MINIATURE SHIELDED MAGNETIC COMPONENT
First Claim
Patent Images
1. A low profile magnetic component comprising:
- a first core fabricated from a magnetic permeable material and defining a receptacle;
a second core fabricated from a magnetic permeable material, the second core fabricated independently from the first core and having a shape different from the first core; and
a preformed coil formed independently from the first and second cores, the coil comprising at least a first lead, a second lead and plurality of turns therebetween;
wherein the first core defines a receptacle that receives substantially all of the plurality of turns of the coil, and at least one of the first and second cores comprises a projection fitted into the coil; and
wherein a nonmagnetic gap is established between the projection and the other of the at least one of the first and second cores, whereby energy is stored in the gap as currently flows through the plurality of turns.
1 Assignment
0 Petitions
Accused Products
Abstract
Low profile, shielded magnetic components for circuit board applications include self centering core and coil assemblies with coil receptacle and centering projections formed in core pieces that are assembled around a preformed coil. Welding and plating techniques for forming termination structure for the preformed coil avoid thermal shock issues. External gapping elements and agents to form a gapped core structure are avoided, and gap size in the cores may be tightly controlled over large production lot sizes.
-
Citations
37 Claims
-
1. A low profile magnetic component comprising:
-
a first core fabricated from a magnetic permeable material and defining a receptacle; a second core fabricated from a magnetic permeable material, the second core fabricated independently from the first core and having a shape different from the first core; and a preformed coil formed independently from the first and second cores, the coil comprising at least a first lead, a second lead and plurality of turns therebetween; wherein the first core defines a receptacle that receives substantially all of the plurality of turns of the coil, and at least one of the first and second cores comprises a projection fitted into the coil; and wherein a nonmagnetic gap is established between the projection and the other of the at least one of the first and second cores, whereby energy is stored in the gap as currently flows through the plurality of turns. - View Dependent Claims (3, 4, 5, 6, 7, 8, 9, 10)
-
-
2. (canceled)
-
11-19. -19. (canceled)
-
20. A low profile magnetic component comprising:
-
a first core fabricated from a magnetic permeable material and defining a receptacle, and said core including a post projecting upwardly into the receptacle; and a preformed coil received in the receptacle of the first core with the post extending through an inner periphery of the coil, the coil comprising at least a first lead, a second lead and plurality of turns therebetween. - View Dependent Claims (21, 22, 23, 24, 25, 26, 27, 28)
-
-
29. A low profile magnetic component comprising:
-
a preformed coil; first means for providing a first magnetic core and for receiving the preformed coil; and second means for providing a second magnetic core, the second means separately provided from the means for providing a first magnetic core and enclosing the preformed coil within the first means; and means for centering the coil with respect to the core, the centering means being integrally provided in one of the first and second magnetic cores for providing a magnetic core; and means for establishing a nonmagnetic gap associated with the means for centering the coil. - View Dependent Claims (30, 31, 32, 33)
-
-
34. A method of manufacturing a low profile magnetic component, the magnetic component including and defining a receptacle, a second core fabricated from a magnetic permeable material and also being fabricated independently from the first core, at least one of the first and second cores further having a projection formed therewith, and a coil formed independently from the first and second cores, said coil comprising first and second leads and a plurality of turns therebetween, said method comprising:
-
assembling the first core, the second core, and the coil so that substantially all of the turns of the coil are located in the receptacle, the projection is inserted into the coil, and a non-magnetic gap is established at an end of the projection; bonding the cores to one another in a fixed position relationship; and terminating the first and second leads to surface mount terminations. - View Dependent Claims (35, 36)
-
-
37. A low profile magnetic component comprising:
-
a first core, said first core fabricated from a magnetic permeable material, and including a receptacle; a second core, said second core fabricated independent from a magnetic permeable material and fabricated independent from said first core; a coil formed independent from the first and second cores, said coil comprising a first lead, a second lead, and a plurality of turns therebetween, said coil comprising an inner periphery and an outer periphery, wherein said first and second leads connect to the coil at the outer periphery; and first and second surface mount terminations configured to connect the first and second leads, respectively, to a circuit board; wherein the first core defines a receptacle adapted to receive the coil and wherein at least one of the first core and the second core includes a projection, said projection adapted to be inserted into the coil and establishing a nonmagnetic gap with the other one of the first and second cores.
-
Specification