# US 2018/0025832 A1 · Multiphase Voltage Converter with Coupled Inductors of Reduced Winding loss and Core Loss

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- Number: US 2018/0025832 A1
- Document ID: US20180025832A1
- Status: Published application
- Kind: A1
- Application number: 15/424,895
- Filed: 2017-02-06
- Published: 2018-01-25
- Earliest claimed: 2015-12-07
- Assignees: Mr. Wenkang Huang; Dr. Bradley M. Lehman
- Inventors: Wenkang Huang; Bradley M. Lehman
- Web page: https://patentgrep.com/patent/US20180025832A1

## CPC

- H02M 3/1584: {with a plurality of power processing stages connected in parallel}
- H01F 17/0006: {Printed inductances (printed coils for dynamo-electric machines H02K3/26; printed circuits H05K)}
- H01F 17/04: with magnetic core
- H01F 27/24: Magnetic cores
- H01F 27/28: Coils; Windings; Conductive connections
- H01F 27/40: Structural association with built-in electric component, e.g. fuse
- H02M: APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF (transformers H01F; dynamo-electric converters H02K47/00; controlling transformers, reactors or choke coils, control or regulation of electric motors, generators or dynamo-electric converters H02P)
- H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES

## Abstract

A multiphase switching DC-DC converter generates an output voltage from an input voltage. The converter includes multiphase coupled inductors having lateral magnetic core and non-looping conductors. The currents in conductors of the inductors flow in opposite directions, and therefore, the coupled inductors are inversely coupled and have a relatively low resistance and relatively small core volume. The reduced resistance of the inductor windings combined with smaller volume of magnetic core in the coupled inductors increases energy conversion efficiency and improves transient response of the converter. The coupled inductors can be employed in buck or boost or buck-boost converters, and they can also be used in buck or boost or buck-boost derived converters with isolation transformers.

## Claims

### Claim 1

A multiphase coupled inductor for a multiphase voltage converter, comprising:
a) a magnetic core having
1) a first core structure extending, in a first plane, along a first linear axis,
2) a second core structure extending, in a first plane, along a linear axis parallel to the said first linear axis;
b) a first inductor comprising a non-looping electrical conductor extending, in a second plane, linearly from a first inductor conductor first end to a first inductor conductor second end, along a second linear axis; and
c) a second inductor comprising a non-looping electrical conductor extending, in a second plane, linearly from a second inductor conductor first end to a second inductor conductor second end, along a linear axis parallel to the said second linear axis.

### Claim 2 (depends on 1)

The multiphase coupled inductor of claim 1, wherein the first linear axis and said second linear axis are essentially perpendicular.

### Claim 3 (depends on 1)

The multiphase coupled inductor of claim 1, wherein the first plane and said second plane are essentially perpendicular.

### Claim 4

A multiphase voltage converter, comprising:
a) a magnetic core;
b) a first phase circuit comprising
1) a first inductor conductor that is non-looping with respect to the magnetic core,
2) top and bottom switches connected to the first inductor conductor first end,
3) a converter voltage output connected to the first inductor conductor second end, and
4) top and bottom switches operable for alternately charging and discharging the first inductor; and
c) a second phase circuit comprising
1) a second inductor conductor that is non-looping with respect to the magnetic core,
2) top and bottom switches connected the second inductor conductor second end,
3) a converter voltage output connected to the second inductor conductor first end, and
4) top and bottom switches operable for alternately charging and discharging the second inductor, wherein
the magnetic core is constructed with an air gap and said construction and arrangement including:
i) a first core structure, extending in a first plane, along a first linear axis,
ii) a second core structure extending, in a first plane, along a linear axis parallel to the said first linear axis,
said first inductor extends, in a second plane, linearly from a first inductor conductor first end to a first inductor conductor second end, along a second linear axis, and
said second inductor extends, in a second plane, linearly from a second inductor conductor first end to a second inductor conductor second end, along a linear axis parallel to the said second linear axis.

### Claim 5 (depends on 4)

The multiphase voltage converter of claim 4, wherein the connections of top and bottom switches of the first and second phase circuits to said first and second inductors such that the first and second inductors are inversely coupled through said magnetic core.

### Claim 6 (depends on 4)

The multiphase voltage converter of claim 4, wherein the first linear axis and said second linear axis are essentially perpendicular.

### Claim 7 (depends on 4)

The multiphase voltage converter of claim 4, wherein the first plane and said second plane are essentially perpendicular.

### Claim 8 (depends on 4)

The multiphase voltage converter of claim 4, further comprising
a third phase circuit comprising:
a) a third inductor that is non-looping with respect to the magnetic core, extending, in a plane parallel to said second plane, linearly from a third inductor conductor first end to a third inductor second end, along a linear axis parallel to said second linear axis,
b) top and bottom switches connected to the third inductor conductor first end,
c) a converter voltage output connected to the third inductor conductor second end, and
d) top and bottom switches operable for alternately charging and discharging the third inductor; wherein
said magnetic core further comprises
a third core structure extends, in a first plane, along a linear axis parallel to the said first linear axis,
a fourth core structure extends, in a first plane, along a linear axis parallel to the said first linear axis,
the connections of top and bottom switches of the first and second phase circuits to said first and second inductors such that the first and second inductors are inversely coupled through said magnetic core,
the connections of top and bottom switches of the second and third phase circuits to said second and third inductors such that the second and third inductors are inversely coupled through said magnetic core.

### Claim 9 (depends on 4)

The multiphase voltage converter of claim 4, further comprising
a third phase circuit comprising:
a) a third inductor that is non-looping with respect to the magnetic core, extending, in a plane parallel to said second plane, linearly from a third inductor conductor first end to a third inductor second end, along a linear axis parallel to said second linear axis,
b) top and bottom switches connected to the third inductor conductor first end,
c) a converter voltage output connected to the third inductor conductor second end, and
d) top and bottom switches operable for alternately charging and discharging the third inductor;
a fourth phase circuit comprising:
a) a fourth inductor that is non-looping with respect to the magnetic core, extending, in a plane parallel to said second plane, linearly from a fourth inductor conductor first end to a fourth inductor second end, along a linear axis parallel to said second linear axis,
b) top and bottom switches connected to the fourth inductor conductor second end,
c) a converter voltage output connected to the fourth inductor conductor first end, and
d) top and bottom switches operable for alternately charging and discharging the fourth inductor, wherein
said magnetic core further comprises
a third core structure extends, in a first plane, along a linear axis parallel to the said first linear axis.

### Claim 10 (depends on 9)

The multiphase voltage converter of claim 9, further comprising
a fifth phase circuit comprising:
a) a fifth inductor that is non-looping with respect to the magnetic core, extending, in a plane parallel to said second plane, linearly from a fifth inductor conductor first end to a fifth inductor second end, along a linear axis parallel to said second linear axis,
b) top and bottom switches connected to the fifth inductor conductor first end,
c) a converter voltage output connected to the fifth inductor conductor second end, and
d) top and bottom switches operable for alternately charging and discharging the fifth inductor;
a sixth phase circuit comprising:
a) a sixth inductor that is non-looping with respect to the magnetic core, extending, in a plane parallel to said second plane, linearly from a sixth inductor conductor first end to a sixth inductor second end, along a linear axis parallel to said second linear axis,
b) top and bottom switches connected to the sixth inductor conductor second end,
c) a converter voltage output connected to the sixth inductor conductor first end, and
d) top and bottom switches operable for alternately charging and discharging the sixth inductor, wherein
said magnetic core further comprises
a fourth core structure extends, in a first plane, along a linear axis parallel to the said first linear axis.

### Claim 11 (depends on 10)

The multiphase voltage converter of claim 10, further comprising
a seventh phase circuit comprising:
a) a seventh inductor that is non-looping with respect to the magnetic core, extending, in a plane parallel to said second plane, linearly from a seventh inductor conductor first end to a seventh inductor second end, along a linear axis parallel to said second linear axis,
b) top and bottom switches connected to the seventh inductor conductor first end,
c) a converter voltage output connected to the seventh inductor conductor second end, and
d) top and bottom switches operable for alternately charging and discharging the seventh inductor;
an eighth phase circuit comprising:
a) an eighth inductor that is non-looping with respect to the magnetic core, extending, in a plane parallel to said second plane, linearly from an eighth inductor conductor first end to an eighth inductor second end, along a linear axis parallel to said second linear axis,
b) top and bottom switches connected to the eighth inductor conductor second end,
c) a converter voltage output connected to the eighth inductor conductor first end, and
d) top and bottom switches operable for alternately charging and discharging the eighth inductor, wherein
said magnetic core further comprises
a fifth core structure extends, in a first plane, along a linear axis parallel to the said first linear axis.

### Claim 12 (depends on 4)

A multiphase voltage converter of claim 4, comprising:
a) a magnetic core comprising
1) a first core structure extending, in a first plane, along a first linear axis,
2) a second core structure extending, in a first plane, along a linear axis parallel to the said first linear axis;
b) a first phase circuit comprising:
1) a first inductor that is non-looping with respect to the magnetic core, extending in a second plane, linearly from a first inductor conductor first end to a first inductor conductor second end, along a second linear axis, wherein the first inductor is connected between a midpoint of the first top and bottom switches and a converter voltage output, and the switches are constructed and arranged to alternately charge and discharge the first inductor, and
2) first top and bottom switches connected in series between a voltage source and ground;
c) a second phase circuit comprising:
1) a second inductor that is non-looping with respect to the magnetic core extending in a plane parallel to said second plane, linearly from a second inductor first end to a second inductor second end, along a second linear axis; wherein the second inductor is connected between a midpoint of the second top and bottom switches and a converter voltage output, and the switches are constructed and arranged to alternately charge and discharge the second inductor, and
2) second top and bottom switches connected in series between a voltage source and ground, wherein
the connections of top and bottom switches of the first and second phase circuits to said first and second inductors such that the first and second inductors are inversely coupled through said magnetic core.

### Claim 13 (depends on 4)

A multiphase voltage converter of claim 4, comprising:
a) a magnetic core comprising
1) a first core structure extending, in a first plane, along a first linear axis,
2) a second core structure extending, in a first plane, along a linear axis parallel to the said first linear axis;
b) a first phase circuit comprising:
1) a first inductor that is non-looping with respect to the magnetic core, extending in a second plane, linearly from a first inductor conductor first end to a first inductor conductor second end, along a second linear axis, wherein the first inductor is connected between a midpoint of the first top and bottom switches and a voltage source, and the switches are constructed and arranged to alternately charge and discharge the first inductor, and
2) first top and bottom switches connected in series between a converter voltage output and ground;
c) a second phase circuit comprising:
1) a second inductor that is non-looping with respect to the magnetic core extending in a plane parallel to said second plane, linearly from a second inductor first end to a second inductor second end, along a second linear axis, wherein the second inductor is connected between a midpoint of the second top and bottom switches and a voltage source, and the switches are constructed and arranged to alternately charge and discharge the second, and
2) second top and bottom switches connected in series between a converter voltage output and ground, wherein
the connections of top and bottom switches of the first and second phase circuits to said first and second inductors such that the first and second inductors are inversely coupled through said magnetic core.

### Claim 14 (depends on 4)

A multiphase voltage converter of claim 4, comprising:
a) a magnetic core comprising
1) a first core structure extending, in a first plane, along a first linear axis,
2) a second core structure extending, in a first plane, along a linear axis parallel to the said first linear axis;
b) a first phase circuit comprising:
1) a first inductor that is non-looping with respect to the magnetic core, extending in a second plane, linearly from a first inductor conductor first end to a first inductor conductor second end, along a second linear axis, wherein the first inductor is connected between a midpoint of the first top and bottom switches and ground, and the switches are constructed and arranged to alternately charge and discharge the first inductor, and
2) first top and bottom switches connected in series between a voltage source and a converter voltage output;
c) a second phase circuit comprising:
1) a second inductor that is non-looping with respect to the magnetic core extending in a plane parallel to said second plane, linearly from a second inductor first end to a second inductor second end, along a second linear axis, wherein the second inductor is connected between a midpoint of the second top and bottom switches and ground, and the switches are constructed and arranged to alternately charge and discharge the second inductor, and
2) second top and bottom switches connected in series between a voltage source and a converter voltage output, wherein
the connections of top and bottom switches of the first and second phase circuits to said first and second inductors such that the first and second inductors are inversely coupled through said magnetic core.

### Claim 15

A single phase voltage converter, comprising:
a) a magnetic core comprising
1) a first core structure extending, in a first plane, along a first linear axis,
2) a second core structure extending, in a first plane, along a linear axis parallel to the said first linear axis;
b) a single phase circuit comprising:
1) an inductor that is non-looping with respect to the magnetic core, extending in a second plane, linearly from an inductor conductor first end to an inductor conductor second end, along a second linear axis, wherein the inductor is connected between a midpoint of the top and bottom switches and ground, and the switches are constructed and arranged to alternately charge and discharge the inductor, and
2) top and bottom switches connected in series between a voltage source and ground.

### Claim 16 (depends on 15)

A single phase voltage converter of claim 15, comprising:
a) a magnetic core comprising
1) a first core structure extending, in a first plane, along a first linear axis,
2) a second core structure extending, in a first plane, along a linear axis parallel to the said first linear axis;
b) a single phase circuit comprising:
1) an inductor that is non-looping with respect to the magnetic core, extending in a second plane, linearly from an inductor conductor first end to an inductor conductor second end, along a second linear axis, wherein the inductor is connected between a midpoint of the top and bottom switches and a voltage source, and the switches are constructed and arranged to alternately charge and discharge the first inductor, and
2) top and bottom switches connected in series between a converter voltage output and ground.

### Claim 17 (depends on 15)

A single phase voltage converter of claim 15, comprising:
a) a magnetic core comprising
1) a first core structure extending, in a first plane, along a first linear axis,
2) a second core structure extending, in a first plane, along a linear axis parallel to the said first linear axis;
b) a single phase circuit comprising:
1) an inductor that is non-looping with respect to the magnetic core, extending in a second plane, linearly from an inductor conductor first end to an inductor conductor second end, along a second linear axis, wherein the inductor is connected between a midpoint of the top and bottom switches and ground, and the switches are constructed and arranged to alternately charge and discharge the inductor, and
2) top and bottom switches connected in series between a voltage source and a converter voltage output.

### Claim 18 (depends on 1, 4, 8, 9, 10, 11, 12, 13, 14, 15, 16)

A voltage converter of claims 1, 4, 8, 9, 10, 11, 12, 13, 14, 15, 16, and 17, further comprising a transformer that provides isolation between input voltage source and converter voltage output.

### Claim 19 (depends on 1, 4, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)

A voltage converter of claims 1, 4, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, and 18, further comprising a magnetic core having air gap(s) filled with low permeability material or partially filled with a ferromagnetic material.