# US 10,504,643 B2 · Electrical device with flexible connectors

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- Number: US 10,504,643 B2
- Document ID: US10504643B2
- Status: Granted
- Kind: B2
- Application number: 15/379,631
- Filed: 2016-12-15
- Published: 2018-06-21
- Granted: 2019-12-10
- Earliest claimed: 2016-12-15
- Assignees: Hamilton Sunstrand Corporation
- Applicants: Hamilton Sundstrand Corporation
- Inventors: Charles Patrick Shepard; Shin Katsumata
- Web page: https://patentgrep.com/patent/US10504643B2

## CPC

- H01F 17/062: {Toroidal core with turns of coil around it}
- H01F 27/2804: {Printed windings}
- H01F 27/2895: {Windings disposed upon ring cores}
- H01F 27/29: Terminals; Tapping arrangements {for signal inductances}
- H01F 27/2814: {with only part of the coil or of the winding in the printed circuit board, e.g. the remaining coil or winding sections can be made of wires or sheets}
- H01F 27/2866: {Combination of wires and sheets}
- H01F 27/292: {Surface mounted devices}
- H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES

## Abstract

An electrical device includes a first flexible connector, including a first flexible conductor and a second flexible conductor, and a flexible insulator disposed between the first flexible conductor and the second flexible conductor, a second flexible connector spaced apart from the first flexible connector, the second flexible connector including a third flexible conductor, a first interconnect to electrically connect the first flexible conductor and the third flexible conductor, a second interconnect to electrically connect the third flexible conductor and the second flexible conductor, wherein the second interconnect is disposed opposite the first interconnect.

## Claims

### Claim 1

An electrical device, comprising:
a continuous ring-shaped first flexible connector defining an annular space, the continuous ring-shaped first flexible connector including:
a first flexible conductor and a second flexible conductor; and
a flexible insulator disposed between the first flexible conductor and the second flexible conductor;
a continuous ring-shaped second flexible connector disposed within the annular space and spaced apart from the continuous ring-shaped first flexible connector to define a ring-shaped annular region between an interior of the continuous ring-shaped first flexible connector and an exterior of the continuous ring-shaped second flexible connector, the continuous ring-shaped second flexible connector including a third flexible conductor;
a first interconnect to electrically connect the first flexible conductor and the third flexible conductor;
a second interconnect to electrically connect the third flexible conductor and the second flexible conductor, wherein the second interconnect is disposed opposite the first interconnect; and
a ring-shaped core disposed in the ring-shaped annular region defined between the interior of the continuous ring-shaped first flexible connector and the exterior of the continuous ring-shaped second flexible connector,
wherein respective upper and lower ends of each of the continuous ring-shaped first flexible connector, the continuous ring-shaped second flexible connector and the ring-shaped core are coplanar.

### Claim 2 (depends on 1)

The electrical device of claim 1, wherein the first interconnect includes a contact pad.

### Claim 3 (depends on 2)

The electrical device of claim 2, wherein the contact pad is aligned with the first flexible conductor to electrically connect the first flexible conductor with the first interconnect.

### Claim 4 (depends on 1)

The electrical device of claim 1, wherein the first interconnect is electrically connected to an input/output trace.

### Claim 5 (depends on 1)

The electrical device of claim 1, wherein the first interconnect is disposed within a first printed wiring board.

### Claim 6 (depends on 1)

The electrical device of claim 1, wherein the second interconnect is disposed within a second printed wiring board.

### Claim 7 (depends on 1)

The electrical device of claim 1, wherein the first flexible connector is a unitary connector.

### Claim 8 (depends on 1)

The electrical device of claim 1, wherein the first flexible connector and the second flexible connector form a toroid.

### Claim 9 (depends on 1)

The electrical device of claim 1, further comprising an insulation barrier disposed adjacent to the first flexible connector.

### Claim 10 (depends on 1)

The electrical device of claim 1, wherein the electrical device is an inductor.

### Claim 11 (depends on 1)

The electrical device of claim 1, wherein the electrical device is a transformer.

### Claim 12

An electrical device, comprising:
a first printed wiring board including a first interconnect;
a second printed wiring board including a second interconnect;
a continuous ring-shaped first flexible connector disposed between the first printed wiring board and the second printed wiring board, the continuous ring-shaped first flexible connector defining an annular space and including:
a first flexible conductor and a second flexible conductor;
a flexible insulator disposed between the first flexible conductor and the second flexible conductor;
a continuous ring-shaped second flexible connector disposed within the annular space and spaced apart from the continuous ring-shaped first flexible connector to define a continuous ring-shaped annular region between an interior of the continuous ring-shaped first flexible connector and an exterior of the continuous ring-shaped second flexible connector, the continuous ring-shaped second flexible connector being disposed between the first printed wiring board and the second printed wiring board and including a third flexible conductor;
wherein the first interconnect electrically connects the first flexible conductor and the third flexible conductor, and the second interconnect electrically connects the third flexible conductor and the second flexible conductor, wherein the second interconnect is disposed opposite the first interconnect; and
a ring-shaped core disposed in the ring-shaped annular region defined between the interior of the continuous ring-shaped first flexible connector and the exterior of the continuous ring-shaped second flexible connector,
wherein respective upper and lower ends of each of the continuous ring-shaped first flexible connector, the continuous ring-shaped second flexible connector and the ring-shaped core are coplanar at the respective innermost surfaces of the first and second printed wiring boards, respectively.

### Claim 13 (depends on 12)

The electrical device of claim 12, wherein the first interconnect includes a contact pad disposed on the first printed wiring board.

### Claim 14 (depends on 13)

The electrical device of claim 13, wherein the contact pad is aligned with the first flexible conductor to electrically connect the first flexible conductor with the first interconnect.

### Claim 15 (depends on 12)

The electrical device of claim 12, wherein the first interconnect is electrically connected to an input/output trace disposed on the first printed wiring board.