Magnetic Electrical Device

• US 20100026443A1
• Filed: 07/29/2008
• Published: 02/04/2010
• Est. Priority Date: 07/29/2008
• Status: Active Grant

• Current Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: Cooper Technologies Company (Eaton Corporation PLC.)
• Inventors: Bogert, Robert James, Yan, Yipeng
• Granted Patent: US 8,378,777 B2
• Time in Patent Office: Days
• US Class Current: 336/234
• CPC Class Codes: H01F 17/0013 with stacked layers
• CPC Class Codes: H01F 17/0033 with the coil helically wound around a magnetic core
• CPC Class Codes: H01F 2017/006 flexible printed inductors
• CPC Class Codes: H01F 2017/0066 with a magnetic layer
• CPC Class Codes: H01F 27/245 made from sheets, e.g. grain-oriented H01F27/26 takes precedence
• CPC Class Codes: H01F 27/2847 Sheets; Strips H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/2866 Combination of wires and sheets
• CPC Class Codes: H01F 27/29 Terminals; Tapping arrangements for signal inductances
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 27/30 Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other support
• CPC Class Codes: H01F 41/041 Printed circuit coils apparatus or processes for manufacturing printed circuits in general H05K3/00
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor
• CPC Class Codes: Y10T 29/49071 by winding or coiling
• CPC Class Codes: Y10T 29/49073 by assembling coil and core
• CPC Class Codes: Y10T 29/49075 including permanent magnet or core

Abstract

A magnetic component and a method for manufacturing a low profile, magnetic component. The method comprises the steps of providing at least one sheet, coupling at least a portion of at least one winding to the at least one sheet, and laminating the at least one sheet with at least a portion of the at least one winding. The magnetic component comprises at least one sheet and at least a portion of at least one winding coupled to the at least one sheet, wherein the at least one sheet is laminated to at least a portion of the at least one winding. The winding may comprise a clip, a preformed coil, a stamped conductive foil, or an etched trace using chemical or laser etching. The sheet may comprise any material capable of being laminated and/or rolled, including, but not limited to, flexible magnetic powder sheets.

Claims

1. A magnetic component, comprising:

at least one sheet, wherein the at least one sheet is substantially planar; and

at least one winding, wherein at least a portion of the at least one winding is coupled to the at least one sheet, and

wherein the at least one sheet is laminated to at least a portion of the at least one winding.

2. The magnetic component of claim 1, wherein the at least one winding comprises one of a preformed coil, a conductive foil, a conductive trace, and a clip.

3. The magnetic component of claim 1, wherein the at least one winding comprises a conductive trace formed on a surface of the at least one sheet by one of chemical etching, photo etching, laser etching, and plating.

4. The magnetic component of claim 1, wherein the at least one sheet is a magnetic powder sheet.

5. The magnetic component of claim 1, wherein the at least one winding comprises a plurality of windings, the plurality of windings formed in series.

6. The magnetic component of claim 1, wherein the at least one winding comprises a plurality of windings, the plurality of windings formed in parallel.

7. The magnetic component of claim 1, further comprising at least one surface mount termination coupled to the at least one winding.

8. The magnetic component of claim 1, wherein the at least one sheet comprises a plurality of sheets, the plurality of sheets positioned on top of one another.

9. The magnetic component of claim 8, wherein the at least one winding is coupled to a surface of a first sheet, the at least one winding forming a pattern on the surface.

10. The magnetic component of claim 9, further comprising a magnetic field formed when current flows through the at least one winding, the magnetic field generated in a vertical orientation through an opening formed by the at least one winding.

11. The magnetic component of claim 8, wherein a first portion of the at least one winding is formed on a first sheet, wherein a second portion of the at least one winding is formed on a second sheet, and wherein the first portion and the second portion are coupled to one another to form a pattern.

12. The magnetic component of claim 11, wherein the first portion is coupled to the second portion through a plurality of vias.

13. The magnetic component of claim 11, further comprising a magnetic field formed when current flows through the at least one winding, the magnetic field generated in a horizontal orientation through an opening formed by the at least one winding.

14. The magnetic component of claim 11, wherein the at least one winding comprises a plurality of windings in a parallel orientation.

15. The magnetic component of claim 14, further comprising a magnetic field formed when current flows through the plurality of windings, the magnetic field generated in a horizontal orientation through an opening formed by the plurality of windings.

16. The magnetic component of claim 14, further comprising a magnetic field formed when current flows through the plurality of windings, the magnetic field generated in a horizontal orientation through a plurality of parallel openings formed by the plurality of windings.

17. The magnetic component of claim 11, wherein the at least one winding is a single winding, and wherein the pattern is serpentine.

18. The magnetic component of claim 17, further comprising a magnetic field formed when current flows through the single winding, the magnetic field generated in a horizontal orientation through a plurality of parallel openings formed by the single winding.

19. The magnetic component of claim 11, wherein the pattern is toroidal.

20. The magnetic component of claim 19, further comprising a plurality of magnetic fields formed when current flows through the at least one winding.

21. The magnetic component of claim 20, wherein a first magnetic field is generated in a vertical orientation and wherein a second magnetic field is generated in a second orientation through an opening formed by the at least one winding.

22. The magnetic component of claim 8, further comprising:

a printed circuit board, wherein a first portion of the at least one winding is formed on the printed circuit board,

wherein a second portion of the at least one winding is formed on a second sheet, the first portion and the second portion coupled to one another to form a spiral pattern.

23. The magnetic component of claim 1, wherein the at least one winding proceeds from one edge of the at least one sheet to an opposing edge of the at least one sheet in a substantially linear orientation.

24. The magnetic component of claim 23, wherein the at least one winding comprises a plurality of windings, the plurality of windings formed in parallel.

25. The magnetic component of claim 1, wherein the at least one winding comprises at least one clip having opposing ends, the at least one clip extending beyond the opposing edges of the at least one sheet in a substantially linear orientation, the opposing ends of the at least one clip forming a plurality of surface mount terminals.

26. The magnetic component of claim 25, wherein the at least one clip comprises a plurality of clips, the plurality of clips formed in parallel.

27. The magnetic component of claim 25, wherein the at least one sheet is a single sheet, the single sheet being rolled around the at least one clip.

28. The magnetic component of claim 1, wherein the at least one winding and the at least one sheet are disposed adjacent to each other without a gap therebetween.

29. A method of forming a magnetic component, comprising:

providing at least one sheet, wherein the at least one sheet is substantially planar;

coupling at least a portion of at least one winding to the at least one sheet; and

laminating the at least one sheet with at least a portion of the at least one winding.