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US 9,870,856 B2Granted
Magnetic component assembly with filled physical gap
AssigneeCooper Technologies Company
InventorsAhila Krishnamoorthy, Robert James Bogert, Yipeng Yan
Life of this patent
Estimating the term…
Abstract
Magnetic component assemblies for circuit boards include single, shaped magnetic core pieces formed with a physical gap and conductive windings assembled to the cores via the gaps. The physical gaps in the cores are filled with a magnetic material to enhance the magnetic performance. The magnetic component assemblies may define power inductors.
Claims44
A surface mount magnetic component assembly comprising:
- only one magnetic core piece fabricated from a first magnetic material and including opposed top and bottom side walls, opposed longitudinal side walls interconnecting the top and bottom side walls, opposed lateral side walls interconnecting the top and bottom side wall and the opposed longitudinal side walls, and a physical gap extending in spaced relation from the bottom side wall;
- a conductive winding including a main winding section extending across a first portion of the physical gap, the conductive winding further including integrally formed and opposed first and second planar terminal sections extending in a spaced apart and parallel relationship to one another, the first and second planar terminal sections being exposed on the respective opposed longitudinal walls;
- and
- a second magnetic material adjacent the main winding section in at least a second portion of the physical gap, wherein the second magnetic material is a distributed gap material.
1 more element
A surface mount magnetic component assembly comprising:
- a magnetic core defined by only one magnetic core piece fabricated from ferrite and including opposed top and bottom side walls, opposed longitudinal side walls interconnecting the top and bottom side walls, opposed lateral side walls interconnecting the top and bottom side wall and the opposed longitudinal side walls, and an integrally formed physical gap extending to at least three of the opposed longitudinal side walls and the opposed lateral side walls;
- a conductive winding comprising a substantially straight and planar main winding section extending in a portion of the physical gap and opposed terminal portions respectively exposed on an exterior of the only one magnetic core piece;
- a bonding agent securing the planar main winding section to the only one magnetic core piece;
- and
- a distributed gap magnetic material filling a remainder of the physical gap.
2 more elements
A surface mount magnetic component assembly comprising:
- a magnetic core defined by only one magnetic core piece fabricated from a first magnetic material;
- wherein the only one magnetic core piece includes opposing top and bottom side walls, opposing longitudinal side walls interconnecting the top and bottom side walls, opposing lateral side walls interconnecting the top and bottom side wall and the opposing longitudinal side walls, and a physical gap opening spaced from the bottom wall and extending to only one of the opposing lateral side walls;
- a preformed conductive winding comprising a planar main winding section extending straight through a first portion of the physical gap and opposed terminal sections extending perpendicular to the main winding section, the opposed terminal sections extending substantially flush with the opposing longitudinal side walls;
- a bonding agent filling a second portion of the physical gap and securing the planar main winding section of the preformed conductive winding to the only one magnetic core piece;
- and
- a second magnetic material extending in a third portion of the physical gap adjacent the planar main winding section, the second magnetic material comprising a prefabricated magnetic strip including a distributed gap material, wherein the bonding agent also secures the prefabricated strip to the only one magnetic core piece;
- wherein the assembly defines a power inductor.
4 more elements
A surface mount magnetic component assembly comprising:
- a magnetic core defined by only one magnetic core piece fabricated from a first magnetic material, the only one magnetic core piece having opposed and generally parallel top and bottom side walls and at least one gap formed therein, the gap extending in a spaced location from but generally parallel to the opposed top and bottom side walls;
- a conductive winding including a planar main winding section extending fully in a portion of the gap;
- and
- a strip of magnetic sheet material extending in the gap adjacent the planar main winding section.
1 more element
Dependencies are inferred from the claim text.