Method for making magnetic components with N-phase coupling, and related inductor structures

摘要

Methods and structures for constructing a magnetic core of a coupled inductor. The method provides for constructing N-phase coupled inductors as both single and scalable magnetic structures, where N is an integer greater than 1. The method additionally describes how such a construction of the magnetic core may enhance the benefits of using the scalable N-phase coupled inductor. The first and second magnetic cores may be formed into shapes that, when coupled together, may form a single scalable magnetic core. For example, the cores can be fashioned into shapes such as a U, an I, an H, a ring, a rectangle, and a comb, that cooperatively form the single magnetic core.

主权项

1. A coupled inductor, comprising:
a magnetic structure including a plurality of first and second magnetic cores, each of the plurality of first magnetic cores having an U-shaped cross section, each of the plurality of second magnetic cores coupled to a respective one of the plurality of first magnetic cores such that the second magnetic core bridges opposing legs of the first magnetic core, the magnetic structure forming first and second outer posts and at least one center post, each center post including portions of at least two of the plurality of first magnetic cores, each outer post including a portion of a respective one of the plurality of first magnetic cores; and a respective winding wound around each of the first and second outer posts and each center post; each first magnetic core and respective second magnetic core collectively forming an aperture having depth, height, and width, the depth of aperture being greater than the height of the aperture; adjacent windings within each aperture being separated from each other by a linear separation distance in the widthwise direction, the linear separation distance being greater than the height of the aperture.