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Title: Magnetic cores with high reluctance differences in flux paths

Abstract

Embodiment of the present invention includes a magnetic structure and a magnetic structure used in a direct current (DC) to DC energy converter. The magnetic structure has an E-core and a plate, with the plate positioned in contact or in near contact with the post surfaces of the E-core. The E-core has a base, a no-winding leg, a transformer leg, and an inductor leg. The no-winding leg, the transformer leg, and the inductor leg are perpendicular and magnetically in contact with the base. The plate is a flat slab with lateral dimensions generally larger than its thickness. The plate has a plate nose that overlaps a top no-winding leg surface of the no-winding leg with a no-winding gap area to form a no-winding gap with a no-winding gap reluctance. The plate also has a plate end that overlaps a top inductor leg surface of the inductor leg with an inductor gap area to form an inductor gap with an inductor gap reluctance. In some embodiments, e.g., where the duty cycle is less than 50 percent, the inductor gap reluctance will be designed to be less than the no-winding gap reluctance. In these cases, the majority of the magnetic flux thatmore » passes through the transformer leg will return through the inductor leg, instead of through the no-winding leg. The inductor and no-winding gap reluctances can he adjusted, so that the electromotive force applied to a charge passing through the inductor will partially cancel the electromotive force applied by the transformer secondary. The gap reluctance ratio can be defined, so that the difference in secondary and inductor electromotive forces is equal to the output voltage defined by an optimal no-ripple duty cycle. In this way no changing current is required through the inductor to create a dI/dt inductive voltage drop across the output inductor. Zero output current ripple is achieved.Various embodiments of the plate, plate shape, and no-winding leg are disclosed. These embodiments allow achieving a high ratio of no-winding gap reluctance to inductor gap reluctance, for practical, affordable magnetic material structures and aspect ratios. A high gap reluctance ratio enables zero output current ripple for the high transformer turns ratios that are needed to achieve high input to output voltage ratios. The embodiments therefore allow achieving low output current ripple for 48 V or higher input voltages, 1 V or lower output voltages, and high output currents.

Inventors:
; ; ; ;
Issue Date:
Research Org.:
International Business Machines Corp., Armonk, NY (United States)
Sponsoring Org.:
USDOE; US Department of Defense (DOD)
OSTI Identifier:
1986950
Patent Number(s):
11532421
Application Number:
17/174,453
Assignee:
International Business Machines Corporation (Armonk, NY)
DOE Contract Number:  
B621073; H98230-19-C-0113
Resource Type:
Patent
Resource Relation:
Patent File Date: 02/12/2021
Country of Publication:
United States
Language:
English

Citation Formats

Yao, Yuan, Takken, Todd Edward, Ferencz, Andrew, Zhang, Xin, and McAuliffe, Liam Daley. Magnetic cores with high reluctance differences in flux paths. United States: N. p., 2022. Web.
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Yao, Yuan, Takken, Todd Edward, Ferencz, Andrew, Zhang, Xin, & McAuliffe, Liam Daley. Magnetic cores with high reluctance differences in flux paths. United States.
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Yao, Yuan, Takken, Todd Edward, Ferencz, Andrew, Zhang, Xin, and McAuliffe, Liam Daley. Tue . "Magnetic cores with high reluctance differences in flux paths". United States. https://www.osti.gov/servlets/purl/1986950.
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@article{osti_1986950,
title = {Magnetic cores with high reluctance differences in flux paths},
author = {Yao, Yuan and Takken, Todd Edward and Ferencz, Andrew and Zhang, Xin and McAuliffe, Liam Daley},
abstractNote = {Embodiment of the present invention includes a magnetic structure and a magnetic structure used in a direct current (DC) to DC energy converter. The magnetic structure has an E-core and a plate, with the plate positioned in contact or in near contact with the post surfaces of the E-core. The E-core has a base, a no-winding leg, a transformer leg, and an inductor leg. The no-winding leg, the transformer leg, and the inductor leg are perpendicular and magnetically in contact with the base. The plate is a flat slab with lateral dimensions generally larger than its thickness. The plate has a plate nose that overlaps a top no-winding leg surface of the no-winding leg with a no-winding gap area to form a no-winding gap with a no-winding gap reluctance. The plate also has a plate end that overlaps a top inductor leg surface of the inductor leg with an inductor gap area to form an inductor gap with an inductor gap reluctance. In some embodiments, e.g., where the duty cycle is less than 50 percent, the inductor gap reluctance will be designed to be less than the no-winding gap reluctance. In these cases, the majority of the magnetic flux that passes through the transformer leg will return through the inductor leg, instead of through the no-winding leg. The inductor and no-winding gap reluctances can he adjusted, so that the electromotive force applied to a charge passing through the inductor will partially cancel the electromotive force applied by the transformer secondary. The gap reluctance ratio can be defined, so that the difference in secondary and inductor electromotive forces is equal to the output voltage defined by an optimal no-ripple duty cycle. In this way no changing current is required through the inductor to create a dI/dt inductive voltage drop across the output inductor. Zero output current ripple is achieved.Various embodiments of the plate, plate shape, and no-winding leg are disclosed. These embodiments allow achieving a high ratio of no-winding gap reluctance to inductor gap reluctance, for practical, affordable magnetic material structures and aspect ratios. A high gap reluctance ratio enables zero output current ripple for the high transformer turns ratios that are needed to achieve high input to output voltage ratios. The embodiments therefore allow achieving low output current ripple for 48 V or higher input voltages, 1 V or lower output voltages, and high output currents.},
doi = {},
journal = {},
number = ,
volume = ,
place = {United States},
year = {2022},
month = {12}
}
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Works referenced in this record:

Low profile coupled inductors and integrated magnetics
patent, August 1998

Coupled-inductor DC-DC power converter
patent, January 2019

Dual Interleaved Flyback Converter for High Input Voltage
patent-application, March 2010

Variable speed variable reluctance electrical machines
patent, June 1987

Rotary electrical machine
patent, March 2014

Tunable Wireless Power Architectures
patent-application, February 2018

Electrical power supply system and process
patent, November 2019

Power Converter with Co-Packaged Secondary Field Effect Transistors (FETs)
patent-application, July 2021

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