] Magnetic device according to claim 1, wherein the second leg of the first L-core segment is perpendicular to the first leg of the first L-core segment and the second leg of the second L-core segment is perpendicular to the first leg of the second L-core segment. [3] Magnetic device according to claim 1 or 2, wherein the length of the first leg of the first L-core segment is greater than the length of the second leg of the first L-core segment and the length of the first leg of the second L-core segment is greater than the length of the second leg of the second L-core segment. [4] Magnetic device according to one of claims 1 to 3, wherein the thickness of the first leg and the second leg of the first L-core segment is equal and the thickness of the first leg and the second leg of the second L-core segment is equal. [5] Magnetic device according to any one of claims 1 to 4, wherein the first and second secondary windings are stamped and formed sheets. [6] Magnetic device according to one of claims 1 to 5, wherein the first and second secondary windings are arranged in contact with the primary winding. [7] Power converters, comprehensive: a main switch that is coupled to an input of the power converter; a magnetic device according to one of the preceding claims, which is coupled to the main switch an auxiliary switch coupled to the magnetic device; and an output filter capacitor coupled to the auxiliary switch and an output of the power converter.

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