Integrated multi-phase power inductor with non-coupled windings and methods of manufacture
First Claim
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1. An inductor component assembly for power supply circuitry on a circuit board, the inductor component assembly comprising:
- a single piece magnetic core that does not possess distributed gap properties, the single piece magnetic core comprising opposing first and second longitudinal side walls, opposing first and second lateral side walls interconnecting the first and second longitudinal side walls, and opposing top and bottom sides interconnecting the respective first and second longitudinal side walls and the respective first and second lateral side walls, wherein at least one interior passageway extends through and between the opposing top and bottom sides in spaced relation from each of the opposing first and second longitudinal side walls and also in spaced relation from each of the opposing first and second lateral side walls;
a first conductive winding extending in the at least one interior passageway, the first conductive winding including a planar winding section exposed on the top side and first and second planar legs each extending perpendicular to the planar winding section and opposing one another, each of the first and second planar legs protruding from the at least one interior passageway on the bottom side; and
a distributed gap magnetic material extending beneath the planar winding section and between the first and second planar legs as a column of material extending to the bottom side of the single piece magnetic core.
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Abstract
A surface mount power inductor component for a circuit board including multi-phase power supply circuitry includes a single piece, integrally fabricated magnetic core piece formed with vertically extending interior passageways provided with vertically elongated pre-formed conductive windings that are not magnetically coupled to reduce the footprint of the inductor component while increasing its power capacity. A distributed gap material is also provided in the vertical passageways with the conductive windings that respectively connect to each phase of electrical power.
14 Citations
19 Claims
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1. An inductor component assembly for power supply circuitry on a circuit board, the inductor component assembly comprising:
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a single piece magnetic core that does not possess distributed gap properties, the single piece magnetic core comprising opposing first and second longitudinal side walls, opposing first and second lateral side walls interconnecting the first and second longitudinal side walls, and opposing top and bottom sides interconnecting the respective first and second longitudinal side walls and the respective first and second lateral side walls, wherein at least one interior passageway extends through and between the opposing top and bottom sides in spaced relation from each of the opposing first and second longitudinal side walls and also in spaced relation from each of the opposing first and second lateral side walls; a first conductive winding extending in the at least one interior passageway, the first conductive winding including a planar winding section exposed on the top side and first and second planar legs each extending perpendicular to the planar winding section and opposing one another, each of the first and second planar legs protruding from the at least one interior passageway on the bottom side; and a distributed gap magnetic material extending beneath the planar winding section and between the first and second planar legs as a column of material extending to the bottom side of the single piece magnetic core. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. An inductor component assembly for power supply circuitry on a circuit board, the inductor component assembly comprising:
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a single piece magnetic core comprising opposing first and second longitudinal side walls, opposing first and second lateral side walls interconnecting the first and second longitudinal side walls, and opposing top and bottom sides interconnecting the respective first and second longitudinal side walls and the respective first and second lateral side walls, wherein a first interior passageway and a second interior passageway extend between the opposing top and bottom sides and a partition wall extends between the first and second interior passageways; a first conductive winding extending in the first interior passageway; a second conductive winding extending in the second interior passageway; wherein each of the first and second conductive windings are substantially identically formed and include a planar winding section exposed on the top side and first and second planar legs each extending perpendicular to the planar winding section and opposing one another, each of the first and second legs protruding from the respective first and second interior passageway on the bottom side; and a distributed gap magnetic material extending beneath the planar winding section of each of the first and second conductive windings as a column of material extending to the bottom side of the single piece magnetic core. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18)
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19. A method of fabricating an inductor component assembly for power supply circuitry on a circuit board, the method comprising:
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providing a single piece magnetic core that does not possess distributed gap properties, the single piece magnetic core including opposing first and second longitudinal side walls, opposing first and second lateral side walls interconnecting the first and second longitudinal side walls, and opposing top and bottom walls interconnecting the respective first and second longitudinal side walls and the respective first and second lateral side walls, wherein at least one interior passageway extends through and between the opposing first and second sides in spaced relation from the first and second longitudinal walls and in spaced relation from the first and second lateral side walls, and wherein a height dimension of the single magnetic core piece between the top and bottom sides is substantially greater than at least one of width dimension between the first and second longitudinal sides and the length dimension between the first and second lateral sides; extending a first conductive winding in the at least one interior passageway, wherein the first conductive winding includes a planar winding section exposed on the top side and first and second planar legs each extending perpendicular to the planar winding section and opposing one another, each of the first and second legs protruding from the at least one interior passageway on the bottom side; and applying a distributed gap magnetic material beneath the planar winding section and between the first and second legs as a column of material extending to the bottom side of the single piece magnetic core.
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Specification