Abstract:
A high temperature magnetic amplifier, which utilizes the nonlinear properties of square loop magnetic cores to achieve very large amounts of both voltage and power amplification. By combining square loop, grain-oriented magnetic materials with high temperatures along with high temperature packaging approaches, high temperature long lifetime components can be produced. The high temperature magnetic amplifier is used as a building block to develop high temperature versions of operational amplifiers, comparators, voltage regulators, timers, counters, modulators, motor starters, servo systems, converters, inverters, power switches and many other devices.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority of U.S. Patent Application 61/645,341, filed May 10, 2012 entitled HIGH TEMPERATURE MAGNETIC AMPLIFIERS, which is hereby incorporated by reference in its entirety. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable. 
     REFERENCE TO A MICROFICHE APPENDIX 
     Not Applicable. 
     RESERVATION OF RIGHTS 
     A portion of the disclosure of this patent document contains material which is subject to intellectual property rights such as but not limited to copyright, trademark, and/or trade dress protection. The owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure as it appears in the Patent and Trademark Office patent files or records but otherwise reserves all rights whatsoever. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to improvements in transformers for a wide range of electronic applications. The fields of use for this invention include Aerospace, Automotive, Power Generation, Power Distribution, Down Hole, Industrial Process, and any other field where high temperature, high reliability, high radiation, and/or high power electronics are needed. The present invention is specifically directed to transformers and electric circuits usable above 450 degrees Celsius. The fields of use for this invention include Aerospace, Automotive, Power Generation, Power Distribution, Down Hole, Industrial Process, and any other field where high temperature, high reliability, high radiation, and/or high power electronics are needed. 
     2. Description of the Known Art 
     As will be appreciated by those skilled in the art, low temperature transformers below 4350 degrees Celsius are known in various forms. Patents include U.S. Pat. No. 4,196,408, issued to Link on Apr. 1, 1980 entitled High temperature transformer assembly; and U.S. Pat. No. 5,368,929, issued to Parker, et al. on Nov. 29, 1994 High temperature insulation for liquid-filled transformers. Each of these patents is hereby expressly incorporated by reference in their entirety. 
     Magnetic amplifiers were invented early in the 20th century, and found use in a wide range of electronics applications until the advent of the transistor. Magnetic amplifiers were used in high power and high reliability applications instead of vacuum tubes for their scalability and mechanical ruggedness. Some magnetic amplifiers achieved voltage gains of over a million, and many different systems utilized them as a basic building block. After the invention of the transistor, the magnetic amplifier was largely forgotten, except for a few special cases such as high power regulators on switching converters. 
     SUMMARY OF THE INVENTION 
     The present invention teaches the construction of high temperature, above 450 degree Celsius capable, magnetic amplifiers and associated circuitry. The purpose of this invention is to serve as a high temperature electronic device in a wide range of electronic applications. 
     The present invention began with the search for ferro-resonant transformers to use in high temperature voltage regulators for telemetry applications. These did not exist. Transformers with heat shields and heat sinks were available, but none of them could operate at the temperatures necessary for our applications. Thus, began the process of creating a high temperature magnetic amplifier structure. Upon realizing its potential applicability to the world of high temperature electronics, the engineers set out to invent a high temperature version of the device. By combining high curie temperature magnetic alloys with high temperature packaging approaches and processes, along with other advanced materials such as SiC rectifiers, the inventors created several high temperature versions of the magnetic amplifier device. Such amplifiers are directly relevant to applications in both high power and wireless extreme environment electronics. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       In the following drawings, which form a part of the specification and which are to be construed in conjunction therewith, and in which like reference numerals have been employed throughout wherever possible to indicate like parts in the various views: 
         FIG. 1  shows a high temperature magnetic amp fabrication. 
         FIG. 2  shows a method for winding magnetic amplifier coils that prevents ac coupling into the control windings. 
         FIG. 3  shows a double window core reactor.  FIG. 4  shows a method for thick film integration. 
         FIG. 5  shows a secondary method for thick film integration. 
         FIG. 6  details the high-level processing steps for thin film magnetic amplifier structures. 
         FIG. 7  shows a block diagram depicting the components needed for a high temperature telemetry system. 
         FIG. 8  shows a magnetic amplifier  800  that utilizes a bridge rectifier  802  to provide DC feedback into a tertiary feedback winding  804 , resulting in extremely large gains. 
         FIG. 9  shows a single-ended self-balancing magnetic amplifier  900 , which presents a high input and low output impedance, as well as very high gain. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The key component of a magnetic amplifier is the saturable core reactor  50 , which can serve to control the inductance of the core windings via a DC or low frequency AC signal. The problem is doing this in a high temperature environment such as that above 450 degrees Celsius. The present invention utilizes one of several saturable core materials  152  that have been identified to provide the required properties at elevated temperatures in combination with a ceramic coated high temperature magnet wire  154  and a low temperature co-fired ceramic toroid case  156 .  FIG. 1  shows the LTCC case in fabrication and the method in which the toroid cases were constructed, the fabricated case  156  after it has been fired, and the toroidal reactor  150 . The magnet wire  154  used for the windings is ceramic coated nickel clad copper from California Fine Wire, Inc. Once the toroid structures were fabricated, much effort was placed into how to wind the ceramic coated magnet wire around the cores. The wire is very fragile, as the ceramic insulation is un-fired, and can easily flake off until the wire has been cured, which must take place after winding, because the cured ceramic cannot flex. 
     Commercially available core materials that have promise for high temperature saturable reactor devices are grain-oriented rectangular-hysteresis loop nickel iron, silicon steel, and iron-cobalt alloys being particularly attractive. Table 1 shows some of the core materials selected for use in 450° C.+magnetic amplifiers. 
     
       
         
               
               
               
               
               
               
             
           
               
                   
               
               
                   
                   
                   
                 DC  
                   
                 Curie 
               
               
                   
                   
                 Saturated 
                 Coercive 
                   
                 Tem- 
               
               
                   
                   
                 Flux 
                 Force 
                 Square- 
                 per- 
               
               
                   
                 Com- 
                 Density 
                 amp- 
                 ness 
                 ature 
               
               
                 Trade Name 
                 position 
                 Tesla 
                 turn/cm 
                 Ratio 
                 Celsius 
               
               
                   
               
             
             
               
                 SUPER- 
                 49% Co 
                 1.9-2.2 
                 0.18-0.44 
                 0.9-1.0 
                 930 
               
               
                 MENDUR 
                   
                   
                   
                   
                   
               
               
                 PERMENDUR 
                 49% Fe 
                   
                   
                   
                   
               
               
                   
                  2% V 
                   
                   
                   
                   
               
               
                 MAGNESIL 
                  3% Si 
                 1.5-1.8 
                  0.5-0.75 
                 0.75-0.85 
                 750 
               
               
                 SILECTRON 
                 97% Fe 
                   
                   
                   
                   
               
               
                 MICROSIL 
                   
                   
                   
                   
                   
               
               
                 SUPERSIL 
                   
                   
                   
                   
                   
               
               
                 DELTAMAZ 
                 50% Ni 
                 1.4-1.6 
                 0.125-0.25  
                 0.94-1.0  
                 500 
               
               
                 ORTHONOL 
                 50% Fe 
                   
                   
                   
                   
               
               
                 49 SQ MU 
                   
                   
                   
                   
                   
               
               
                 ALEEGHENY 
                 48% Ni 
                 1.15-1.4  
                 0.062-0.187 
                  0.8-0.92 
                 480 
               
               
                 4750 
                 52% Fe 
                   
                   
                   
                   
               
               
                 48 ALLOY 
                   
                   
                   
                   
                   
               
               
                 CARPENTER 
                   
                   
                   
                   
                   
               
               
                 49 
                   
                   
                   
                   
                   
               
               
                 4-79 
                 79% Ni 
                 0.66-0.82 
                 0.025-0.82  
                 0.8-1.0 
                 460 
               
               
                 PERMALLOY 
                 17% Fe 
                   
                   
                   
                   
               
               
                 PERMALLOY 
                   
                   
                   
                   
                   
               
               
                 80 SQ MU 79 
                   
                   
                   
                   
                   
               
               
                   
               
             
          
         
       
     
     Another very important characteristic for saturable reactors is that they have an effective air gap as small as possible, in order not to shear over the hysteresis loop, causing it to lose its squareness. The amplification properties of the core relate to the slope of the permeability, and as such, when the hysteresis loop is sheared over, the amplifying effects are lessened. This leads to one of the difficulties of the physical saturable reactor/magnetic amplifier construction. Since the effective airgap must be minimized a closed magnetic path should be maintained, meaning that the usual interleaving technique for transformer core construction is often not adequate for magnetic amplifiers, due to the air gaps present at the joints. For this invention, the preferred method is the use of either tape wound toroid cores or closed path punched laminations. 
     As shown in  FIG. 2 , the arrangement of the windings upon a saturable reactor  200  also greatly affects the performance of the magnetic amplifier. In addition to the aforementioned control and load windings, other windings such as bias, feedback, sensing, and other special purpose windings can be included in the basic magnetic amplifier structure, but must be done so in a way that leakage effects are reduced to a minimum, and more importantly, in a way that prevents the circulation of disturbing AC currents of the fundamental frequency in the DC bias, control, and feedback windings. These currents can be induced by transformer action from AC components of currents flowing in the load winding if proper designs are not employed. As shown in  FIG. 2 , one of the ways to minimize these induced currents is to wind the control windings  202 , and other DC windings, such as bias and feedback, in series-aiding, with the AC load windings  204  being wound in series-opposition. Although this configuration yielded very good results for the initial saturable reactor system investigated, there are two drawbacks to this approach. The first one is obvious, in that two separate cores first core  206 , second core  208  are needed, requiring a larger volume to implement. The second, not so obvious, drawback is that when the number of control windings Ne is much larger than the number of load windings NL, very large voltages are induced on the control windings through transformer action, and although they are cancelled out, the large voltages require thicker insulation, which takes up precious window area  210  within the cores. 
     A solution to both of these drawbacks is presented in  FIG. 3 , which eliminates these problems. In this configuration, a double window core reactor  300  utilizes a double window core  301  which has a first window  302  and second window  304  stamped into it which yields a first outer core leg  306 , and a second outer core leg  308  one on each side, for the first outer load winding  310  and second outer load winding  312 , while the center core leg  314 , which is twice the width of the outer legs houses a single control winding  316 . Hence, one core is used, an entire control winding is eliminated, and the flux from the load windings is cancelled out, and therefore large voltages are never induced on the control windings. 
       FIG. 4  shows one approach to integrating the magnetic structures in a thick film system  400 . By reorienting the magnetic core  402 , the windings  404  can be made in a planar fashion on a multi-layer LTCC substrate  406 , allowing for more than an adequate amount of turns.  FIG. 4  shows a first layer  408 , second layer  410 , third layer  412 , fourth layer  414  and fifth layer  416 . With this approach, the substrate is actually made in two pieces. Once the core  402  is inserted into the back portion  401  of the substrate  406 , the front portion  403  of the substrate can be brazed in place to form the complete substrate  406 . The electrical connections are then completed via a simple wire bonding procedure across the joint  405 . By using a step back  418  for each layer to the next, one can layer the wire bonds  420  in a stepped manner and all of the electrical layers  408 ,  410 ,  412 ,  414 ,  416  can be connected with very short wire bonds  420 . 
       FIG. 5  shows an alternative approach to integrating the magnetic structures  500  in a thick film system. In this concept, the substrate  502  can be manufactured in a single piece, again with planar windings  504  that can be stacked through many layers. Once the LTCC substrate has been fired, a split ceramic bobbin  506  is placed around the windings. After the split bobbin is in place, the magnetic tape  508  is wound around the bobbin  506 , creating a toroidal magnetic structure which yields a completely closed magnetic path,  FIG. 5 , bottom. With suitable fixturing, the process can be automated for precise and repeatable magnetic components, which can yield magnetic devices that are almost completely free from mechanical degradation, resulting in extremely long lifetime magnetic amplifier systems. 
       FIG. 6  shows yet another approach for extremely reliable integrated magnetic devices that are also extremely miniaturized. By implementing magnetic structures  600  in a thin-film process, both the magnetic cores  602  and their associated windings  604  can be fabricated on the same substrate  606 , with multiple structures on a single chip. The end result can be a full telemetry system that fits into a volume of less than a dime, allowing high temperature, high reliability systems to be placed in space limited areas, allowing for a virtually unlimited number of sensing applications. The thin film process obviously lends itself to mass production manufacturing, driving the cost for full telemetry systems down even further. Another benefit of thin film magnetics is that they can allow for very high frequency magnetics to be employed, yielding benefits to magnetic amplifier systems such as extremely fast response times. 
       FIG. 6  details the high-level processing steps for thin film magnetic amplifier structures, although there are many other ways to implement such a system. To begin with, an alumina substrate  650  is wet-etched with sodium hydroxide to form an aperture  652 . After the alumina has been etched to a suitable depth, a thin film metal adhesion layer, such as 500 angstroms titanium followed by 500 angstroms tungsten, is sputtered onto the etched trench, and then the magnetic alloy 654 is electroplated up to the desired thickness. Following this initial electroplating, an insulating layer  656  of alumina is sputtered or flame-sprayed onto the magnetic alloy 654, leaving two spaces  658  un-coated for further plating for the core. Once the alumina insulator has been deposited, another adhesion layer is sputtered onto the alumina, along with a high conductivity metal  660  such as gold. These steps are repeated until the desired number of high conductivity windings  662  has been deposited. After this step, a winding cap  664  of alumina is deposited onto the windings to encapsulate them, at which point the core top  665  of the magnetic alloy is further electroplated up to yield a closed magnetic structure forming the core  602 . A final top cap  668  deposition of alumina provides protection to the plated magnetic alloy. Further enhancements to the magnetic structure can be added, such as depositing the magnetic alloy as a series of thin laminations to further increase the frequency capabilities of the devices. 
       FIG. 7  shows a block diagram depicting the components needed for a high temperature telemetry system  700 , including magnetic amplifiers to provide all of the signal conditioning operations. Although it is true that the high temperature magnetic amplifier can find use in nearly all high temperature electronics areas, the focus of the research proposed here is to utilize the newly developed technology in conjunction with high temperature sensors. The synthesis of a truly reliable high temperature sensing system will allow for great returns on safety for aerospace personnel, reduced emissions through smart control of turbines, and dramatic cost savings for aerospace and land based turbine systems. As such, the system design in this research targets one of the harshest environments high temperature electronics can be exposed to—the gas turbine rotor and blade. For sensor systems to deliver useful data from a turbine blade in a typical natural gas power generation turbine, the systems must be capable of simultaneous operation at temperatures &gt;450° C. and g-loads &gt;10,000 g&#39;s, and must be fully wireless because no power can be wired in to the rotating components without drastically reducing rotor lifetimes. These systems must also survive harsh thermal cycling conditions during turbine startup and shutdown. Furthermore, for turbine sensor systems to actually be used in field operation, the systems must be robust enough to last for years in operation, as they are effectively useless in predictive health maintenance if they fail before the part they are expected to be monitoring. 
     For turbine blade instrumentation, power is delivered to the electronics via induced power. Static coils line the stator, and transmit AC power to a power pickup coil next to the transmitter electronics on the blade neck. Using the high temperature transformers, this design can completely eliminate the need for transistors, with the exception of the RF portions which require only three devices total. Commercially available GaN transistors can be used for the RF components. As noted previously, magnetic amplifier based systems require AC voltage to function, which is actually ideal in this type of system, wherein AC power is the only power available for the wireless system in the first place. In turbine applications, induced AC power varies in amplitude, as changes in loading and temperatures within the turbine cause the rotor to expand and contract, resulting in a power signal that must be regulated. In the old transistor based systems, an incredibly stable DC regulation is required, as the operating points of the discrete JFET devices in the amplifier are very sensitive to voltage variation. In contrast, the present invention&#39;s magnetic based operational amplifiers simply require modest AC voltage regulation, which can be achieved with the use of a constant voltage transformer, CVT, also referred to as a ferro-resonant transformer  702 . 
     Once the induced AC has been regulated through the CVT, a portion of the AC power is delivered to the magnetic amplifier based opamp  708 . The sensor signal delivered to the input of the opamp is electrically isolated from the rest of the opamp, which provides several advantages over transistor based counterparts. One of these advantages is that very good signal resolution can be achieved in comparison to the transistor based system. In the transistor system, induced AC power needs to be rectified, then tightly regulated and filtered, since a low level sensor signal&#39;s full output range could be swamped out through variations caused by loose regulation or through AC ripple. In the case of even a simple saturable reactor system, it is simply the DC sensor input that serves to saturate the reactor cores. Perhaps even more important is the ability to introduce closed loop compound feedback in a magnetic opamp, which has not been possible to do using discrete transistor designs. This will truly revolutionize the capabilities of high temperature electronics systems, as constant gain vs. temperature systems can be achieved, which means that these systems can be mass-produced, since individual tuning and calibration vs. temperature can be eliminated. 
     The remaining blocks in the sensor system  704 ,  706 ,  710 ,  712  are comprised of the RF circuitry, including a rectifier  704 , oscillator  706 , and amplifier  710  required to create a carrier signal  712 , and modulate the sensor information onto that signal. This can be done through the implementation of an LC oscillator  706  built around GaN transistors, which are actually commercially available devices. The theoretical operating temperature of GaN is above that of SiC, coming in at around 650° C. We have built RF circuitry out of these devices that have operated in a lab environment up to 550° C., and testing was limited to the temperature of the test setup itself. Good DC power can be delivered to the RF blocks simply by implementing a GaN bridge rectifier  704  between the CVT  702  and the RF blocks. 
     Once the basic core materials and winding configurations are successfully implemented, basic circuit structures can then actually be fabricated. One of these structures, using only the two core saturable reactor, is a voltage variable inductor, wherein the variable inductance is placed into an LC oscillator, and the frequency of that oscillator was made to vary with the sensor output. However, with a few additional elements, many, many more circuit structures can be implemented. 
       FIG. 8  shows a magnetic amplifier  800  that utilizes a bridge rectifier  802  to provide DC feedback into a tertiary feedback winding  804 , resulting in extremely large gains. Thus demonstrating the additional elements that can be implemented. The most important of the additional elements is the rectifier  802 , which is actually quite a mature technology in both SiC and GaN, as it is already used in commercial applications for power electronics systems. The first application of the rectifier  802  is to turn the AC current in the load windings  806 ,  808  into a DC current that can be used further down the electrical system, such as for servo drives or non-feedback based comparators. The more exciting feature that rectifiers  802  allow is the ability to apply feedback to the saturable reactor  810 . In this manner, a DC control voltage can produce an appreciable AC gain in the load winding, and a portion of the AC current in the load winding can be rectified and fed back across a tertiary feedback winding of the reactor, which when properly implemented can result in incredibly large voltage, current, or power gains from the magnetic amplifier structure.  FIG. 8  displays a circuit diagram wherein windings Nc 1   818 , NLI  806 , and NF 1   804  are the control, load, and feedback windings on a single first saturable core  806 , while Nc 2   820 , NL 2   808 , and NF 2   805  are windings on a second saturable core  816 . The amplifier circuit  800  consists of these windings, an AC source  812 , a load resistor  814 , and a rectifier  802 . The rectifier  802  converts the AC current going through the load windings  806 ,  808  into a DC current that can be made to flow through the feedback windings  804 ,  805 . Depending on the relative number of turns of the feedback and load windings, it is possible to provide 100 percent feedback, based on ampere-turns rather than current, by means of external feedback. 
     In previous low temperature magnetic amplifiers, practical gains of over one million have been realized with this type of structure. Although this type of amplifier can provide a large amount of gain, it does not influence the effective input impedance of the control circuit, and the resistance seen by a sensor would only be that of the control windings themselves, and any series resistance added to the control windings. Adding resistance in series, however, simply reduces the current through the windings, so the gain of the circuit is decreased dramatically. By adding a fourth winding, compound-feedback can be implemented, which can lead to a magnetic amplifier based op-amp, with characteristics approaching that of an ideal amplifier. This component could perhaps be the most important part of a sensor telemetry system; as such a device can provide precise, constant gain and high common-mode rejection. 
       FIG. 9  shows a single-ended self-balancing magnetic amplifier  900 , which presents a high input and low output impedance, as well as very high gain. The basic design of a single-ended, self-balancing magnetic amplifier is depicted in  FIG. 9 , which shows a system of first core  902  and second core  904  with each having a load winding  906 ,  908 , feedback winding  910 ,  912 , bias winding  914 ,  916 , and control winding  918 ,  920  such that each core has four windings per core. The circuit amplifier  900  also uses three bridge rectifiers  930 ,  940 ,  950 . The load windings NL are wound in series aiding, while the feedback, bias, and control windings, NF, NB, and Ne, are wound in series-opposing, such that any voltages induced by the AC supply Vp are opposed. The load resistor RL  958 , the series resistor RK  962 , and the feedback windings NF with a regeneration control shunting resistor Rp are supplied by two separate full-wave bridge rectifiers. The bias windings NB carry current from a third full-wave bridge rectifier with a series impedance Z  942  and a DC series resistor RB  944 . The bias current produces additional DC magnetization which is opposing to the magnetization produced by the feedback windings NF, and independent of the control current flowing through control windings Ne. The basic idea behind this circuit is to use compound feedback of both magnetic and electric coupling. The magnetic feedback in this case is positive feedback, which produces an effectively infinite gain inside the reactors, while negative electrical feedback is achieved by resistance-coupling a portion of the load current into the control circuit loop. When high permeability core materials are used, the total ampere-turns of the load windings NL are equal to the total ampere-turns of the control windings Ne and the feedback windings NF. When the input signal VIN  960  is applied to the control windings, the load current IL increases such that a voltage drop takes place across the resistor RK  962 . The polarity of VIN  960  opposes an increase in load current IL, and the resistor RK exercises a controlling effect on the load current. If positive feedback is used, and the resistors are selected, a large gain with extreme stability, a linear input-output characteristic, and a high speed response can be achieved. Additionally, the input current required from the sensor is extremely small, as the sensor sees very high effective input impedance looking into the control windings. Another important aspect of this amplifier is that, unlike the amplifier depicted in  FIG. 8 , the gain is made independent of the number of control windings, and over certain ranges, variations in the supply voltage amplitude and frequency, and variations of the value of the load RL, have a minimal effect the voltage ratio, which is what is required of an ideal amplifier.