In one embodiment, an apparatus includes an array of transformers and common mode chokes each comprising a magnetic core and windings wound around the magnetic core at opposing locations on the magnetic core, and a retaining groove on each of the magnetic cores to maintain the windings in their opposing locations on the magnetic core. The transformers and common mode chokes are positioned in the array with the windings on each of the magnetic cores located offset to the windings of adjacent magnetic cores in the array to reduce crosstalk and improve common mode noise rejection.

A transformer includes a magnetic core, a first winding and at least one second winding. The magnetic core has a window through which the first winding passes through without contacting the magnetic core. The second winding passes through the window of the magnetic core and is wound on the magnetic core. The second winding has a distance from the first winding, and a semi-conductive part is disposed between the second winding and the magnetic core. The present disclosure can effectively lower the risk of partial discharge between the second winding and the magnetic core, and thus the transformer of the present disclosure has high reliability.

In some examples, an isolation transformer can include a first wire having a first insulation thickness and a second wire having a second insulation thickness that is different than the first insulation thickness. The isolation transformer can further include a plurality of magnetic cores of magnetic material that can be configured to surround portions of each of the first and second wires along respective circumferences of the first and second wires to provide the isolation transformer.

A transformer includes an isolation core casing of a power converter. The transformer includes a primary winding, a secondary winding, a magnetic core, a cover, and a cup. The cover and cup are joined and sealed together to form the core casing. The primary winding is wound directly on the magnetic core, and the magnetic core is sealed within the core casing. The secondary winding is wound around the core casing such that the primary and secondary windings are electrically isolated from each other by a solid insulation barrier provided by the core casing, resulting in no increase in the creepage or the clearance path between the primary and the secondary windings, which allows the transformer to be miniaturized without negatively affecting safety and converter performance due to leakage inductance.

A vehicle, an inductor assembly for power electronics in a vehicle, and a method of providing and cooling an inductor assembly are provided. According to one example, the vehicle is provided with an inductor assembly in a vehicle electrical system with a variable voltage converter (VVC). The inductor assembly includes a core formed from a plurality of core segments spaced apart from one another to define gaps therebetween, with each of the plurality of core segments forming an internal fluid passage extending therethrough. The inductor assembly has a winding surrounding at least one of the plurality of core segments. A fluid system is connected to the core to provide pressurized fluid to the fluid passages of the plurality of core segments to circulate fluid through the core of the inductor assembly.

An embedded coil assembly embodiment includes a ferrite ring having an annular axis. The ferrite ring is positioned on a conductive metal surface. A plurality of separate, spaced apart conductive structures extend over the ferrite ring and are attached to the conductive metal surface in a first region of the conductive surface positioned radially outwardly of the annular axis of the ferrite ring and in a second region of the conductive surface positioned radially inwardly of the annular axis of the ferrite ring. An encapsulation layer covers, the ferrite ring and at least a portion of the plurality of conductive structures.

In one embodiment, an apparatus includes a plurality of transformers and a plurality of common mode chokes, each of the transformers and the common mode chokes comprising a magnetic core and windings wound around the magnetic core at generally opposite sides thereof. The transformers and common mode chokes are arranged in an array with the windings on each of the magnetic cores positioned generally orthogonal to the windings of adjacent magnetic cores in the array to reduce crosstalk and improve common mode noise rejection.

A transformer includes a core with a surface, a primary winding with two or more primary winding turns wrapped about the core, and a secondary winding with one and only one secondary winding turn extending about the core. The one and only one secondary winding turn is interleaved among the two or more primary winding turns on the surface of the core to limit magnetic flux leakage along the primary winding and the secondary winding. Power converters and power conversion methods are also described.

A power electronics device includes one or more electrical windings included in an insulating substrate. A cavity and a channel connected to the cavity are also included in the insulating substrate, and a magnetic core is located in the cavity. The device also includes primary and secondary side electrical components located on first and second regions of a principal surface of the insulating substrate. An isolation region is located on the principal surface of the insulating substrate between the first and second regions, and the channel extends from the cavity to a first channel opening at an outside edge of the insulating substrate such that, when viewed along a thickness direction of the insulating substrate, the isolation region completely overlaps the first channel.

The present invention relates to an inductor (10) for high frequency and high power applications. The inductor (10) comprises at least one wire conductor (20), and a coil zone (30). Windings of the at least one wire conductor comprises the at least one wire conductor being wound around the coil zone to form a substantially torus shape centred around an axis extending in an axial direction of the torus shape. At an outer extent of the coil zone, outer windings of the at least one wire conductor are substantially at a first radial distance from the axis. At an inner extent of the coil zone, inner windings of the at least one wire conductor are substantially at a second radial distance from the axis and substantially at a third radial distance from the axis respectively. When an inner winding of the at least one conductor is at the second radial distance the next inner winding of the at least one conductor is at the third radial distance.