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US 8,294,544 B2Granted
Method for making magnetic components with M-phase coupling, and related inductor structures
AssigneeVolterra Semiconductor Corporation
InventorsAlexandr Ikriannikov, Anthony Stratakos
Life of this patent
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Abstract
An M-phase coupled inductor including a magnetic core and M windings, where M is an integer greater than one. The magnetic core is formed of a core material, and the magnetic core includes a first outer leg forming a first gap. The first gap includes a first gap material having lower magnetic permeability than the core material. Each winding is wound at least partially around at least a portion of the magnetic core, and each winding has a respective leakage inductance. The first gap causes the leakage inductances to be greater than if the first outer leg did not form the first gap. The coupled inductor may be used in a power supply, and the power supply may be used in a computing apparatus.
Claims35
An M-phase coupled inductor, M being an integer greater than one, the coupled inductor comprising:
- a magnetic core formed of core material, the magnetic core including:
- first and second opposing end magnetic elements,
- M adjacent inner legs, each of the M adjacent inner legs disposed between and connecting the first and second opposing end magnetic elements, and
- a first outer leg:
- connected to the first opposing end magnetic element at a first end thereof outside of the M adjacent inner legs,
- connected to an innermost edge of the first opposing end magnetic element nearest an innermost edge of the second opposing end magnetic element, and extending along a first lengthwise direction toward a first end of the second opposing end magnetic element outside of the M adjacent inner legs, and
- including a first gap along the first lengthwise direction, the first gap having a thickness less than a distance between the respective innermost edges of the first and second opposing end magnetic elements at their respective first ends, the first gap including first gap material having lower magnetic permeability than the core material;
- and
- M windings, each winding wound at least partially around at least a portion of a respective one of the inner legs, each winding having a respective leakage inductance,
- wherein the first gap provides a path for leakage flux, the leakage flux contributing to the respective leakage inductances of the M windings, and
- wherein each inner leg has a respective width, and adjacent inner legs are separated by a separation distance that is less than 25% of the respective width of either adjacent inner leg.
8 more elements
An M-phase power supply, M being an integer greater than one, the power supply comprising:
- a coupled inductor including:
- a magnetic core formed of core material, the magnetic core including:
- first and second opposing end magnetic elements,
- M adjacent inner legs, each of the M adjacent inner legs disposed between and connecting the first and second opposing end magnetic elements, and
- a first outer leg:
- connected to the first opposing end magnetic element at a first end thereof outside of the M adjacent inner legs,
- connected to an innermost edge of the first opposing end magnetic element nearest an innermost edge of the second opposing end magnetic element, and extending along a first lengthwise direction toward a first end of the second opposing end magnetic element outside of the M adjacent inner legs, and
- including a first gap along the first lengthwise direction, the first gap having a thickness less than a distance between the respective innermost edges of the first and second opposing end magnetic elements at their respective first ends, the first gap including first gap material having lower magnetic permeability than the core material, and
- M windings, each winding wound at least partially around at least a portion of a respective one of the inner legs, each winding having a respective first end, a respective second end, and a respective leakage inductance, each first end electrically coupled to a common first node,
- wherein the first gap provides a path for leakage flux, the leakage flux contributing to the respective leakage inductances of the M windings;
- and
- M switching circuits, each switching circuit electrically coupled to the second end of a respective winding and configured and arranged to switch the second end between at least two different voltages.
9 more elements
A computing apparatus, comprising:
- a computer processor;
- and
- an M-phase power supply electrically coupled to the processor for at least partially powering the processor, M being an integer greater than one, the power supply including:
- a coupled inductor including:
- a magnetic core formed of core material, the magnetic core including:
- first and second opposing end magnetic elements,
- M adjacent inner legs, each of the M adjacent inner legs disposed between and connecting the first and second opposing end magnetic elements, and
- a first outer leg:
- connected to the first opposing end magnetic element at a first end thereof outside of the M adjacent inner legs,
- connected to an innermost edge of the first opposing end magnetic element nearest an innermost edge of the second opposing end magnetic element, and extending along a first lengthwise direction toward a first end of the second opposing end magnetic element outside of the M adjacent inner legs, and
- including a first gap along the first lengthwise direction, the first gap having a thickness less than a distance between the respective innermost edges of the first and second opposing end magnetic elements at their respective first ends, the first gap including first gap material having lower magnetic permeability than the core material;
- and
- M windings, each winding wound at least partially around at least a portion of a respective one of the inner legs, each winding having a respective first end, a respective second end, and a respective leakage inductance, each first end electrically coupled to a common first node, and
- wherein the first gap provides a path for leakage flux, the leakage flux contributing to the respective leakage inductances of the M windings;
- and
- M switching circuits, each switching circuit electrically coupled to the second end of a respective winding and configured and arranged to switch the second end between at least two different voltages.
13 more elements
An M-phase coupled inductor, M being an integer greater than one, the coupled inductor comprising:
- a magnetic core formed of core material selected from the group consisting of a ferrite material and a powdered iron material, the magnetic core including:
- first and second opposing end magnetic elements,
- M adjacent inner legs, each of the M adjacent inner legs disposed between and connecting the first and second opposing end magnetic elements, and
- a first outer leg:
- connected to the first opposing end magnetic element at a first end thereof outside of the M adjacent inner legs,
- connected to an innermost edge of the first opposing end magnetic element nearest an innermost edge of the second opposing end magnetic element, and extending along a first lengthwise direction toward a first end of the second opposing end magnetic element outside of the M adjacent inner legs, and
- including a first gap along the first lengthwise direction, the first gap having a thickness less than a distance between the respective innermost edges of the first and second opposing end magnetic elements at their respective first ends, the first gap including first gap material having lower magnetic permeability than the core material;
- and
- M windings, each winding wound at least partially around at least a portion of a respective one of the inner legs, each winding having a respective leakage inductance,
- wherein the first gap provides a path for leakage flux, the leakage flux contributing to the respective leakage inductances of the M windings.
7 more elements
Dependencies are inferred from the claim text.