Hybrid planar common-mode choke

Patent metadata

Field	Value
Publication number	US-9318253-B2
Application number	US-201414268346-A
Country	US
Kind code	B2
Filing date	May 2, 2014
Priority date	May 2, 2014
Publication date	Apr 19, 2016
Grant date	Apr 19, 2016

Abstract

A common-mode choke includes a plurality of hybrid core inductors and a printed circuit board. Each of the plurality of hybrid core inductors includes a first core made of a first material, a second core made of a second material, and at least one common coil configured to generate a magnetic field in both the first and second cores. The printed circuit board is configured to connect the plurality of hybrid core inductors in series.

First claim

The invention claimed is:

1. A common-mode choke comprising:
a plurality of hybrid core inductors, wherein each of the plurality of hybrid core inductors comprises:
a first core comprising a first material;
a second core comprising a second material, wherein the first core and the second core are configured in a coaxial configuration; and
at least one common coil configured to generate a magnetic field in both the first and second cores; and

a printed circuit board configured to connect the plurality of hybrid core inductors in series, wherein the plurality of hybrid core inductors are connected to the printed circuit board in a planar configuration.

2. The common-mode choke of claim 1 , further comprising:
a base plate, wherein the plurality of hybrid core inductors are positioned between the printed circuit board and the base plate; and
an insulating material connected between the plurality of hybrid core inductors and the baseplate.

3. The common-mode choke of claim 2 , wherein the insulating material is in thermal contact with both the second core and the at least one coil.

4. The common-mode choke of claim 1 , wherein the at least one coil comprises:
a first coil connected to receive a first power phase input;
a second coil connected to receive a second power phase input; and
a third coil connected to receive a third power phase input.

5. The common-mode choke of claim 1 , wherein the first material is ferrite and the second material is nanocrystalline.

6. The common-mode choke of claim 1 , wherein the plurality of hybrid core inductors comprises three hybrid core inductors.

7. A power conversion system comprising:
a three-phase input power source;
an active rectifier that converts alternating current from the three-phase power source into direct current power for a load;
at least one planar common-mode choke connected to filter common-mode electromagnetic interference generated by the active rectifier, wherein the at least one planar common-mode choke comprises:
a plurality of hybrid core inductors that each comprise a first core and a second core, wherein the first core and the second core share at least one multiphase coil connected to the three-phase power source, and wherein the first core and the second core are configured in a coaxial configuration; and
a printed circuit board configured to connect the plurality of hybrid core inductors in series, wherein the plurality of hybrid core inductors are connected to the printed circuit board in a planar configuration.

8. The power conversion system of claim 7 , wherein the at least one planar common-mode choke further comprises:
a base plate, wherein the plurality of hybrid core inductors are positioned between the printed circuit board and the base plate; and
an insulating material connected between the plurality of hybrid core inductors and the baseplate.

9. The power conversion system of claim 8 , wherein the insulating material is in thermal contact with one of the first core and the second core of each of the plurality of hybrid core inductors, and wherein the insulating material is in further thermal contact with the at least one multiphase coil of each of the plurality of hybrid core inductors.

10. The power conversion system of claim 7 , wherein the at least one multiphase coil comprises:
a first coil connected to receive a first power phase input from the three-phase input power source;
a second coil connected to receive a second power phase input from the three-phase input power source; and
a third coil connected to receive a third power phase input from the three-phase input power source.

11. The power conversion system of claim 7 , wherein the first core of each of the plurality of hybrid core inductors is a ferrite core and the second core of each of the plurality of hybrid core inductors is a nanocrystalline core.

12. A power conversion system comprising:
a three-phase input power source;
an active rectifier that converts alternating current from the three-phase power source into direct current power for a load;
at least one planar common-mode choke connected to filter common-mode electromagnetic interference generated by the active rectifier, wherein the at least one planar common-mode choke comprises:
a plurality of hybrid core inductors that each comprise a first core and a second core, wherein the first core and the second core share at least one multiphase coil connected to the three-phase power source;
a printed circuit board configured to connect the plurality of hybrid core inductors in series, wherein the plurality of hybrid core inductors are connected to the printed circuit board in a planar configuration;
a base plate, wherein the plurality of hybrid core inductors are positioned between the printed circuit board and the base plate; and
an insulating material connected between the plurality of hybrid core inductors and the baseplate, wherein the insulating material is in thermal contact with one of the first core and the second core of each of the plurality of hybrid core inductors, and wherein the insulating material is in further thermal contact with the at least one multiphase coil of each of the plurality of hybrid core inductors.

13. The power conversion system of claim 12 , wherein the at least one multiphase coil comprises:
a first coil connected to receive a first power phase input from the three-phase input power source;
a second coil connected to receive a second power phase input from the three-phase input power source; and
a third coil connected to receive a third power phase input from the three-phase input power source.

14. The power conversion system of claim 12 , wherein the first core of each of the plurality of hybrid core inductors is a ferrite core and the second core of each of the plurality of hybrid core inductors is a nanocrystalline core.

Assignees

• Hamilton Sundstrand Corp

Inventors

• Rozman Gregory I
• Gieras Jacek F

Classifications

• H01F3/10 Primary

  Composite arrangements of magnetic circuits · CPC title

• H01F27/24 Primary

  Magnetic cores · CPC title

• H01F37/00

  Fixed inductances not covered by group H01F17/00 · CPC title

• H01F30/12

  Two-phase, three-phase or polyphase transformers · CPC title

• H01F17/062

  Toroidal core with turns of coil around it · CPC title