# US 2013/0278371 A1 · Flat coil planar transformer and methods > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2013/0278371 A1 - Document ID: US20130278371A1 - Status: Published application - Kind: A1 - Application number: 13/802,033 - Filed: 2013-03-13 - Published: 2013-10-24 - Earliest claimed: 2012-03-27 - Assignees: Pulse Electronics, Inc. - Applicants: Pulse Electronics, Inc. - Inventors: Ma Hongzhong; Robert Lu - Web page: https://patentgrep.com/patent/US20130278371A1 ## CPC - H01F 27/2871: {Pancake coils} - H01F 5/00: Coils (superconducting coils H01F6/06; fixed inductances of the signal type H01F17/00) - H01F 27/2852: {Construction of conductive connections, of leads} - H01F 27/292: {Surface mounted devices} - H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES ## Abstract A low cost, reduced form factor, high performance electronic device for use in electronic circuits and methods. In one exemplary embodiment, the device includes a unitary header assembly construction that ensures device coplanarity and also includes vertically oriented terminal pins. The device utilizes preconfigured flat coil windings that are disposed directly within a planar core. The flat coil windings further include features that are configured to mate with the header assembly terminal pins which substantially simplify the manufacturing process. Methods for manufacturing the device are also disclosed. ## Claims ### Claim 1 An inductive device, comprising: a header assembly comprising a plurality of terminals; at least one core; and one or more flat coil windings disposed in proximity to said at least one core and electrically coupled with respective ones of said terminals. ### Claim 2 (depends on 1) The inductive device of claim 1, wherein at least one of said one or more windings comprises a first terminal aperture, said first terminal aperture configured for receiving a portion of a first terminal. ### Claim 3 (depends on 2) The inductive device of claim 2, further comprising a second terminal aperture, said second terminal aperture configured to receiving a portion of a second terminal. ### Claim 4 (depends on 3) The inductive device of claim 3, wherein the first terminal aperture is associated with a primary winding of a transformer and said second terminal aperture is associated with a secondary winding of said transformer. ### Claim 5 (depends on 3) The inductive device of claim 3, wherein said first and second terminal apertures reside at different levels within said inductive device. ### Claim 6 (depends on 1) The inductive device of claim 1, wherein at least one of said one or more flat coil windings comprises a notch, said notch configured to place said at least one of said one or more windings further away from an adjacent terminal. ### Claim 7 (depends on 1) The inductive device of claim 1, wherein at least a portion of said plurality of terminals comprise a chamfer feature. ### Claim 8 (depends on 7) The inductive device of claim 7, wherein said chamfer feature is configured to facilitate insertion of said respective terminal into a terminal aperture of said one or more flat coil windings. ### Claim 9 (depends on 1) The inductive device of claim 1, wherein said one or more flat coil windings comprises at least three discrete flat coil windings. ### Claim 10 (depends on 1) The inductive device of claim 1, wherein said header assembly further comprises: a polymer carrier that defines a core receiving feature; wherein said plurality of terminals each comprise a flat coil receiving end and a printed circuit board mating end. ### Claim 11 (depends on 10) The inductive device of claim 10, wherein said core receiving feature comprises a cavity, said cavity having one or more standoff features disposed therein. ### Claim 12 (depends on 11) The inductive device of claim 11, wherein said at least one core includes a standoff receiving feature, said standoff receiving feature sized to accommodate said one or more standoff features. ### Claim 13 (depends on 10) The inductive device of claim 10, wherein said flat coil receiving end comprises a vertically oriented terminal having a chamfered feature disposed thereon. ### Claim 14 (depends on 10) The inductive device of claim 10, wherein said printed circuit board mating end is disposed within a footprint area defined by said polymer carrier. ### Claim 15 A flat coil winding, comprising: a metal winding comprising a width and a thickness, said width being greater in dimension than said thickness; wherein said metal winding is wound into a spiral characterized by an inner radius and an outer radius where the difference between said outer radius and said inner radius is said width. ### Claim 16 (depends on 15) The flat coil winding of claim 15, wherein said metal winding further comprises one or more terminal receiving apertures disposed therein. ### Claim 17 (depends on 16) The flat coil winding of claim 16, wherein said one or more terminal receiving apertures are substantially rectangular in shape. ### Claim 18 (depends on 15) The flat coil winding of claim 15, further comprising a notch, said notch configured to provide additional distance between said metal winding and an adjacent terminal on an inductive device to which the flat coil winding is ultimately positioned. ### Claim 19 An electronics assembly comprising: a power source; a printed circuit board; and an inductive device mounted on said printed circuit board that is in electrical communication with said power source, said inductive device comprising: a header assembly comprising a plurality of terminals; at least one core; and one or more flat coil windings disposed in proximity to said at least one core and electrically coupled with respective ones of said terminals. ### Claim 20 (depends on 19) The electronics assembly of claim 19, wherein said inductive device is configured to provide a lower direct current resistance than a comparable inductive device comprised of printed circuit board windings.