LOW PROFILE LAYERED COIL AND CORES FOR MAGNETIC COMPONENTS

• US 20100171581A1
• Filed: 03/16/2010
• Published: 07/08/2010
• Est. Priority Date: 09/12/2006
• Status: Active Grant

• Current Assignee: Cooper Technologies Company (Eaton Corporation PLC.)
• Original Assignee: Cooper Technologies Company (Eaton Corporation PLC.)
• Inventors: Bogert, Robert James, Manoukian, Daniel Minas
• Granted Patent: US 8,484,829 B2
• Time in Patent Office: Days
• US Class Current: 336/192
• CPC Class Codes: H01F 17/0006 Printed inductances printed coils for dynamo-electric machines H02K3/26; printed circuits H05K
• CPC Class Codes: H01F 17/04 with magnetic core
• CPC Class Codes: H01F 2027/2819 Planar transformers with printed windings, e.g. surrounded by two cores and to be mounted on printed circuit
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 5/003 Printed circuit coils
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor
• CPC Class Codes: Y10T 29/49073 by assembling coil and core
• CPC Class Codes: Y10T 29/49075 including permanent magnet or core
• CPC Class Codes: Y10T 29/49078 Laminated
• CPC Class Codes: Y10T 29/49126 Assembling bases
• CPC Class Codes: Y10T 29/49147 Assembling terminal to base

Abstract

A low profile magnetic component with planar coil portion, polymer-based supporting structure and methods of fabrication.

Claims

1-37. -37. (canceled)

38. A method of manufacturing magnetic components including a coil winding and a core structure therefor, the method comprising:

assembling at least one coil winding with a plurality of flexible dielectric sheet layers; and

laminating the plurality of flexible dielectric sheets around the at least one coil winding to form a dielectric body.

39. The method of claim 38, wherein assembling the coil winding with the plurality of flexible dielectric sheet layers comprises stacking the plurality of flexible dielectric sheet layers with the at least one coil winding interposed between at least two of the flexible dielectric sheet layers.

40. The method of claim 38, wherein laminating the plurality of flexible dielectric sheet layers comprises pressure laminating the plurality of flexible dielectric sheets around the at least one coil winding.

41. The method of claim 38, wherein the flexible dielectric sheet layers include thermoplastic resin, and assembling the at least one coil with a plurality of flexible dielectric sheet layers comprises stacking the plurality of flexible dielectric sheet layers while the flexible dielectric sheet layers are in a solidified state.

42. The method of claim 41, wherein the flexible dielectric sheet layers comprise a polymer based dielectric film, and laminating the polymer based film comprises adhesively laminating the plurality of dielectric sheets.

43. The method of claim 41, wherein the flexible dielectric sheet layers comprise a polymer based dielectric film, and laminating the polymer based film comprises adhesivelessly laminating the plurality of dielectric sheets.

44. The method of claim 38, further comprising pre-fabricating the at least one coil winding independently of any of the plurality of flexible dielectric sheet layers.

45. The method of claim 44, further comprising pre-fabricating the coil winding on a planar dielectric layer, and assembling the planar dielectric layer with the plurality of flexible sheet layers.

46. The method of claim 44, further comprising forming the at least one coil with a number of turns extending around an open center area.

47. The method of claim 46, further comprising applying a magnetic core material, separately provided and distinct from the plurality of flexible dielectric sheets, into at least the open center area.

48. The method of claim 47, wherein applying a magnetic core material comprises introducing a magnetic powder material to the open center area.

49. The method of claim 48, further comprising introducing an iron powder material to the open center area.

50. The method of claim 38, further comprising providing circuit terminations for the coil winding on the dielectric body.

51. The method of claim 50, wherein providing circuit terminations comprises providing surface mount terminations on at least one of the flexible dielectric sheets.

52. The method of claim 38, further comprising singulating the dielectric sheets into discrete inductor components.

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

assembling at least one coil winding with a plurality of flexible dielectric sheet layers; and

laminating the plurality of flexible dielectric sheets around at least one coil winding to form a dielectric body.

54. The magnetic component claim 53, wherein assembling the coil winding with the plurality of flexible dielectric sheet layers comprises stacking the plurality of flexible dielectric sheet layers with the at least one coil winding interposed between at least two of the flexible dielectric sheet layers.

55. The magnetic component of claim 53, wherein laminating the plurality of flexible dielectric sheets comprises pressure laminating the plurality of flexible dielectric sheets around the at least one coil winding.

56. The magnetic component of claim 53, wherein the flexible dielectric sheet layers include thermoplastic resin, and assembling the at least one coil with a plurality of flexible dielectric sheet layers comprises stacking the plurality of flexible dielectric sheet layers in a solidified state.

57. The magnetic component of claim 56, wherein the flexible dielectric sheet layers comprise a polymer based dielectric film, and laminating the polymer based film comprises adhesively laminating the plurality of dielectric sheets.

58. The magnetic component of claim 56, wherein the flexible dielectric sheet layers comprise a polymer based dielectric film, and laminating the polymer based film comprises adhesivelessly laminating the plurality of dielectric sheets.

59. The magnetic component of claim 53, wherein the coil winding is pre-fabricated independently of any of the plurality of flexible dielectric sheet layers.

60. The magnetic component of claim 59, wherein the coil winding is fabricated on a base layer, and the process further comprising assembling the base layer with the plurality of flexible sheet layers.

61. The magnetic component of claim 59, wherein the at least one coil includes a number of turns extending around an open center area.

62. The magnetic component of claim 61, further comprising applying a magnetic core material, separately provided and distinct from the plurality of flexible dielectric sheets, into at least the open center area.

63. The magnetic component of claim 62, wherein applying a magnetic core material comprises introducing a magnetic powder material to the open center area.

64. The magnetic component of claim 63, further comprising introducing an iron powder material to the open center area.

65. The magnetic component of claim 53, further comprising providing circuit terminations for the coil winding on the dielectric body.

66. The magnetic component of claim 65, wherein providing circuit terminations comprises providing surface mount terminations on at least one of the flexible dielectric sheets.

67. The magnetic component of claim 53, further comprising singulating the dielectric sheets into discrete inductor components.

68. The magnetic component of claim 53, wherein the magnetic component is an inductor.

69. A magnetic component comprising:

a laminated structure comprising

at least one pre-fabricated coil winding extending for a number of turns about an open center area and having first and second ends; and

a plurality of flexible dielectric sheet layers pressure laminated around the at least one coil winding to form a dielectric body; and

first and second terminations electrically connected to the first and second ends of the coil winding.

70. The magnetic component of claim 69, wherein the first and second terminations comprise surface mount terminations.

71. The inductor component of claim 69, wherein the flexible dielectric sheet layers comprise a thermoplastic resin.

72. The inductor component of claim 69, further comprising a magnetic material, separately provided from the flexible dielectric sheet layers, filling the open center area.

73. The inductor component of claim 72, wherein the magnetic material comprises a magnetic powder material.

74. The inductor component of claim 73, wherein the magnetic powder material comprises an iron powder material.