IE85787B1

IE85787B1 - A transformer for multi-output power supplies

Info

Publication number: IE85787B1
Application number: IE2006/0182A
Authority: IE
Inventors: Young George
Original assignee: Commergy Technologies Limited
Filing date: 2006-03-10
Publication date: 2011-06-08

Abstract

ABSTRACT This invention relates to a transformer for multi-output power supplies such as those commonly found in electronic equipment. The transformer comprises a magnetic core and a plurality of windings, at least some of which are fractional windings, arranged about the magnetic core. The transformer comprises a dual transformer structure with a pair of transformers, a main transformer and an auxillary transformer which are connected together. In this way, readily available magnetic components may be used in the construction of the transformer and the simple construction allows for a large cr0ss—sectional area of transformer to be deployed so that reduced turn counts of windings may be used. Figure 1

Description

A Transformer for multl-output: power supplies This invention relates to a transformer for multi-output power supplies comprising a magnetic core and a plurality of windings, at least some of which being fractional windings, arranged about the magnetic core. it is not uncommon to have transformers that are required to provide a number of output power supplies for use in the operation of electronic equipment. One such example is that found in the standard desk-top power supplies with the “ATX set” of 12 V, 5V. 3V3 and -12V supplies being provided. Typically. an incoming AC mains line voitage is converted into a DC voltage suitable for manipulation in the transformer. and the transformer thereafter transforms the suitable DC voltage into each of the required DC voltage levels. By and large. the required DC voltage levels are obtained by ccntroillng the number of secondary winding turns on the transformer. Normally, it is considered advantageous to provide all of the windings of a transformer on a common magnetic core. This obviates the need to provide a separate transformer for each and every DC voltage required. This can save considerable space on the circuit board thereby facilitating minimisation of the circuit board‘.

However, there are numerous ditticulties associated with this approach. First of ali, by placing the plurality of windings about a common magnetic core, this can cause difﬁcultias particularly when working with low voltages. as frequently fractional turns are required in order to achieve the desired conversion ratio. Fractional turns may be implemented very simply conceptually using a multi-leg core, typically an X-core, but the practical implementation can pose signiﬁcant challenges to the designer. These challenges relate primarily to issues associated with maintaining low leakage inductance between the windings as well as managing wide ranges of current that n appear in ﬂux-balancing windings. Leakage inductance can give rise to cross regulation challenges and therefore it can often be quite difficult to provide a suitable transformer for multl-output power supplies using a common magnetic core. it is also desirable in many designs to implement the output stage as a full-duty cycle stage thus facilitating zero voltage switching (ZVS) operation and also maximising transformer utilisation. Again this can be relatively difficult to achieve with known approaches. it is the object therefore of the present invention to provide a transformer for multi- output power supplies that is relatively simple to construct and relatively inexpensive to manufacture that overcomes at least some of the difﬁculties with the known implementations of the transformers for multi-output power supply.

Statements of Invention According to the invention there is provided a transformer for multi-output power supplies comprising a magnetic core and a plurality of windings, at least some of which give effect to fractional windings, arranged about the magnetic core, characterised in that the transformer further comprises a dual transformer structure having a main transformer and an auxiliary transformer in which the main transformer comprises an E-core connected to a flat core section and the auxiliary transformer comprises a second E-core connected to a second flat core section mounted on the flat core section of the main transformer. By having such a transformer it is possible to use readily available and relatively inexpensive planar- type and other low-proﬁle magnetic cores in the construction of the transformer.

This approach allows for a large cross-sectional area to be deployed so that reduced turn counts of windings may be used. Again this simpliﬁes manufacture and construction. In the construction shown it is possible to realise fractional turn ratios by using one transformer as a main transformer and the other transformer as an auxiliary transformer thereby allovlﬁng adjustment of the turns ratio used in a relatively simple manner. This is seen as a particularty simple construction of transformer and may be manufactured in a simple and efficient manner. in one embodiment of the invention there is provided a transformer in which the windings are provided by way of foil sections. Alternatively, the windings may be provided by way of stamping sections. In another embodiment still the windings may be provided by way of wire assemblies. In a further still embodiment, the windings may be provided by way of rigid or alternatively flexible PCB implementations.

The transfonner of the present invention may be mounted directly on a printed circuit board (PCB) and the windings connected directly into the PCB. This is seen as a particularly simple way of mounting the transformer on a PCB.

Alternatively, the windings may be connected to the PCB via termination wires.

The termination wires are seen to be useful as the precise connection point of the windings on the board may be varied as required by placement needs. in a further embodiment of the invention there is provided a transformer in which there is provided a daughter PCB mounted on the transformer magnetic core having at least one electronic component thereon. Preferably, the electronic component mounted on the daughter PCB will comprise a synchronous rectiﬁer switch mounted on the daughter PCB. it is envisaged that this synchronous rectiﬁer switch will be provided by way of a MOSFET. This is seen as a particularly simple and useful implementation of transformer. In this way, low inductance connections may be established between the switching elements and the windings, and there will also be close thermal couplings between the magnetic elements, typically ferrite, and the semi-conductor elements. in the case of a quasi full-duty cycle implementation, the output inductor values are very small and this construction can facilitate being able to incorporate them into the overall assembly.

In one embodiment of the invention there is provided a transformer in which the plurality of windings comprise approximate mirror images of each other. By having the plurality of windings as an approximate mirror image of each other it is possible to manufacture the windings in a very simple manner.

In another embodiment of the invention there is provided a transformer in which the winding on the auxiliary transformer is tapped using a UV connection and there is provided a flux balancing winding on the auxiliary core to provide an additional output vottage. This is seen as particularly useful as additional output voltages may be required on the transformer. For example, it would be possible to provide the full ATX set on the one transformer core by implementing such a transformer construction. it is envisaged that the flux balancing winding on the auxiliary transfonner comprises a 2 + 2 winding thereby giving a 4V output. By having a 4V output it would be possible to derive a 3V3 output for use in the common ATX set in a relatively simple manner.

Detailed descriﬂion of the inventigg The invention will now be more clearly understood from the foilowing description of some embodiments thereof, given by way of example only with reference to the accompanying drawings. in which:- Fig. 1 is a front perspective view of a transformer for multi-output power supplies accordin to the invention; Fig. 2 is rear perspective view of the transformer shown in Fig. 1; Fig. 3 is a diagrammatic representation of the outline footprint of the transformer of Figs. 1 and 2; Fig. 4 is a plan view of a 12V winding; and Fig. 5 is a front perspective view of an alternative construction of transformer according to the invention.

Referring-to the drawings and initially to Figs. 1 and 2 thereof. there is shown a transformer. indicated generally by the reference numeral 1. for multi-output power supplies comprising a magnetic core 3 and a plurality of windings 5. 7. 9 arranged about the magnetic core 3. The transformer further comprises a dual transformer structure having a main transformer 11 and an auxiliary transformer 13. the auxiliary transformer 13 being mounted back-to-back on the main transfonner 11.

The main transformer comprises an E-core 15 connected to a flat core section 17.

The auxiliary transformer comprises a second E-core 19 connected to a second fiat core section 21 which in turn is connected to the first ﬂat core 17 of the main transformer 11. The windings 5, 7, 9 are formed by way of foil sections and are mounted directly onto a printed circuit board (PCB) (not shown). The winding 7 is a 12V winding implemented by tapping the winding at a 5V point, and drawing the winding through the auxiliary transformer 13. using 5 turns at 2V per turn. and thereafter drawing the winding 7 through the E-core 15 of the main transformer 11. in addition to the above, in order to operate the transformer in a balanced fashion. a further half turn winding (not shown) for the 5VA and 5VB voltages needs to be provided through the opposite leg and this can be provided by way of the stamping winding 5 shown on the front of the transformer 1.

Referring to Fig. 3 of the drawings there is shown an outline footprint of the transformer on a PCB 31. A plurality of sockets 33 are provided for termination of each of the windings. As an alternative to providing sockets 33 in this manner, it is also possible to provide termination wires so that the connection points may be varied to allow more ﬂexibility in the mounting of the transformer on the PCB.

Referring now to Fig. 4 of the drawings there is shown a transformer winding. indicated generally by the reference numeral 41, suitable for use in the transformer according to the invention. The transformer winding 41 is a winding suitable for implementing a 12V and 5V centre-tapped output winding. A second 12V winding provided for the transformer will effectively be a mirror image of the winding shown however there may be some alteration in the size of the apertures for suitable mountings of the foil about the magnetic structure. The winding 41 is tapped initially at the 5V point 43 before it is led through an auxiliary transformer (not shown) at 2V per turn before being returned through the remaining E-section of the main transformer (not shown).

Referring to Fig. 5 of the drawings there is shown an alternative embodiment of transformer. indicated generally by the reference numeral 51, where iike parts have been given the same reference numerals as before. The transformer 51 further comprises a daughter PCB 53 mounted on the main transformer 11. The daughter PCB 53 has a plurality of active switching devices. in this case synchronous rectifier MOSFETs 55 mounted thereon. in this way. low inductance connections may be established between the switching elements and the windings and it is possible to derive beneﬁts from close thermal coupling between the magnetic element. typically ferrite, and the semiconductor elements. In the case of a quasi full-duty cycle implementation, the output inductor values are very email and this can facilitate being able to incorporate them with the overali assembly. in the embodiments shown, the transformer is able to provide a 12V and a 5V supply. It must be understood that it is also possible to provide a 3V3 supply also.

This may be achieved by putting an additional 2+2 turn winding on the auxiliary transformer section. This will give at 4V output from the transformer. For supplying a 3V3 output at the end of a cable, such a voltage (4V) may be appropriate and gives optimal head room for magnetic ampliﬁer (magamp) approaches. This allows for the transfomier to derive a voltage suitable for regulation by magamp approaches. Furthermore. it is envisaged that the transformer may be operated in a balanced fashion by providing a further half tum winding for the SVA and 5VB voltages through the opposite leg and this may be provided by the foillstamping winding 5 shown on the front of the assembly. Alternatively, it may be possible to place this half turn winding between the two transformer sections 11. 13 or another convenient location as would be understood.

Finally, although only one key winding set has been shown in the embodiments provided, it is envisaged that it may be preferable to provide a plurality of winding sets arranged parallel to each other in order to give reduced conduction loss andlor reduced interwinding leakage inductance. Reduced inductance will result in a minimisation of the spiking on reotiﬁers and will aid cross-regulation in the transformer. in this speciﬁcation, both the main and the auxiliary transformers have been shown to comprise an E-core connected to a flat core section. Thereafter, the ﬂat core section of the main transformer has been connected to the ﬂat core section of the auxiliary transformer. it will be understood that instead of using a ﬂat core section in either the main transformer or the auxiliary transformer. it is possible to use a further E-core section in the main transformer and/or the auxiliary transformer connected to the original E-core section with the arms of the E-core sections being connected together. Similarly. in the embodiments shown, the connection between the main and auxiliary transfonners has been shown with the ﬂat core sections connected together but equally well two E-core sections could be connected back- to~back or an E-core section of one of the main transformer and the auxiliary transformer could be connected to a flat core section of the other of the main transformer and the auxiliary transformer if desired.

In the embodiments shown, the transformer is able to provide a 12V and a 5V supply. it must be understood that it is also possible to provide a 3V3 supply also.

This may be achieved by putting an additional 2+2 turn winding on the auxiliary transformer section. This will give a 4V output from the transformer. For supplying a 3V3 output at the end of a cable, such a voltage (4V) may be appropriate and gives optimal head room for magnetic ampliﬁer (magamp) approaches. This allows for the transformer to derive a voltage suitable for regulation by magamp approaches. Furthermore, it is envisaged that the transformer may be operated in a balanced fashion by providing a further half turn winding for the 5VA and 5VB voltages through the opposite leg and this may be provided by the foil/stamping winding 5 shown on the front of the assembly. Alternatively, it may be possible to place this half turn winding between the two transformer sections 11, 13 or another convenient location as would be understood.

Finally, although only one key winding set has been shown in the embodiments provided, it is envisaged that it may be preferable to provide a plurality of winding sets arranged parallel to each other in order to give reduced conduction loss andlor reduced interwinding leakage inductance. Reduced inductance will result in a minimisation of the spiking on rectiﬁers and will aid cross-regulation in the transformer. in this specification, both the main and the auxiliary transformers have been shown to comprise an E-core connected to a flat core section. Thereafter, the flat core section of the main transformer has been connected to the flat core section of the auxiliary transformer. It will be understood that instead of using a ﬂat core section in either the main transformer or the auxiliary transformer, it is possible to use a further E-core section in the main transformer and/or the auxiliary transformer connected to the original E-core section with the arms of the E-core sections being connected together.

Claims

1. Claims A transformer for multi-output power supplies comprising a magnetic core and a plurality of windings, at least some of which give effect to fractional windings, arranged about the magnetic core, characterised in that the transformer further comprises a dual transformer structure having a main transfonner and an auxiliary transformer in which the main transfonner comprises an E—core connected to a flat core section and the auxiliary transformer comprises a second E—core connected to a second fiat core section mounted on the flat core section of the main transformer. A transformer as claimed in claim 1 in which the second flat core section of the auxiliary transformer is substituted by a further E-core connected to the second E-core of the auxiliary transformer. A transformer as claimed in claim 1 or claim 2 in which the flat core section of the main transformer is substituted by a further E-core connected to the ﬁrst E—core of the main transformer. A transformer as claimed in any preceding claim in which the windings are provided by way of stamping sections. A transformer as claimed in any preceding claim in which there is provided a daughter PCB mounted on the transformer magnetic core having at least one electronic component thereon. A transformer as claimed in claim 5 in which there are provided at least one synchronous rectifier switch mounted on the daughter PCB. A transformer as claimed in claim 6 in which the synchronous rectiﬁer switch is a MOSFET. A transformer as claimed in any preceding claim in which the plurality of windings comprise approximate mirror images of each other. A transformer as claimed in any preceding claim in which the winding on the auxiliary transformer is tapped using a OV connection and there is provided a flux balancing winding on the auxiliary core to provide an additional output voltage. A transfomter as claimed in claim 10 in which the flux balancing winding on the auxiliary transformer comprises a 2+2 winding thereby giving a 4V output.