Flyback converters with improved magnetic configurations

Patent metadata

Field	Value
Publication number	US-11728740-B2
Application number	US-202117346803-A
Country	US
Kind code	B2
Filing date	Jun 14, 2021
Priority date	Jun 14, 2021
Publication date	Aug 15, 2023
Grant date	Aug 15, 2023

Abstract

Disclosed herein is an improved flyback converter that separates the magnetic components of the converter into a transformer and a separate, discrete energy storage inductor. This arrangement can improve the operating efficiency of the converter by reducing the commutation losses as compared to a conventional flyback converter. The magnetic components may be constructed on separate magnetic cores or may be constructed on magnetic cores having at least one common element, thereby allowing for at least partial magnetic flux cancellation in a portion of the core, reducing core losses.

First claim

The invention claimed is:

1. A flyback converter comprising:
input terminals configured to receive an input voltage;
a transformer having a primary winding selectively energized by the input voltage and a secondary winding that delivers an output voltage via a rectifier;
a discrete energy storage inductor separate from the primary and secondary windings and coupled in parallel with one of the primary winding or the secondary winding; and
a main switching device that switches to:
selectively energize the primary winding; and
alternately store energy in the energy storage inductor and allow energy stored in the energy storage inductor to be delivered to the transformer;

wherein:
the transformer is constructed on a first magnetic core, and the discrete energy storage inductor is constructed on a second magnetic core;
the first and second magnetic cores have at least one common element; and
magnetic flux from the discrete energy storage inductor and magnetic flux from the transformer at least partially cancel in the at least one common element.

2. The flyback converter of claim 1 wherein the discrete energy storage inductor is coupled in parallel with the primary winding.

3. The flyback converter of claim 1 wherein:
turning on the main switching device causes a current through the discrete energy storage inductor in a first direction and a current through the primary winding in a corresponding direction; and
turning off the main switching devices causes the current to continue flowing through the discrete energy storage inductor in the first direction while reversing the current through the primary winding.

4. The flyback converter of claim 1 further comprising circuitry coupled between the transformer and the discrete energy storage inductor that offsets effects of unequal parasitic impedances as between the discrete energy storage inductor and the transformer.

5. The flyback converter of claim 4 wherein the discrete energy storage inductor is coupled in parallel with the primary winding and the circuitry comprises:
first and second diodes coupled in series with each other and the primary winding and oriented to permit current flow through the primary winding in a first direction; and
a third diode coupled in anti-parallel with the series combination of the first and second diodes so as to permit current flow through the primary winding in a second direction opposite the first direction.

6. The flyback converter of claim 4 wherein the discrete energy storage inductor is coupled in parallel with the primary winding and the circuitry comprises:
a first diode coupled in series with the primary winding and oriented to permit current flow through the primary winding in a first direction; and
a switching device coupled across the first diode and operated to permit current flow through the primary winding in a second direction opposite the first direction with minimal voltage drop.

7. A flyback converter comprising:
a primary winding selectively energized by an input voltage;
a secondary winding magnetically coupled to the primary winding that delivers an output voltage via a rectifier;
a discrete energy storage inductor separate from the primary and secondary windings and coupled in parallel with one of the primary winding and the secondary winding; and
a main switching device that:
switches on to cause a current through the discrete energy storage inductor in a first direction and a current through the primary winding in a corresponding direction, thereby selectively energizing the primary winding and storing energy in the energy storage inductor; and
switches off to cause the current to continue flowing through the discrete energy storage inductor in the first direction while reversing the current through the primary winding, thereby allowing energy stored in the energy storage inductor to be delivered to the primary winding;

wherein:
the primary and secondary windings are constructed on a first magnetic core, and the discrete energy storage inductor is constructed on a second magnetic core;
the first and second magnetic cores have at least one common element; and
magnetic flux from the discrete energy storage inductor and magnetic flux from the primary and secondary windings at least partially cancel in the at least one common element.

8. The flyback converter of claim 7 wherein the discrete energy storage inductor is coupled in parallel with the primary winding.

9. The flyback converter of claim 7 further comprising circuitry coupled between the primary or secondary winding and the discrete energy storage inductor that offsets effects of unequal parasitic impedances as between the discrete energy storage inductor and the transformer.

10. The flyback converter of claim 9 wherein the discrete energy storage inductor is coupled in parallel with the primary winding and the circuitry comprises:
first and second diodes coupled in series with each other and the primary winding and oriented to permit current flow through the primary winding in a first direction; and
a third diode coupled in anti-parallel with the series combination of the first and second diodes so as to permit current flow through the primary winding in a second direction opposite the first direction.

11. The flyback converter of claim 9 wherein the discrete energy storage inductor is coupled in parallel with the primary winding and the circuitry comprises:
a first diode coupled in series with the primary winding and oriented to permit current flow through the primary winding in a first direction; and
a switching device coupled across the first diode and operated to permit current flow through the primary winding in a second direction opposite the first direction with minimal voltage drop.

12. A power converter comprising:
a primary winding selectively energized by an input voltage;
a secondary winding magnetically coupled to the primary winding that delivers an output voltage to a load via a rectifier;
a discrete energy storage inductor magnetically decoupled from the primary and secondary windings and electrically coupled in parallel with one of the primary winding or the secondary winding; and
at least one switching device that switches between a first state that stores energy in the discrete energy storage inductor and a second state that causes energy stored in the discrete energy storage inductor to be delivered to the load;
wherein:
the primary and secondary windings form a transformer constructed on a first magnetic core, and the discrete energy storage inductor is constructed on a second magnetic core;
the first and second magnetic cores have at least one common element; and
magnetic flux from the discrete energy storage inductor and magnetic flux from the transformer at least partially cancel in the at least one common element.

13. The power converter of claim 12 wherein the discrete energy storage inductor is coupled in parallel with the primary winding.

14. The power converter of claim 12 further comprising circuitry coupled between the transformer and the discrete energy storage inductor that offsets effects of unequal parasitic impedances as between the discrete energy storage inductor and the transformer.

15. The power converter of claim 14 wherein the discrete energy storage inductor is coupled in parallel with the primary winding and the circuitry comprises:
first and second diodes coupled in series with each other and the primary winding and oriented to permit current flow through the primary winding in a first direction; and
a third diode coupled in anti-parallel with the

Assignees

• Apple Inc

Inventors

• Phadke Vijay G
• Maddineni Prudhvi Mohan

Classifications

• H02M3/33592 Primary

  having a synchronous rectifier circuit or a synchronous freewheeling circuit at the secondary side of an isolation transformer · CPC title

• H01F27/38

  Auxiliary core members; Auxiliary coils or windings · CPC title

• H02M1/0064

  Magnetic structures combining different functions, e.g. storage, filtering or transformation · CPC title

• H02M1/348

  Passive dissipative snubbers · CPC title

• H02M3/33507 Primary

  with automatic control of the output voltage or current, e.g. flyback converters (H02M3/33561, H02M3/33569 take precedence) · CPC title