阅读说明：本技术 在四角柱中心有磁柱的低磁芯损耗变压器 (Low magnetic core loss transformer with magnetic column in center of four-corner column ) 是由 徐良杰 刘燕 王硕望 于 2019-10-24 设计创作，主要内容包括：一种用于高传输比和高功率密度应用的低磁芯损耗变压器,可以在磁性金属板之间有五个柱子,包括四个角柱和至少一个中心柱。中心柱提供了一条额外的磁通路径,以减少热量和磁芯损耗并提高效率。通过使多个中心柱有几种对称布置的N走线配置,可以进一步降低磁通密度。低磁芯损耗变压器实现了灵活的电压传输比。该比率可以是偶数或奇数。奇数比设计能够满足未来数据中心提供400伏高分布电源总线的要求。变压器绕组可以是印刷电路板(PCB)上的走线,该电路板集成电子组件用于紧凑和模块化设计。(A low core loss transformer for high transmission ratio and high power density applications may have five columns between magnetic metal plates, including four corner columns and at least one center column. The center post provides an additional flux path to reduce heat and core losses and improve efficiency. The magnetic flux density can be further reduced by having several symmetrically arranged N-trace configurations for the plurality of center posts. The low core loss transformer achieves a flexible voltage transfer ratio. The ratio may be even or odd. The odd ratio design can meet the requirement of providing a 400-volt high-distribution power bus in a future data center. The transformer windings may be traces on a Printed Circuit Board (PCB) that integrates electronic components for compact and modular design.)

1. A low core loss transformer comprising:

an upper magnetic metal plate;

a lower magnetic metal plate parallel to the upper magnetic metal plate;

a plurality of pillars made of magnetic metal, the plurality of pillars being located between the upper magnetic metal plate and the lower magnetic metal plate;

a first flux emitting column of the plurality of columns located at a first angular position;

a first flux-receiving post of the plurality of posts located at a second angular position;

a second flux emitting leg of the plurality of legs located at a third angular position;

a second flux-receiving post of the plurality of posts located at a fourth angular position;

a central flux-receiving post of the plurality of posts located at a central location;

wherein the center position is located in the middle of a straight line between the first angular position and the third angular position;

wherein the center position is located midway in a line between the second angular position and the fourth angular position;

a primary winding wound around each flux receiving leg a plurality of times in a clockwise direction and each flux transmitting leg a plurality of times in a counter-clockwise direction;

a first secondary winding wound around the first flux-emitting leg;

a third secondary winding wound around the second flux-emitting leg.

2. The low core loss transformer of claim 1, further comprising:

a second secondary winding that wraps around the first flux emitting leg one turn;

a fourth secondary winding that wraps around the second flux-emitting leg one turn;

wherein the first and third secondary windings are each wound one turn;

a Printed Circuit Board (PCB) having a metal layer patterned to form metal traces, the metal traces on the PCB forming the primary winding;

wherein the PCB is located between the upper magnetic metal plate and the lower magnetic metal plate;

wherein the plurality of posts are mounted through holes in the PCB.

3. The low magnetic core loss transformer of claim 2, wherein the PCB has exactly four metal layers, wherein the primary winding is disposed on two of the four metal layers, wherein the first secondary winding and the third secondary winding are formed on a first of the four metal layers, wherein the second secondary winding and the fourth secondary winding are formed on a fourth of the four metal layers,

wherein the first and fourth metal layers are located near a surface of the PCB, and the primary winding is disposed on two of the four metal layers, the two metal layers being an inner metal layer between the first and fourth metal layers.

4. The low magnetic core loss transformer of claim 3, wherein the first, second, third, and fourth secondary windings are each not completely wound around the flux emission post, wherein a notch is formed in each of the first, second, third, and fourth secondary windings, the notch having a notch metal node separated from the secondary winding by a first gap and a second gap; further comprising for each of the first, second, third and fourth secondary windings:

a transistor mounted to couple across the first gap;

a capacitor mounted to couple across the second gap;

wherein the transistor and capacitor are part of a synchronous rectifier when the transformer induces current into the secondary winding.

5. The low core loss transformer of claim 2, wherein the first, second, third and fourth angular positions form a parallelogram, the center position being located at the center of the parallelogram.

6. The low core loss transformer of claim 5, wherein the upper and lower magnetic metal plates extend beyond the first, second, third and fourth angular positions.

7. The low core loss transformer of claim 2, wherein the cross-sectional area of each flux transmitting post is at least 50% greater than the cross-sectional area of each flux receiving post.

8. The low magnetic core loss transformer of claim 2, wherein the primary winding is sequentially wound around the second flux receiving leg, then around the first flux emitting leg, then around the central flux receiving leg, then around the second flux emitting leg, and then around the first flux receiving leg.

9. The low magnetic core loss transformer of claim 2, wherein the primary winding is wound four turns around the first flux-emitting limb, four turns around the second flux-emitting limb, three turns around the first flux-receiving limb, three turns around the second flux-receiving limb, and three turns around the center flux-receiving limb; wherein the primary winding has seventeen turns, each secondary winding has only one turn, and the turn ratio is 17: 1.

10. the low magnetic core loss transformer of claim 2, wherein the primary winding is wound four turns around the first flux-emitting leg, four turns around the second flux-emitting leg, three turns around the first flux-receiving leg, three turns around the second flux-receiving leg, and two turns around the central flux-receiving leg, wherein the primary winding has sixteen turns, only one turn per secondary winding, and a turn ratio of 16: 1.

11. a low core loss five leg core comprising:

a top magnetic metal plate for conducting magnetic flux;

a bottom magnetic metal plate for conducting magnetic flux;

an upper left magnetic metal post for conducting magnetic flux from the bottom magnetic metal plate into the top magnetic metal plate;

a top right magnetic metal post for conducting magnetic flux from the top magnetic metal plate into the bottom magnetic metal plate;

a central magnetic metal post for conducting magnetic flux from the top magnetic metal plate into the bottom magnetic metal plate;

a bottom left magnetic metal post for conducting magnetic flux from the top magnetic metal plate into the bottom magnetic metal plate;

a bottom right magnetic metal post for conducting magnetic flux from the bottom magnetic metal plate into the top magnetic metal plate;

wherein the central magnetic metal pillar is located between the top and bottom magnetic metal plates and at a central location between the top left magnetic metal pillar, the top right magnetic metal pillar, the bottom left magnetic metal pillar, and the bottom right magnetic metal pillar;

wherein an average distance from the central magnetic metal pillar to the upper left magnetic metal pillar, the upper right magnetic metal pillar, the lower left magnetic metal pillar, and the lower right magnetic metal pillar is less than an average distance between adjacent ones of the upper left magnetic metal pillar, the upper right magnetic metal pillar, the lower left magnetic metal pillar, and the lower right magnetic metal pillar;

a primary winding wound around each of said upper left magnetic metal post, said upper right magnetic metal post, said lower left magnetic metal post, said lower right magnetic metal post, and said central magnetic metal post a plurality of turns, said primary winding connecting said plurality of turns in series between a primary input and a primary output and carrying a primary current that produces a magnetic flux on said upper left magnetic metal post, said upper right magnetic metal post, said lower left magnetic metal post, said lower right magnetic metal post, and said central magnetic metal post;

a first secondary winding wound around the upper left magnetic metal post;

a third secondary winding wound around the lower right magnetic metal pillar, wherein a first secondary current and a third secondary current are simultaneously induced by magnetic flux in the upper left magnetic metal pillar and the lower right magnetic metal pillar;

a second secondary winding wound around the upper left magnetic metal post; and

a fourth secondary winding wound around the right lower magnetic metal pillar, wherein a second secondary current and a fourth secondary current are simultaneously induced by magnetic flux in the left upper magnetic metal pillar and the right lower magnetic metal pillar.

12. The low magnetic core loss five-column magnetic core of claim 11, wherein the primary winding is wound around each of the center, upper right, and lower left magnetic metal columns in a clockwise direction when viewed from the top magnetic metal plate;

wherein the primary winding is wound around each of the upper left and lower right magnetic metal posts in a counterclockwise direction when viewed from the top magnetic metal plate.

13. The low core loss five-leg magnetic core of claim 12, further comprising:

a Printed Circuit Board (PCB) disposed between the upper and lower magnetic metal plates and wound around the upper left magnetic metal column, the upper right magnetic metal column, the lower left magnetic metal column, the lower right magnetic metal column, and the central magnetic metal column, the PCB having metal traces to form the primary winding and to form the first, second, third, and fourth secondary windings.

14. The low core loss five column magnetic core of claim 13, further comprising:

a transistor and a capacitor mounted on the PCB and connected to the first, second, third and fourth secondary windings, wherein the transistor and the capacitor rectify the first, second, third and fourth secondary currents.

15. The low magnetic core loss five-column magnetic core of claim 14, wherein the primary winding is sequentially wound around the left lower magnetic metal column, the left upper magnetic metal column, the center magnetic metal column, the right lower magnetic metal column, and the right upper magnetic metal column.

16. The low magnetic core loss five-column magnetic core of claim 14, wherein the primary winding is wound three times around the left lower magnetic metal column, four times around the left upper magnetic metal column, two or three times around the central magnetic metal column, four times around the right lower magnetic metal column, and three times around the right upper magnetic metal column in that order;

wherein the primary winding forms a total of seventeen turns when wound three times around the central magnetic metal post;

wherein the primary winding forms a total of sixteen turns when wound two times around the central magnetic metal post;

wherein the first, second, third, and fourth secondary windings each comprise no more than one turn.

17. A multi-center low core loss transformer comprising:

a plurality of center posts located near a center position, the plurality of center posts including a first center post and a second center post;

four corner posts arranged around the plurality of center posts;

wherein the first and second center posts are closer to the center position than the four corner posts;

top and bottom magnetic metal plates above and below the four corner posts and the plurality of center posts and connected to the four corner posts and the plurality of center posts;

a first secondary winding that winds a first corner post of the four corner posts by one turn;

a second secondary winding that is wound one turn around the first corner post;

a third secondary winding that winds a third one of the four corner posts by one turn;

a fourth secondary winding wound one turn around the third leg;

wherein the third one of the four corner posts is opposite the first corner post, the third corner post being closer to the central location than the first corner post, closer to a second one of the four corner posts, and closer to a fourth one of the four corner posts;

a primary winding wound a plurality of times around the first, second, third, and fourth ones of the four corner posts and wound a plurality of times around the first and second center posts.

18. The multi-center low core loss transformer of claim 17, wherein the primary winding is wound in a counter-clockwise direction around the first corner post a plurality of times, then around the fourth corner post a plurality of times, then around the first center post a plurality of times in a clockwise direction, then around the second corner post a plurality of times in a clockwise direction, then around the third corner post a plurality of times in a counter-clockwise direction.

19. The multi-center low core loss transformer of claim 18, further comprising:

a Printed Circuit Board (PCB) located between the top magnetic metal plate and the bottom magnetic metal plate;

patterning metal wires in the PCB form two pattern metal layers of the primary winding;

and patterning metal routing on the PCB forms two surface metal layers of the first, second, third and fourth secondary windings.

20. The multi-center low core loss transformer of claim 19, further comprising:

a capacitor and a transistor disposed on said PCB for each of said first, second, third and fourth secondary windings, said capacitor connected to a tail end of each of said secondary windings, said transistor connected to a head end of each of said secondary windings, wherein opposite ends of said capacitor and said transistor not connected to said secondary windings are connected together as a secondary-side ground node.