Magnetic device and power converter employing the same

1. A magnetic device, comprising:

a magnetic core, comprising:

a first core section, comprising:

a single-piece, first L-core segment including a first leg and a second leg extending therefrom, and

an opposing, single-piece, second L-core segment including a first leg and a second leg extending therefrom; and

a second core section, comprising:

a single-piece, first L-core segment including a first leg and a second leg extending therefrom, and

an opposing, single-piece, second L-core segment including a first leg and a second leg extending therefrom, a surface of said second core section being mated to a surface of said first core section;

a first primary winding and a second primary winding formed around at least one of said first leg and said second leg of said first L-core segment or said second L-core segment of said first core section or said second core section;

a center-tapped secondary winding with a first secondary winding and a second secondary winding formed around at least one of said first leg and said second leg of said first L-core segment or said second L-core segment of said first core section or said second core section, said first primary winding and said first secondary winding being formed around a common leg; and

an inductor winding formed around at least one of said first leg and said second leg of said first L-core segment or said second L-core segment of said first core section or said second core section.

2. The magnetic device as recited in claim 1 wherein said second leg of said first L-core segment of said first core section is substantially perpendicular to said first leg of said first L-core segment of said first core section, and said second leg of said second L-core segment of said first core section is substantially perpendicular to said first leg of said second L-core segment of said first core section.

3. The magnetic device as recited in claim 1 wherein a length of said first leg of said first L-core segment of said first core section is elongated with respect to a length of said second leg of said first L-core segment of said first core section, and a length of said first leg of said second L-core segment of said first core section is elongated with respect to a length of said second leg of said second L-core segment of said first core section.

4. The magnetic device as recited in claim 1 wherein a thickness of said first leg and said second leg of said first L-core segment of said first core section is substantially equal and a thickness of said first leg and said second leg of said second L-core segment of said first core section is substantially equal.

5. The magnetic device as recited in claim 1 wherein said inductor winding is coupled to a center tap between said first secondary winding and said second secondary winding.

6. The magnetic device as recited in claim 1 wherein said first primary winding and said first secondary winding are formed around said first leg of said second L-core segment of said first core section, said second primary winding and said second secondary winding are formed around said first leg of said second L-core segment of the second core section, and said inductor winding is formed around said second leg of said second L-core segments of said first core section and said second core section.

7. The magnetic device as recited in claim 1 wherein said first primary winding and said first secondary winding are formed around said first leg of said first L-core segment of said first core section, said second primary winding and said second secondary winding are formed around said first leg of said first L-core segment of said second core section, and said inductor winding is formed around said first leg of said second L-core segments of said first core section and said second core section.

8. The magnetic device as recited in claim 1 wherein an end surface of said first leg of said first L-core segment of said first core section is mated to an end surface of said first leg of said first L-core segment of said second core section, and an exterior surface of said second leg of said second L-core segment of said first core section is mated to an exterior surface of said second leg of said second L-core segment of said second core section.

9. The magnetic device as recited in claim 1 wherein an end surface of said second leg of said first L-core segment of said first core section is mated to an end surface of said second leg of said first L-core segment of said second core section, and an exterior surface of said first leg of said second L-core segment of said first core section is mated to an exterior surface of said first leg of said second L-core segment of said second core section.

10. The magnetic device as recited in claim 1 wherein first and second secondary windings are stamped and formed sheets of metal.

11. A power converter, comprising:

a main switch coupled to an input of said power converter;

a magnetic device coupled to said main switch, comprising:

a magnetic core, comprising:

a first core section, comprising:

a single-piece, first L-core segment including a first leg and a second leg extending therefrom, and

an opposing, single-piece, second L-core segment including a first leg and a second leg extending therefrom; and

a second core section, comprising:

a single-piece, first L-core segment including a first leg and a second leg extending therefrom, and

an opposing, single-piece, second L-core segment including a first leg and a second leg extending therefrom, a surface of said second core section being mated to a surface of said first core section;

a first primary winding and a second primary winding formed around at least one of said first leg and said second leg of said first L-core segment or said second L-core segment of said first core section or said second core section;

a center-tapped secondary winding with a first secondary winding and a second secondary winding formed around at least one of said first leg and said second leg of said first L-core segment or said second L-core segment of said first core section or said second core section, said first primary winding and said first secondary winding being formed around a common leg; and

an inductor winding formed around at least one of said first leg and said second leg of said first L-core segment or said second L-core segment of said first core section or said second core section;

an auxiliary switch coupled to said magnetic device; and

an output filter capacitor coupled to said auxiliary switch and an output of said power converter.

12. The power converter as recited in claim 11 wherein said second leg of said first L-core segment of said first core section is substantially perpendicular to said first leg of said first L-core segment of said first core section, and said second leg of said second L-core segment of said first core section is substantially perpendicular to said first leg of said second L-core segment of said first core section.

13. The power converter as recited in claim 11 wherein a length of said first leg of said first L-core segment of said first core section is elongated with respect to a length of said second leg of said first L-core segment of said first core section, and a length of said first leg of said second L-core segment of said first core section is elongated with respect to a length of said second leg of said second L-core segment of said first core section.

14. The power converter as recited in claim 11 wherein a thickness of said first leg and said second leg of said first L-core segment of said first core section is substantially equal and a thickness of said first leg and said second leg of said second L-core segment of said first core section is substantially equal.

15. The power converter as recited in claim 11 wherein said inductor winding is coupled to a center tap between said first secondary winding and said second secondary winding.

16. The power converter as recited in claim 11 wherein said first primary winding and said first secondary winding are formed around said first leg of said second L-core segment of said first core section, said second primary winding and said second secondary winding are formed around said first leg of said second L-core segment of the second core section, and said inductor winding is formed around said second leg of said second L-core segments of said first core section and said second core section.

17. The power converter as recited in claim 11 wherein said first primary winding and said first secondary winding are formed around said first leg of said first L-core segment of said first core section, said second primary winding and said second secondary winding are formed around said first leg of said first L-core segment of said second core section, and said inductor winding is formed around said first leg of said second L-core segments of said first core section and said second core section.

18. The power converter as recited in claim 11 wherein an end surface of said first leg of said first L-core segment of said first core section is mated to an end surface of said first leg of said first L-core segment of said second core section, and an exterior surface of said second leg of said second L-core segment of said first core section is mated to an exterior surface of said second leg of said second L-core segment of said second core section.

19. The power converter as recited in claim 11 wherein an end surface of said second leg of said first L-core segment of said first core section is mated to an end surface of said second leg of said first L-core segment of said second core section, and an exterior surface of said first leg of said second L-core segment of said first core section is mated to an exterior surface of said first leg of said second L-core segment of said second core section.

20. The power converter as recited in claim 11 wherein said first and second secondary windings are stamped and formed sheets of metal.