MAGNETIC COMPONENTS AND METHODS OF MANUFACTURING THE SAME

• US 20100039200A1
• Filed: 08/31/2009
• Published: 02/18/2010
• Est. Priority Date: 07/11/2008
• 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 8,659,379 B2
• Time in Patent Office: Days
• US Class Current: 336/147
• CPC Class Codes: H01F 17/04 with magnetic core
• CPC Class Codes: H01F 2017/048 with encapsulating core, e.g. made of resin and magnetic powder
• CPC Class Codes: H01F 27/2847 Sheets; Strips H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 3/10 Composite arrangements of magnetic circuits

Abstract

Magnetic component assemblies including coil coupling arrangements, that are advantageously utilized in providing surface mount magnetic components such as inductors and transformers.

Claims

1. A magnetic component assembly comprising:

a monolithic magnetic body, and

a plurality of distinct, mutually coupled coils situated in the magnetic body, wherein mutually coupled coils are arranged in the magnetic body in a flux sharing relationship with one another.

2. The magnetic component assembly of claim 1, wherein the distinct, mutually coupled coils comprises a plurality of substantially planar coils within the magnetic body, each of the plurality of coils defining a central flux area through which a magnetic flux generated by the coil may pass, and wherein a portion of the flux generated by each respective coil returns only in the central flux area of the respective coil without passing through the central flux area of an adjacent coil.

3. The magnetic component assembly of claim 2, wherein the plurality of substantially planar coils includes at least first and second coils spaced from one another in a direction perpendicular to the plane of the coils.

4. The magnetic component assembly of claim 3, wherein the central flux area of each coil and the spacing from adjacent coils in the direction perpendicular to a plane of the coils defines a cross sectional area through which the generated flux passes in the magnetic body.

5. The magnetic component assembly of claim 4, wherein the cross sectional area between adjacent ones of the plurality of coils is unequal.

6. The magnetic component assembly of claim 2, wherein at least first and second adjacent coils are spaced apart from one another in a direction normal to the plane of the coils such that the central flux areas of the first and second coils are separated from one another by a first distance.

7. The magnetic component assembly of claim 6, further comprising a third coil spaced apart from the second coil in a direction normal to the plane of the coils, wherein the third coil is spaced apart from second coil in the direction normal to the plane of the coils such that the central flux areas of the second and third coils are separated from one another by a second distance different from the first difference.

8. The magnetic body of claim 1, wherein the body comprises magnetic metal powder particles surrounded by a non-magnetic material, wherein adjacent metal powder particles are separated from one another by the non-magnetic material

9. The magnetic component assembly of claim 1, wherein the distinct, mutually coupled coils are configured to carry different phases of electrical power.

10. The magnetic component assembly of claim 1, wherein the each of the distinct, mutually coupled coils comprises first and second leads protruding from the magnetic body.

11. The magnetic component assembly of claim 10, wherein the magnetic body comprises a plurality of sides, and each of the first and second leads of each respective coil protrudes from a single one of the plurality of sides of the magnetic body.

12. The magnetic component assembly of claim 10, wherein the magnetic body comprises a plurality of sides, and wherein the first and second leads of each respective coil protrudes from different ones of the plurality of sides of the magnetic body.

13. The magnetic component assembly of claim 10, wherein the first and second leads of each coil protrudes from opposing ones of the plurality of sides of the magnetic body.

14. The magnetic component assembly of claim 10, wherein the magnetic body comprises a plurality of sides, and terminal leads of each respective coil wrap around at least one of the sides.

15. The magnetic component assembly of claim 1, wherein the coils are substantially C-shaped.

16. The magnetic component assembly of claim 1, wherein each of the coils complete a first number of turns of a winding.

17. The magnetic component assembly of claim 16, wherein the first number of turns is a fractional number less than one.

18. The magnetic component assembly of claim 16, further comprising a circuit board, the circuit board configured with a layout defining a second number of turns of a winding, each coil being connected to one of the second number of turns.

19. The magnetic component assembly of claim 18, wherein the second number of turns is a fractional number less than one.

20. The magnetic component assembly of claim 1, wherein the distinct, mutually coupled coils comprises a plurality of substantially planar coils arranged in spaced apart, substantially parallel planes, wherein each coil defines a central flux area through which a magnetic flux generated by the coil may pass, and the coil central flux areas are arranged to partly overlap and partly non-overlap one another in a direction substantially perpendicular to the plane of the coils, wherein a substantial portion of the flux generated by at least one the coils passes through the central flux area of at least one of the other coils.

21. The magnetic component assembly of claim 20, wherein the magnetic body surrounds the coils, the magnetic body having a plurality of sides;

each coil having opposing first and second leads, and the first and second leads of each coil protruding from one of the plurality of sides; and

the first and second leads of adjacent coils extending from different sides of the magnetic body.

22. The magnetic component assembly of claim 21, wherein the magnetic body has four orthogonal sides, with first and second coil leads extending from each of the four orthogonal sides.

23. The magnetic component assembly of claim 21, wherein a substantial portion of the flux generated by at least one the coils passes through the central flux area of all of the other coils.

24. The magnetic component assembly of claim 1, wherein the distinct, mutually coupled coils comprises at least three substantially planar coils arranged in spaced apart, substantially parallel planes,

each coil defining a coil aperture, and

the coils being arranged so that the coil apertures of adjacent coils do not completely overlap one another in a direction substantially perpendicular to the planar coils.

25. The magnetic component assembly of claim 24, wherein the at least three coils comprises first and second coils extending in a substantially coplanar relationship in a first plane, the third coil extending in a second plane spaced from but generally parallel to the first plane.

26. The magnetic component assembly of claim 25, wherein each coil defines a central flux area through which a magnetic flux generated by the coil may pass, and the third coil positioned relative to the first and second coils so that a substantial portion of the flux generated by the third coil passes through the central flux areas of the first and second coils.

27. The magnetic component assembly of claim 1, wherein the distinct, mutually coupled coils comprises are formed on a substrate material and include a plurality of partial turns defining a central flux area through which through which a magnetic flux generated by the coil may pass, the central flux areas of at least two of the coils overlapping one another in the magnetic body such that a portion of the flux generated by one of the coils passes through the central flux area of at least one other of the plurality of coils.