Transformer with integrated leakage inductance
AssigneeToyota Motor Engineering & Manufacturing North America, Inc.
InventorsMasanori Ishigaki, Jongwon Shin
Life of this patent
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Abstract
A transformer includes a magnetic core assembly including a cylindrical bobbin around which transformer windings are wrapped. Primary transformer windings are wrapped around the cylindrical bobbin of the magnetic core assembly with additional primary transformer windings that are extended to come in contact with one or more external surfaces of the magnetic core assembly. Secondary transformer windings are wrapped around the cylindrical bobbin of the magnetic core assembly with additional secondary transformer windings that are extended to come in contact with the one or more external surfaces of the magnetic core assembly.
Claims20
A transformer comprising:
- a magnetic core assembly including a cylindrical bobbin around which transformer windings are wrapped;
- primary transformer windings wrapped around the cylindrical bobbin of the magnetic core assembly with additional primary transformer windings that are extended to come in contact with one or more external surfaces of the magnetic core assembly;
- and
- secondary transformer windings wrapped around the cylindrical bobbin of the magnetic core assembly with additional secondary transformer windings that are extended to come in contact with the one or more external surfaces of the magnetic core assembly.
A method comprising:
- determining desired amounts of leakage inductance for DC-DC power conversion circuitry based on power and voltage characteristics of a power source or power sink connected to the DC-DC power conversion circuitry on a primary side and a secondary side of a transformer;
- identifying one or more locations on one or more external surfaces of a magnetic core assembly of the transformer including an amount of magnetic flux that is less than a predetermined threshold;
- and
- increasing an amount of leakage inductance of the transformer to correspond to the desired amounts of leakage inductance for the DC-DC power conversion circuitry by extending primary and secondary windings of the transformer to come in contact with the one or more external surfaces of the magnetic core assembly including the amount of magnetic flux that is less than the predetermined threshold.
A system comprising:
- a transformer including
- a magnetic core assembly including a cylindrical bobbin around which transformer windings are wrapped,
- primary transformer windings wrapped around the cylindrical bobbin of the magnetic core assembly with additional primary transformer windings that are extended to come in contact with one or more external surfaces of the magnetic core assembly, and
- secondary transformer windings wrapped around the cylindrical bobbin of the magnetic core assembly with additional secondary transformer windings that are extended to come in contact with the one or more external surfaces of the magnetic core assembly;
- and
- DC-DC power conversion circuitry including a first switch and a second switch on either side of the transformer with a first capacitor and a second capacitor cross-connected across the transformer.
Dependencies are inferred from the claim text.