MAGNETIC ELECTRICAL DEVICE

• US 20100171579A1
• Filed: 03/16/2010
• Published: 07/08/2010
• 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 8,910,373 B2
• Time in Patent Office: Days
• US Class Current: 336/83
• 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

1-29. -29. (canceled)

30. A method of manufacturing a magnetic component including a coil winding in a magnetic core structure, the method comprising:

stacking a plurality of substantially planar and flexible magnetic powder sheets;

locating the coil winding between at least two of the stacked magnetic powder sheets; and

pressure laminating the flexible magnetic powder sheets around the coil winding to define a magnetic core containing the winding;

wherein the sheets are flexed over the coil winding and no physical gap is created in the magnetic core.

31. The method of claim 30, further comprising pre-fabricating the coil winding independently from any of the flexible magnetic powder sheets.

32. The method of claim 31, wherein fabricating the coil winding comprises winding a flexible wire conductor for a number of turns about an open center area.

33. The method of claim 32, wherein the coil includes first and second leads, the method further comprising providing first and second terminals, and connecting the first and second terminals to the respective first and second leads.

34. The method of claim 33, wherein the terminals are formed on one of the flexible magnetic powder sheets.

35. The method of claim 33, wherein comprising electrically connecting terminals to the first and second leads comprises providing surface mount terminals.

36. The method of claim 30, wherein the flexible magnetic powder sheets include magnetic powder material mixed with a thermoplastic resin, and stacking the plurality of substantially planar and flexible magnetic powder sheets comprises stacking the flexible magnetic powder sheets in a solidified state.

37. The method of claim 30, wherein the coil winding is configured for use as a miniature power inductor.

38. The method of claim 30, further comprising:

pressure laminating first and second flexible magnetic powder sheets to form a first subassembly;

pressure laminating third and fourth flexible magnetic powder sheets to form a second subassembly; and

pressure laminating the first and second subassemblies around the coil winding.

39. A magnetic component including a coil winding in a magnetic core structure, the component formed by the process of:

stacking a plurality of substantially planar and flexible magnetic powder sheets;

locating the coil winding between at least two of the stacked magnetic powder sheets; and

pressure laminating the flexible magnetic powder sheets around the coil winding to define a magnetic core containing the winding;

wherein the sheets are flexed over the coil winding and no physical gap is created in the magnetic core.

40. The magnetic component claim 40, wherein the coil winding is pre-fabricated independently from any of the flexible magnetic powder sheets.

41. The magnetic component of claim 40, wherein the coil winding comprises a flexible wire conductor wound for a number of turns about an open center area.

45. The method of claim 40, wherein the flexible magnetic powder sheets include magnetic powder material mixed with a thermoplastic resin, and stacking the plurality of substantially planar and flexible magnetic powder sheets comprises stacking the flexible magnetic powder sheets in a solidified state.

46. The method of claim 40, wherein the coil winding is configured for use as a miniature power inductor.

47. The method of claim 40, wherein the process further comprises:

pressure laminating first and second flexible magnetic powder sheets to form a first subassembly;

pressure laminating third and fourth flexible magnetic powder sheets to form a second subassembly; and

pressure laminating the first and second subassemblies around the coil winding.

42. The magnetic component of claim 42, wherein the coil includes first and second leads, the process further comprising electrically connecting terminals to the first and second leads.

43. The method of claim 43, wherein the terminals are formed on one of the flexible magnetic powder sheets.

44. The method of claim 43, wherein comprising electrically connecting terminals to the first and second leads comprises providing surface mount terminals.