Reconfiguring tape wound cores for inductors
AssigneePeregrine Power LLC
InventorBruce W. Carsten
Life of this patent
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Abstract
A tape wound inductor core device, inductors including same and methods of manufacture. Tape wound material may be cut and/or shaped into “pucks” that have an exterior surface made up of or defined substantially by the edge surfaces of the layers of the constituent conductive material, with all or most of the broad surfaces disposed inwardly, thereby reducing eddy currents and associated losses. Various puck configurations, inductor arrangements and fabrication techniques are disclosed.
Claims32
A tape wound inductor core device, comprising:
- a first tape wound core puck including alternating layers of conductive material and insulative material, the conductive material layers each having a broad surface and an edge surface;
- wherein the plurality of conductive material layers are arranged within the tape wound puck such that the edge surfaces are exposed substantially exteriorly and the broad surfaces are situated substantially interiorly.
A tape wound core device, comprising:
- a first tape wound core puck including a plurality of alternating layers of tape wound conductive material and insulative material, the conductive material layers each having a broad surface and an edge surface and being arranged in substantially parallel planes, the conductive layers arranged within the first puck so that the majority of the external surfaces of the first puck are defined by the edge surfaces of the conductive layers;
- wherein the first core puck as a maximum lateral cross-sectional dimension, D1, and
- wherein the length, D2, of the greatest lateral cross-sectional measure of an exteriorly disposed broad surface of one of said conductive layers is 60% or less of D1.
A tape wound inductor device comprising:
- a first section of tape wound material including a plurality of layers of conductive material, the edges of the conductive layers forming a first edge surface;
- a second section of tape wound material including a plurality of layers of conductive material, the edges of these conductive layers forming a second edge surface;
- a first, a second and a third tape wound core puck, each including a plurality of layers of conductive material, a substantial majority of the exterior surface of the first, second and third core pucks being defined by the edges of the layers of conductive material in the respective puck;
- wherein the first core puck is directly coupled to the first edge surface of the first tape wound section, the second core puck is directly coupled to the second edge surface of the second tape wound section, and the third core puck is situated between and separated by an air gap from the first and second core pucks.
A method of forming a tape wound inductor core puck device, comprising the steps of:
- forming alternating layers of conductive tape material and insulative tape material to form a first tape wound structure, the layers of conductive material having an edge surface and a broad surface, the first tape wound structure having at least a first exterior surface formed by the broad surface of an exteriorly disposed one of said layers of conductive material;
- processing the first tape wound structure to form a first core puck therefrom, the first core puck having:
- a maximum lateral cross-sectional dimension, D1, and
- a largest lateral cross-sectional measure of an exteriorly disposed broad surface of one of the conductive layers, D2, that is one-half or less of D1.
Dependencies are inferred from the claim text.