Integrated power electronics component with shared core

Abstract

An integrated inductor-transformer includes a first transformer and an inductor sharing a common magnetically permeable core. The first transformer includes a first primary coil and a first secondary coil wound around a same first core portion of the core. The inductor includes an inductor coil wound around a second core portion of the core. When the first primary coil is energized, a first magnetic flux generated by the first transformer in the first core portion is cancelled in the second core portion, and a second magnetic flux generated by the inductor in the second core portion is cancelled in the first core portion.

Description

[0001] INTEGRATED POWER ELECTRONICS COMPONENT WITH SHARED CORE

[0002] Summary

[0003] In some aspects of the present description, an integrated inductor-transformer is provided, the integrated inductor-transformer including a first transformer 200 and an inductor 100 sharing a common magnetically permeable core. The first transformer includes a first primary coil and a first secondary coil wound around a same first core portion of the core. The inductor includes an inductor coil wound around a second core portion of the core. When the first primary coil is energized, a first magnetic flux generated by the first transformer in the first core portion is cancelled in the second core portion, and a second magnetic flux generated by the inductor in the second core portion is cancelled in the first core portion.

[0004] In some aspects of the present description, an integrated power electronics component is provided, the integrated power electronics component including a substantially planar magnetically permeable core having substantially co-planar, substantially planar, magnetically permeable first and second core portions, a first transformer having a primary coil and a secondary coil wound around, and inductively coupled to, the first core portion, and an inductor having an inductor coil wound around, and inductively coupled to, the second core portion. The substantially planar first core portion at least partially surrounds and defines a through opening in the core. The substantially planar second core portion is connected at a first location of the first core portion and extends away from the first core portion. A magnetic coupling coefficient between the inductor and the first transformer is less than about 0.1, and a magnetic coupling coefficient between the primary and secondary coils is greater than about 0.5.

[0005] In some aspects of the present description, a method of making an integrated power electronics component is provided, the method including winding a magnetically permeable film about a longitudinal axis multiple times to form a wound magnetically permeable film comprising a plurality of substantially concentric turns of the magnetically permeable film; slicing the wound magnetically permeable film along a cross-sectional plane substantially orthogonal to the longitudinal axis to form a magnetically permeable core including a slice of the magnetically permeable film having a central core opening defined at least in part by an innermost winding of the sliced magnetically permeable film; forming a transformer by winding a primary coil and a secondary coil around a first portion of the core; and forming an inductor by winding an inductor coil around a second portion of the core, such that a ratio of a magnetic coupling coefficient between the primary and secondary coils to a magnetic coupling coefficient between the inductor and the transformer greater than about 10.

[0006] In some aspects of the present description, an integrated power electronics component is provided the integrated power electronics component including a first transformer and a second transformer sharing a common magnetically permeable core. The first transformer includes a first primary coil and a first secondary coil wound around a same first core portion of the core. The second transformer includes a second primary coil and a second secondary coil wound around a same second core portion of the core. When the first primary coil is energized, a first magnetic flux generated by the first transformer in the first core portion is cancelled in the second core portion, and a second magnetic flux generated by the second transformer in the second core portion is cancelled in the first core portion.

[0007] Brief Description of the Drawings

[0008] FIG. 1 is a perspective view of an integrated inductor-transformer with a shared magnetically permeable core, in accordance with an embodiment of the present description;

[0009] FIGS. 2 A and 2B provide perspective views of a shared magnetically permeable core, in accordance with embodiments of the present description;

[0010] FIG. 3 is a top view of a shared magnetically permeable core formed from a loop of magnetically permeable material, in accordance with an embodiment of the present description;

[0011] FIG. 4 is a top view of an integrated power electronics component with a shared magnetically permeable core, in accordance with an alternate embodiment of the present description;

[0012] FIGS. 5A and 5B provide perspective views of integrated power electronics components with shared magnetically permeable cores, in accordance with alternate embodiments of the present description;

[0013] FIGS. 6A and 6B illustrate the flow of magnetic fields through integrated power electronics components, in accordance with an embodiment of the present description;

[0014] FIG. 7 illustrates a method of making an integrated power electronics component, in accordance with an embodiment of the present description;

[0015] FIG. 8 illustrates a method of making a shared magnetically permeable core, in accordance with an alternate embodiment of the present description; and

[0016] FIG. 9 is a schematic of a power electronics circuit which may contain an integrated power electronics component, in accordance with an embodiment of the present description.

[0017] Detailed Description

[0018] In the following description, reference is made to the accompanying drawings that form a part hereof and in which various embodiments are shown by way of illustration. The drawings are not necessarily to scale. It is to be understood that other embodiments are contemplated and may be made without departing from the scope or spirit of the present description. The following detailed description, therefore, is not to be taken in a limiting sense.

[0019] An LLC resonant converter is one of the basic topologies in power electronics, especially in switched mode power supplies. The term “LLC” represents the magnetizing inductance (L) of a transformer, the self-inductance (L) of an additional inductor, and a series capacitance (C). Values of the three components should make resonance, which is important to achieve a higher efficiency. For example, the frequency of an LLC resonant converter (e.g., the example circuit of FIG. 9) is calculated using the following formula:

[0020] The simplest way to get the second L, Lr, is using a separate inductor component having an inductance value of Lr. In this case, we need two magnetic components, the inductor and transformer. Another way to get Lr is using a leakage inductance from the transformer. To do this, the coupling coefficient of the transformer should be lowered intentionally. It can create the leakage inductance in the resonant tank (e.g., see the “Resonant tank” shown in FIG. 9 herein) in the primary side of the transformer. At the same time, this reduces the coupling efficiency of the transformer because the coupling coefficient decreases.

[0021] According to some aspects of the present description, an integrated inductor-transformer includes an inductor and a transformer that share the same magnetic core. In some embodiments, the magnetic core of the inductor is arranged and / or folded so that the magnetic flux generated from the transformer can be canceled at the inductor region. Due to this structure, the two magnetic components can be magnetically isolated and can work as separate components. Other embodiments of integrated power electronics components are possible, as described herein, including a power electronics component with one inductor and two or more transformers and a power electronics component with two integrated transformers (but no inductor) sharing a magnetic core.

[0022] According to some aspects of the present description, an integrated inductor-transformer includes a first transformer and an inductor sharing a common magnetically permeable core. In some embodiments, the first transformer includes a first primary coil and a first secondary coil wound around a same first core portion of the core. In some embodiments, the inductor includes an inductor coil wound around a second core portion of the core. In some embodiments, when the first primary coil is energized, a first magnetic flux generated by the first transformer in the first core portion is cancelled in the second core portion, and a second magnetic flux generated by the inductor in the second core portion is cancelled in the first core portion.

[0023] In some embodiments, the second core portion may include first and second legs facing each other. In some such embodiments, the inductor coil is wound around a combination of the first and second legs of the second core portion. In some embodiments, the first core portion and the second core portion together may form a loop of magnetically permeable material (e.g., a wound roll of magnetically permeable material). In some such embodiments, the second core portion may be formed from a “pinched” or compressed portion of the loop, wherein the inductor coil is wound around the pinched portion of the loop. In some such embodiments, the second core portion may have a different shape than the first core portion (e.g., the second core portion may be pinched and compressed, while the first core portion may be substantially uncompressed, or the second core portion may contain more or less core material than the first core portion). In some embodiments, the integrated inductor-transformer may further include a third core portion of the core and a second transformer. In some such embodiments, the second core portion may be disposed between and connected to the first core portion and the third core portion, and the second transformer may include a second primary coil and a second secondary coil wound around a same first portion of the third core. In some such embodiments, when any magnetic flux is generated that flows through at least one of the first core portion and the third core portion, any magnetic flux generated by the first transformer in the first core portion and by the second transformer in the third core portion may be cancelled in the second core portion, and any magnetic flux generated by the inductor in the second core portion may be cancelled in the first and third core portions. In some embodiments, the first core portion, the second core portion, and the third core portion may together comprise a loop of magnetically permeable material, and the second core may be a pinched portion of the loop between the first core portion and the third core portion, wherein the inductor coil is wound around the pinched portion of the loop. That is, in some such embodiments, the loop may be compressed in the middle, forming something similar to a figure 8, with the middle of the figure 8 including the second core portion.

[0024] In some embodiments, any of the embodiments of the integrated inductor-transformer may be used in a power electronics circuit. For example, in some embodiments, the power electronics circuit may be an LLC resonant converter, as described elsewhere herein.

[0025] According to some aspects of the present description, an integrated power electronics component includes a substantially planar magnetically permeable core having substantially coplanar, substantially planar, magnetically permeable first and second core portions, a first transformer including a primary coil and a secondary coil wound around, and inductively coupled to, the first core portion, and an inductor including an inductor coil wound around, and inductively coupled to, the second core portion. In some embodiments, the substantially planar first core portion at least partially surrounds and defines a through opening. In some embodiments, the substantially planar second core portion may be connected at a first location of the first core portion and may extend away from the first core portion.

[0026] In some embodiments, a magnetic coupling coefficient between the inductor and the first transformer is less than about 0.1, or less than about 0.08, or less than about 0.06, or less than about 0.04, or less than about 0.02, or less than about 0.1, or less than about 0.01, or less than about 0.001. In some embodiments, a magnetic coupling coefficient between the primary and secondary coils is greater than about 0.5, or greater than about 0.6, or greater than about 0.7, or greater than about 0.8, or greater than about 0.9, or greater than about 0.95, or greater than about 0.98, or greater than about 0.99, or greater than about 0.995.

[0027] Table 1 summarizes the results of a simulation of resistances, inductances, and coupling coefficients of the integrated inductor-transformer structure. As shown in this table, the magnitude of the coupling coefficients between the inductor and the transformer (k 13 and k23) are less than 0.001, which means there is substantially no inductive coupling between them. On the contrary, the magnitude of the coupling coefficient (kl 2) between the primary and secondary coils of the transformer is close to 1.

[0028] Table 1. Simulation Results of Resistances, Inductances, and Coupling Coefficients.

[0029] In some embodiments, the substantially planar second core portion includes first and second legs facing each other, and the inductor coil may be wound around a combination of the first and second legs of the second core portion. For example, in some embodiments, the substantially planar magnetically permeable core may include a loop of magnetically permeable material, and the substantially planar second core portion may be formed as a pinched portion of the loop, such that the pinched portion includes the first and second legs (i.e., the first and second legs are the segments of the loop that are “pinched together” to form the pinched portion, with the first leg being a first segment of the loop pressed toward the second leg, which is a second segment of the loop).

[0030] In some embodiments, the first transformer may be wound around a second location of the first core portion, and the second location may be substantially diametrically opposed to the first location of the first core portion. Stated another way, the length of the first core portion between the first location (where the second core portion is attached) and the second portion (where the transformer is wound) traveling the loop between the first and second location in one direction may be substantially identical to the length of the first core portion between the first and second locations when traveling in the opposite direction.

[0031] When the second location (i.e., the location of the first transformer on the first core portion) is not substantially diametrically opposed to the first location (i.e., the location where the second core portion is attached to the first core portion) on the “loop” of the first core portion, the performance of the structure (i.e., the intended magnetic isolation of the inductor and the transformer) is negatively affected. Stated another way, if the transformer and the inductor (the second core portion holding the inductor) are not distributed substantially symmetrically around the first core portion, the coupling coefficients between the inductor and the transformer increase (indicating stronger magnetic coupling, rather than the desired isolation).

[0032] Table 2 below summarizes the results of a simulation of resistances, inductances, and coupling coefficients of the integrated inductor-transformer structure when the transformer is moved closer to the inductor (moved around the “loop” of the first core portion). As shown in this table, the magnitude of the coupling coefficients between the inductor and the transformer (kl3 and k23) have increased to around 0.05, compared to the 0.00015 value in Table 1, which means there is an increase in inductive coupling between the inductor and transformer when they are not distributed symmetrically.

[0033] Table 2. Simulation Results when Inductor, Transformer Not Symmetrically Distributed

[0034] In some embodiments, the integrated power electronics component may include more than just a first transformer. For example, the integrated power electronics component may further include a plurality of transformers (e.g., 2, 3, 4, 5, 6, 8, or 10 transformers) including the first transformer, wherein the transformers of the plurality of transformers are arranged substantially symmetrically around the first core portion (having equal space between then around the loop of the first core portion, see, e.g., FIG. 5A).

[0035] As with the arrangement of a single transformer relative to the inductor described elsewhere herein, the symmetric distribution of the plurality of transformers relative to the first location (i.e., the location of the second core portion and the inductor) is important to achieve best performance (i.e., the optimum magnetic isolation between the magnetic components).

[0036] Table 3 summarizes the results of a simulation of resistances, inductances, and coupling coefficients of the integrated inductor-transformer structure with a single inductor and multiple transformers when the transformers are distributed symmetrically around the first core portion. In this embodiment, the coupling coefficients between the inductor and transformer are 0.0001.

[0037] Table 3. Simulation Results with Symmetrically Distributed Plurality of Transformers According to some aspects of the present description, a method of making an integrated power electronics component includes winding a magnetically permeable film about a longitudinal axis multiple times to form a wound magnetically permeable film having a plurality of substantially concentric turns of the magnetically permeable film; slicing the wound magnetically permeable film along a cross-sectional plane substantially orthogonal to the longitudinal axis to form a magnetically permeable core including a slice of the magnetically permeable film having a central core opening defined at least in part by an innermost winding of the sliced magnetically permeable film; forming a transformer by winding a primary coil and a secondary coil around a first portion of the core; and forming an inductor by winding an inductor coil around a second portion of the core, such that a ratio of a magnetic coupling coefficient between the primary and secondary coils to a magnetic coupling coefficient between the inductor and the transformer greater than about 10.

[0038] In some embodiments, winding a magnetically permeable film about a longitudinal axis multiple times to form a wound magnetically permeable film may further include compressing a section of the wound magnetically permeable film along the longitudinal axis to create the second portion of the core.

[0039] In some embodiments, winding a magnetically permeable film about a longitudinal axis multiple times to form a wound magnetically permeable film may further include compressing a section of the wound magnetically permeable film along the longitudinal axis to create the second portion of the core, the second portion of the core disposed between the first portion of the core and a third portion of the core (i.e., compressing the wound magnetically permeable film in a center, forming the first and third portions of the core on either side of the second portion of the core). In some such embodiments, the method may further include forming a second transformer by winding a second primary coil and a second secondary coil around the third portion of the core.

[0040] According to some aspects of the present description, an integrated power electronics component may include a first transformer and a second transformer sharing a common magnetically permeable core. In some embodiments, the first transformer may include a first primary coil and a first secondary coil wound around a same first core portion of the core. In some embodiments, the second transformer may include a second primary coil and a second secondary coil wound around a same second core portion of the core. In some embodiments, when the first primary coil is energized, a first magnetic flux generated by the first transformer in the first core portion is cancelled in the second core portion, and a second magnetic flux generated by the second transformer in the second core portion is cancelled in the first core portion.

[0041] In some embodiments, the second core portion may include first and second legs facing each other, and the second primary coil and the second secondary coil are wound around a combination of the first and second legs of the second core portion. In some such embodiments, the first core portion and the second core portion may together include (be formed from) a loop of magnetically permeable material, and the second core portion may be formed as a pinched portion of the loop. In some such embodiments, the second primary coil and the second secondary coil may be wound around the pinched portion of the loop to form the second transformer.

[0042] Turning now to the figures, FIG. 1 is a perspective view of an embodiment of an integrated inductor-transformer with a shared magnetically permeable core, according to the present description. In some embodiments, integrated inductor-transformer 300 may include a first transformer 200 and an inductor 100 sharing a common magnetically permeable core (shared core) 50. In some embodiments, first transformer 200 includes a first primary coil 210 and a first secondary coil 220 wound around a same first core portion 50a of the core (e.g., wound around the “loop” of the shared core 50). In some embodiments, the inductor 100 includes an inductor coil 110 wound around a second core portion 50b of the common core 50.

[0043] In some embodiments, it is ideal that the windings of the first primary coil 210 and first secondary coil 220 be distributed symmetrically around the first core portion 50a (to provide optimal magnetic isolation between first transformer 200 and inductor 100). The windings may be close together in a single location on first core portion 50a (e.g., see FIG. 6A), or spread symmetrically around first core portion 50a, as shown in the embodiment of FIG. 1A.

[0044] FIGS. 2A and 2B provide perspective views of alternate embodiments of a shared magnetically permeable core, such as the embodiment of shared core 50 of FIG. 1. In the embodiment of FIG. 2A, shared core 50 is substantially planar and includes a substantially planar first core portion 50a and a coplanar, substantially planar second core portion 50b. In some embodiments, first core portion 50a at least partially surrounds and defines a through opening 55. In some embodiments, second core portion 50b may be connected at a first location 57 of first core portion 50a and extend away from the first core portion 50a (i.e., away from through opening 55 of first core portion 50a).

[0045] It should be noted that, although first core portion 50a and through opening 55 are shown as being substantially circular in FIGS. 2A and 2B, first core portion 50a and through opening 55 may be any appropriate shape, including, but not limited to, square, rectangular, triangular, oval, and elliptical. The figures are not intended to be limited.

[0046] In the embodiment of FIG. 2 A, second core portion 50b may include a first leg 52 and a second leg 54 facing each other, separated by a division 56 between first leg 52 and second leg 54. It should be noted that, in some embodiments, first leg 52 and second leg 54 may be in contact with each other (i.e., a width of division 56 may be substantially zero) or there may be a gap between first leg 52 and second leg 54 (i.e., division 56 has a non-zero width).

[0047] As discussed elsewhere herein, both the embodiments of the shared core 50 of FIG. 2 A and FIG. 2B, and variations thereof, provide for the desired magnetic isolation of an inductor wound around second core portion 50b and a transformer wound around first core portion 50a.

[0048] When the second core portion 50b includes a first leg 52 and second leg 54 facing each other, as shown in the embodiment of FIG. 2B, this may be the result of how shared core 50 was created. For example, FIG. 3 is a top view of an embodiment of a shared magnetically permeable core 50 formed from a loop of magnetically permeable material 58, according to the present description. In such an embodiment, which may be created by a method such as than shown in FIG. 7 discussed elsewhere herein, first core portion 50a and the second core portion 50b together may be formed from a loop of magnetically permeable material 58 surrounding and defining a through opening 55. In some such embodiments, second core portion 50b may be a “pinched” or compressed portion of the loop of magnetically permeable material 58.

[0049] FIG. 4 is a top view of an embodiment of an integrated power electronics component with a shared magnetically permeable core, wherein the shared core has more than a first core part and a second core part. In the embodiment of FIG. 4, the integrated inductor-transformer 300a is similar to the embodiment of the integrated inductor-transformer 300 of FIG. 1 (and thus elements in FIG. 4 with like reference numbers to elements in FIG. 1 are assumed to have the same function unless otherwise noted herein), except integrated inductor-transformer 300a further includes a third core portion 50c of the shared core 50 and a second transformer 200b (note that first transformer 200 is also labeled as 200a in FIG. 4). In some such embodiments, second core portion 50b is disposed between and connected to first core portion 50a and third core portion 50c, and the second transformer 200b includes a second primary coil 210b and a second secondary coil 220b wound around a same first portion of third core 50c.

[0050] It should be noted that, in the embodiment and symmetric arrangement of FIG. 4, when a magnetic flux is generated that flows through at least one of first core portion 50a and third core portion 50c, any magnetic flux generated by the first transformer 200a in first core portion 50a and by second transformer 200b in third core portion 50c will be substantially cancelled in second core portion 50b, and any magnetic flux generated by inductor 100 in second core portion 50b will be substantially cancelled in the first 50a and third 50c core portions.

[0051] FIGS. 5A and 5B provide perspective views of alternate embodiments of an integrated power electronics component with shared magnetically permeable cores, according to the present description. Looking first at embodiment 300b of the integrated power electronics component of FIG. 5 A, it is shown that integrated power electronics component 300b may further include a plurality of transformers (200a, 200b, 200c) including first transformer 200a. Although the example embodiment of FIG. 5 A includes three transformers, any appropriate number of transformers may be used in embodiments within the scope of the present description, such as 2, 3, 4, 5, 6, 8, or 10 transformers. As described elsewhere herein, an optimum arrangement of the plurality of transformers is one in which the plurality of transformers is arranged substantially symmetrically around first core portion 50a.

[0052] FIG. 5B illustrates an alternate embodiment of an integrated power electronics component 300c. In this alternate embodiment, the integrated power electronics component 300c includes a first transformer 200a and a second transformer 200b sharing a common magnetically permeable core 50, rather than a first transformer 200 and inductor 100 as in the embodiment of FIG. 1. In some such embodiments, first transformer 200a includes first primary coil 210 and first secondary coil 220 wound around a same first core portion 50a of the core, and second transformer 200b includes second primary coil 210b and second secondary coil 220b wound around a same second core portion 50b of the core. As with the integrated inductor-transformer 300 of FIG. 1, the first transformer 200a and second transformer 220b are magnetically isolated from each other (i.e., when the first primary coil 210 is energized, a first magnetic flux generated by first transformer 200a in first core portion 50a is cancelled in second core portion 50b, and a second magnetic flux generated by second transformer 200b in second core portion 50b is cancelled in first core portion 50a.

[0053] FIGS. 6 A and 6B illustrate the flow of magnetic fields through embodiments of integrated power electronics components, according to the present description. In the embodiment of FIG. 6 A, the second core portion 50b of shared core 50 of integrated inductor-transistor 300 is a solid projection (i.e., does not have a first leg and a second leg), while in the embodiment of FIG. 6A, the second core portion 50b of shared core 50 of integrated inductor-transistor 300 is split (i.e., includes a first leg and a second leg, such as the shared core 50 of FIG. 2A). Both the embodiments of FIGS. 6A and 6B allow for the inductor 100 to be magnetically isolated from transformer 200.

[0054] The flow of magnetic fields 70 through the shared core 50 is shown in FIGS. 6A and 6B by arrows indicating a simulated path. In the embodiment of FIG. 6 A, with the solid second core portion 50b, the magnetic fields 70 flowing through first core portion 50a do not have a significant effect on the operation of inductor 100 because the direction of magnetic fields 70 are substantially the same as the in both first core portion 50a and second core portion 50b. In the embodiment of FIG. 6B, the magnetic fields 70 pass through first leg 52 in a direction opposite the direction of the magnetic fields 70 in second leg 54, such that the effects caused by the two legs are substantially cancelled.

[0055] FIG. 7 illustrates an embodiment of a method of making an integrated power electronics component, according to the present description. In method part (A), a magnetically permeable film 58 is wound about a longitudinal axis 95 multiple times to form a wound magnetically permeable film 80 having a plurality of substantially concentric turns of the magnetically permeable film 58.

[0056] In method part (B), and in some embodiments, a section of the wound magnetically permeable film 80 along the longitudinal axis 95 may be compressed or “pinched” to create compressed wound magnetically permeable film 80a, including a second portion 50b (which will eventually become second portion 50b of the shared core 50).

[0057] In method part (C), compressed wound magnetically permeable film 80a is sliced along a cross-sectional plane substantially orthogonal to the longitudinal axis to form a magnetically permeable core 50 including a slice of the compressed wound magnetically permeable film 80a having a central core opening 55 defined at least in part by an innermost winding 53 of the compressed sliced magnetically permeable film 80a.

[0058] In method part (D), a transformer 200 is formed by winding a primary coil and a secondary coil around a first portion of the core, and an inductor 100 is formed by winding an inductor coil around a second portion of the core.

[0059] FIG. 8 illustrates an alternate embodiment of a method of making a shared magnetically permeable core, according to the present description. In method part (A2), similar to part (A) of FIG. 7, a magnetically permeable film is wound about a longitudinal axis 95 multiple times to form a wound magnetically permeable film 80 having a plurality of substantially concentric turns of the magnetically permeable film. The illustration of method part (A2) shows wound magnetically permeable film 80 from an end of the film 80, looking down longitudinal axis 95. In method part (B2), the wound magnetically permeable film 80 is compressed along the longitudinal axis to create second portion of the core, the second portion of the core disposed between a first portion of the core and a third portion of the core. This embodiment of the method may be used, for example, to create a shared magnetic core for an embodiment of the integrated power electronics component, such as the embodiment of FIG. 4, in which a first transformer 200a is wound around a first core portion 50a, a second transformer 200b is wound around a third core portion 50c, and an inductor is wound around second core portion 50b.

[0060] Finally, FIG. 9 is a schematic of a power electronics circuit which may contain any of the embodiments of an integrated power electronics component as provided in the present description. The power electronics circuit shown in FIG. 9 is an example of a LLC resonant power converter, as described elsewhere herein. Embodiments of the integrated power electronics components described herein may be used to provide the inductances shown in the “resonant tank” section of the schematic in FIG. 9. The circuit shown in FIG. 9 is not intended to be limiting, and the integrated power electronics components described herein may be used and applied in a variety of other applications.

[0061] Terms such as “about” will be understood in the context in which they are used and described in the present description by one of ordinary skill in the art. If the use of “about” as applied to quantities expressing feature sizes, amounts, and physical properties is not otherwise clear to one of ordinary skill in the art in the context in which it is used and described in the present description, “about” will be understood to mean within 10 percent of the specified value. A quantity given as about a specified value can be precisely the specified value. For example, if it is not otherwise clear to one of ordinary skill in the art in the context in which it is used and described in the present description, a quantity having a value of about 1, means that the quantity has a value between 0.9 and 1.1, and that the value could be 1.

[0062] Terms such as “substantially” will be understood in the context in which they are used and described in the present description by one of ordinary skill in the art. If the use of “substantially equal” is not otherwise clear to one of ordinary skill in the art in the context in which it is used and described in the present description, “substantially equal” will mean about equal where about is as described above. If the use of “substantially parallel” is not otherwise clear to one of ordinary skill in the art in the context in which it is used and described in the present description, “substantially parallel” will mean within 30 degrees of parallel. Directions or surfaces described as substantially parallel to one another may, in some embodiments, be within 20 degrees, or within 10 degrees of parallel, or may be parallel or nominally parallel. If the use of “substantially aligned” is not otherwise clear to one of ordinary skill in the art in the context in which it is used and described in the present description, “substantially aligned” will mean aligned to within 20% of a width of the objects being aligned. Objects described as substantially aligned may, in some embodiments, be aligned to within 10% or to within 5% of a width of the objects being aligned.

[0063] All references, patents, and patent applications referenced in the foregoing are hereby incorporated herein by reference in their entirety in a consistent manner. In the event of inconsistencies or contradictions between portions of the incorporated references and this application, the information in the preceding description shall control.

[0064] Descriptions for elements in figures should be understood to apply equally to corresponding elements in other figures, unless indicated otherwise. Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and / or equivalent implementations can be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this disclosure be limited only by the claims and the equivalents thereof.

Claims

What is claimed:

1. An integrated inductor-transformer, comprising a first transformer and an inductor sharing a common magnetically permeable core, the first transformer comprising a first primary coil and a first secondary coil wound around a same first core portion of the core, the inductor comprising an inductor coil wound around a second core portion of the core, such that when the first primary coil is energized, a first magnetic flux generated by the first transformer in the first core portion is cancelled in the second core portion, and a second magnetic flux generated by the inductor in the second core portion is cancelled in the first core portion.

2. The integrated inductor-transformer of claim 1, wherein the second core portion comprises first and second legs facing each other, and the inductor coil is wound around a combination of the first and second legs of the second core portion.

3. The integrated inductor-transformer of claim 1, wherein the first core portion and the second core portion together comprise a loop of magnetically permeable material, and the second core portion comprises a pinched portion of the loop, wherein the inductor coil is wound around the pinched portion of the loop.

4. The integrated inductor-transformer of claim 1, further comprising a third core portion of the core and a second transformer, wherein the second core portion is disposed between and connected to the first core portion and the third core portion, and the second transformer comprises a second primary coil and a second secondary coil wound around a same first portion of the third core.

5. The integrated inductor-transformer of claim 4, wherein when a magnetic flux is generated that flows through at least one of the first core portion and the third core portion, any magnetic flux generated by the first transformer in the first core portion and by the second transformer in the third core portion is cancelled in the second core portion, and any magnetic flux generated by the inductor in the second core portion is cancelled in the first and third core portions.

6. The integrated inductor-transformer of claim 4, wherein the first core portion, the second core portion, and the third core portion together comprise a loop of magnetically permeable material, and the second core comprises a pinched portion of the loop between the first core portion and the third core portion, wherein the inductor coil is wound around the pinched portion of the loop.

7. A power electronics circuit, comprising the integrated inductor-transformer of claim 1.

8. The power electronics circuit of claim 7, wherein the power electronics circuit is an LLC resonant converter.

9. An integrated power electronics component, comprising: a substantially planar magnetically permeable core comprising substantially co-planar, substantially planar, magnetically permeable first and second core portions, the substantially planar first core portion at least partially surrounding and defining a through opening, the substantially planar second core portion connected at a first location of the first core portion and extending away from the first core portion; a first transformer comprising a primary coil and a secondary coil wound around, and inductively coupled to, the first core portion; and an inductor comprising an inductor coil wound around, and inductively coupled to, the second core portion, such that a magnetic coupling coefficient between the inductor and the first transformer is less than about 0.1, and a magnetic coupling coefficient between the primary and secondary coils is greater than about 0.5.

10. The integrated power electronics component of claim 9, wherein the substantially planar second core portion comprises first and second legs facing each other, and the inductor coil is wound around a combination of the first and second legs of the second core portion.

11. The integrated power electronics component of claim 10, wherein the substantially planar magnetically permeable core comprises a loop of magnetically permeable material, and the substantially planar second core portion comprises a pinched portion of the loop, the pinched portion comprising the first and second legs.

12. The integrated power electronics component of claim 9, wherein the first transformer is wound around a second location of the first core portion, and the second location is substantially diametrically opposed to the first location of the first core portion.

13. The integrated power electronics component of claim 9, further comprising a plurality of transformers comprising the first transformer, wherein the plurality of transformers are arranged substantially symmetrically around the first core portion.

14. A method of making an integrated power electronics component, comprising: winding a magnetically permeable film about a longitudinal axis multiple times to form a wound magnetically permeable film comprising a plurality of substantially concentric turns of the magnetically permeable film;slicing the wound magnetically permeable film along a cross-sectional plane substantially orthogonal to the longitudinal axis to form a magnetically permeable core comprising a slice of the magnetically permeable film comprising a central core opening defined at least in part by an innermost winding of the sliced magnetically permeable film; forming a transformer by winding a primary coil and a secondary coil around a first portion of the core; and forming an inductor by winding an inductor coil around a second portion of the core, such that a ratio of a magnetic coupling coefficient between the primary and secondary coils to a magnetic coupling coefficient between the inductor and the transformer greater than about 10.

15. The method of claim 14, wherein winding a magnetically permeable film about a longitudinal axis multiple times to form a wound magnetically permeable film further comprises compressing a section of the wound magnetically permeable film along the longitudinal axis to create the second portion of the core.

16. The method of claim 14, wherein winding a magnetically permeable film about a longitudinal axis multiple times to form a wound magnetically permeable film further comprises compressing a section of the wound magnetically permeable film along the longitudinal axis to create the second portion of the core, the second portion of the core disposed between the first portion of the core and a third portion of the core.

17. The method of claim 16, further comprising forming a second transformer by winding a second primary coil and a second secondary coil around the third portion of the core.

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