Planar magnetic structure
AssigneeDelphi Technologies, Inc.
InventorROBERT D. MAPLE
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Abstract
A planar magnetic structure has an electrically insulating carrier made up of a base portion and opposed upstanding sidewalls. A plurality of planar primary windings and planar secondary windings are interstitially disposed within the carrier with planar dielectric spacers located between each adjacent pair of windings. A ferrite core envelopes the assembly to magnetically couple the windings. The carrier and windings form at least two spaces-apart sets of cooperating registration features which maintain the windings in fixed alignment with the carrier.
Claims21
A magnetic structure comprising:
- an electrically insulating carrier comprising a base portion and a plurality of upstanding sidewalls forming a regularly shaped cavity;
- a plurality of substantially planar dielectric spacers configured for nesting disposition within said cavity;
- a plurality of substantially planar windings configured for disposition within said cavity, with each said planar winding interstitially disposed between an adjacent pair of said dielectric spacers;
- and
- a ferrite core operative to magnetically couple said windings,
- said carrier and said windings forming first and second spaced-apart sets of cooperating registration features operative to maintain said windings in fixed alignment with said carrier.
A magnetic structure comprising:
- an electrically insulating carrier comprising a base portion and a plurality of upstanding sidewalls forming a regularly shaped cavity;
- a plurality of substantially planar dielectric spacers configured for nesting disposition within said cavity;
- a plurality of substantially planar primary windings configured for disposition within said cavity, with each said planar primary winding interstitially disposed between an adjacent pair of said dielectric spacers;
- a plurality of substantially planar secondary windings configured for disposition within said cavity, with each said planar secondary winding interstitially disposed between an adjacent pair of said dielectric spacers;
- and
- a ferrite core operative to magnetically couple said windings,
- said carrier and said primary windings forming first and second spaced-apart sets of cooperating registration features operative to maintain said windings in fixed alignment with said carrier, and
- said carrier and said secondary windings forming third and fourth spaced-apart sets of cooperating registration features operative to maintain said windings in fixed alignment with said carrier.
A method of assembling a planar magnetic structure comprising the steps of:
- interleaving stamped planar metal windings and dielectric spacers into a non-conductive carrier having alignment facilitators that correspond to alignment mechanisms on said planar metal windings and dielectric spacers;
- aligning said alignment mechanisms on said planar metal windings into said alignment facilitators on at least two sides;
- securing the terminations of said planar metal windings using said alignment mechanisms and said alignment facilitators;
- and
- surrounding said carrier and interleaved dielectric spacers and planar metal windings with a ferrite core.
Dependencies are inferred from the claim text.