Inductor coils and transformer coils with optimal high energy storage locations

Abstract

Inductor Coils and Transformer Coils with Optimal High Energy Storage Locations.

What is claimed is: 
     
         1 . An inductor coil or transformer coils that form low loss inductors and low loss transformers comprise magnetic core materials that have maximal permeability and minimal magnetic core losses by further comprising high energy density electroceramic members that:
 minimize Eddy current losses by consisting of any one or all of the flowing atomic elements:
 nickel (Ni), cobalt (Co), zinc (Zn), copper (Cu) titanium (Ti), or chromium (Cr); 
   minimize hysteresis losses by additionally consisting of any one or all of the following atomic elements:
 lead (Pb), strontium (Sr) and magnesium (Mg); 
   minimize residual magnetic loss by additionally having a microstructure with a uniform grain size distribution not greater than 7 μm, preferably a uniform grain size distribution in the range of 5-7 μm; and,   further minimize Eddy current losses by embedding one or more thin amorphous silica layers having thickness ≤: 1 μm.   
     
     
         2 . The magnetic core materials of  claim 1 , wherein high energy density electroceramic members have electrical resistivity ≥10 5  Ω-cm, preferably ≥10 7  Ω-cm. 
     
     
         3 . The inductor coil or transformer coils of  claim 1 , wherein higher energies and higher magnetic field strengths are created by introducing dielectric discontinuities by include non-magnetic media within the magnetic core materials to create “air gaps” that allow higher currents to energize the inductor coil or transformer coils before the onset of magnetic saturation. 
     
     
         4 . The inductor coil of  claim 3 , wherein the non-magnetic media comprises amorphous silica. 
     
     
         5 . The inductor coil or transformer coils of  claim 3 , wherein the inductor coil and transformer coils form a closed magnetic path by means of toroidal geometries that reduce parasitic noise generated by fringing fields and Eddy current losses generated by electromagnetic interactions between magnetic fringing fields leaking out of the magnetic core material and currents in the coil windings. 
     
     
         6 . The inductor coil or transformer coils of  claim 5 , wherein a layer of non-magnetic material is inserted between a coil winding and a high energy density electroceramic member within the magnetic core materials to minimize fringing fields penetrating into conductive elements of a winding. 
     
     
         7 . The inductor coil or transformer coils of  claim 6 , wherein the high energy density electroceramic members have relative permeability μ R ≥20, preferably μ R ≥400. 
     
     
         8 . The inductor coil or transformer coils of  claim 7 , wherein dielectric discontinuities are placed at optimal energy storage locations within the magnetic core material to optimize performance as an energy storing inductor coil or a flyback transformer. 
     
     
         9 . The inductor coil or transformer coils of  claim 8 , wherein the optimal energy storage location within the magnetic core material of a flyback transformer is beneath one or more secondary coil windings and the optimal energy storage location within the magnetic core material of an energy storing inductor is beneath one or more the coil winding. 
     
     
         10 . The energy storing inductor or flyback transformer coil of  claim 9 , wherein dielectric discontinuities within optimal energy storage locations comprise a continuous volume of ultra-low loss amorphous silica dielectric or a collection of small volume distributed amorphous silica dielectric members. 
     
     
         11 . The optimal energy storage locations as in  claim 9  that optimally comprise a patterned three dimensional array of dielectric discontinuities that generates a stable distribution of localized micro-volumes of extreme magnetic flux densities that induce maximal inductive coupling within the adjacent windings as the energy storing inductor coil or flyback transformer is reverse cycled, wherein physical spacing between said of micro-volumes of extreme magnetic flux density ranges between 1/10,000th to 1/10th the volume of the magnetic core material located beneath the secondary coil winding. 
     
     
         12 . The energy storing inductor or flyback transformer coil of  claim 11 , wherein the maximal volume of the patterned three dimensional array of dielectric discontinuities within optimal energy storage locations comprises 1.2× the width of winding above the optimal energy storage location multiplied by the cross-sectional area of the magnetic core material around which the winding is wrapped. 
     
     
         13 . The energy storing inductor or flyback transformer coil of  claim 11 , wherein the minimal volume of the patterned three dimensional array of dielectric discontinuities within optimal energy storage locations comprises the width or less than the width of the of winding above the optimal energy storage location multiplied by the cross-sectional area of the magnetic core material around which the winding is wrapped. 
     
     
         14 . The inductor coil or transformer coils of  claim 1 , wherein coil windings are encapsulated with enveloping amorphous silica dielectric to enable the inductor coil or transformer coils to sustain very large differential voltage drops. 
     
     
         15 . The inductor coil or transformer coils of  claim 14 , wherein high hardness constraining members are located at the center of a coil winding and the high hardness constraining members are enveloped by low resistivity conducting elements having resistivity less than 10 −5  Ω-cm, preferably with resistivity less than 10 −7  Ω-cm. 
     
     
         16 . The inductor coil or transformer coils of  claim 15 , wherein the constraining members comprise low-CTE ceramic having a coefficient of 0.5 ppm/° C. 
     
     
         17 . The inductor coil and transformer coils of  claim 16 , wherein the constraining members additional comprise MAX-Phase ceramic in layered combination with the low-CTE ceramic. 
     
     
         18 . The inductor coil or transformer coils of  claim 15 , wherein the inductor coil or transformer coils comprise toroidal geometry that forms a magnetic current having a closed path to minimize spurious noise. 
     
     
         19 . The inductor coil or transformer coils of  claim 18 , wherein proximity losses and flux jumping losses are reduced by maintaining consistent spacing between coil windings. 
     
     
         20 . The transformer coils of  claim 19 , wherein interleaved primary and secondary coil windings are used to effectuate turn ratios. 
     
     
         21 . The transformer coils of  claim 20 , wherein interleaved primary and secondary coil windings include one or more parallel groupings of windings formed through parallel connection to ring conductor that electrical connects the parallel groupings in series, while the windings of the other transformer coil is electrically connected in series.