FILTER INDUCTOR FOR HEAVY-CURRENT APPLICATION

• US 20170309390A1
• Filed: 04/19/2017
• Published: 10/26/2017
• Est. Priority Date: 04/20/2016
• Status: Active Grant

• Current Assignee: Bel Fuse Limited (Bel Fuse)
• Original Assignee: Bel Fuse Limited (Bel Fuse)
• Inventors: Yao, Jianbin, Huang, Hai
• Granted Patent: US 10,643,784 B2
• Time in Patent Office: Days
• CPC Class Codes: H01F 17/04 with magnetic core
• CPC Class Codes: H01F 17/043 with two, usually identical or nearly identical parts enclosing completely the coil (pot cores)
• CPC Class Codes: H01F 2027/297 with pin-like terminal to be inserted in hole of printed path
• CPC Class Codes: H01F 27/24 Magnetic cores
• CPC Class Codes: H01F 27/2852 Construction of conductive connections, of leads
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 27/306 Fastening or mounting coils or windings on core, casing or other support
• CPC Class Codes: H01F 41/0206 Manufacturing of magnetic cores by mechanical means magnetic cores per se H01F27/24
• CPC Class Codes: H01F 41/10 Connecting leads to windings making electric connections in general H01R43/00
• CPC Class Codes: H05K 1/0263 High current adaptations, e.g. printed high current conductors or using auxiliary non-printed means; Fine and coarse circuit patterns on one circuit board H05K1/0293 takes precedence
• CPC Class Codes: H05K 1/184 Components including terminals inserted in holes through the printed circuit board and connected to printed contacts on the walls of the holes or at the edges thereof or protruding over or into the holes
• CPC Class Codes: H05K 2201/086 for inductive purposes, e.g. printed inductor with ferrite core
• CPC Class Codes: H05K 2201/1003 Non-printed inductor

Abstract

A filter inductor for high-current applications. The filter inductor includes a magnetic core and a winding. The winding includes a shaped section having opposing ends, a pair of arm sections laterally extending from the opposing ends of the shaped section, respectively, and a pair of inductor pins, each extending perpendicular from an end of a respective arm section. The magnetic core includes a first core portion and a second core portion. The first core portion includes a recessed channel configured to receive the shaped section of the winding. The second core portion includes a pair of recessed regions configured to receive the pair of arm sections of the winding, respectively. The first core portion and the second core portion are coupled in contact to one another to secure the shaped section of the winding within the magnetic core. The filter inductor can be edge-mounted to a printed circuit board.

Claims

1. A passive magnetic component, comprising:

a magnetic core; and

a winding,

wherein the winding includes a shaped section having opposing ends, a pair of arm sections extending laterally from the opposing ends of the shaped section, respectively, and a plurality of first pins, each first pin extending substantially perpendicular from an end of a respective one of the pair of arm sections.

2. The passive magnetic component of claim 1 wherein the winding further includes at least one second pin extending substantially perpendicular from the end of the respective one of the pair of arm sections in a direction opposite the first pin.

3. The passive magnetic component of claim 1 wherein the magnetic core includes a first core portion having a recessed channel configured to receive at least the shaped section of the winding.

4. The passive magnetic component of claim 3 wherein the magnetic core further includes a second core portion having a pair of recessed regions configured to receive the pair of arm sections, respectively.

5. The passive magnetic component of claim 4 wherein the first core portion and the second core portion are coupled in contact to one another to secure at least the shaped section of the winding within the magnetic core.

6. The passive magnetic component of claim 1 wherein the shaped section of the winding is a C-shaped section.

7. The passive magnetic component of claim 1 wherein the pair of arm sections have substantially the same length.

8. The passive magnetic component of claim 1 wherein the winding including the shaped section, the pair of arm sections, and the plurality of first pins are formed from a sheet of metal.

9. The passive magnetic component of claim 8 wherein the sheet of metal is a sheet of copper material.

10. The passive magnetic component of claim 1 wherein at least one first pin among the plurality of first pins has at least one stop for limiting an insertion of the at least one first pin through a hole in a printed circuit board.

11. A method of fabricating a passive magnetic component, comprising:

forming a winding as an integrated structure, the winding including a shaped section having opposing ends, a pair of arm sections extending laterally from the opposing ends of the shaped section, respectively, and a plurality of first pins, each first pin extending substantially perpendicular from an end of a respective one of the pair of arm sections;

providing a magnetic core assembly including a first core portion and a second core portion;

forming a recessed channel in the first core portion to conform to a shape of the shaped section of the winding;

receiving the shaped section of the winding in the recessed channel of the first core portion; and

coupling the first core portion and the second core portion in contact to one another to secure at least the shaped section of the winding within the magnetic core assembly.

12. The method of claim 11 further comprising:

forming a pair of recessed regions in the second core portion to conform to cross-sections of the pair of arm sections of the winding, respectively.

13. The method of claim 12 further comprising:

receiving the pair of arm sections in the pair of recessed regions of the second core portion, respectively.

14. The method of claim 11 wherein the forming of the winding as the integrated structure includes forming the winding from a sheet of metal.

15. A printed circuit board assembly, comprising:

a printed circuit board having an edge; and

a passive magnetic component configured to be mounted along the edge of the printed circuit board.

16. The printed circuit board assembly of claim 15 wherein the passive magnetic component includes:

a magnetic core; and

a winding,

wherein the winding includes a shaped section having opposing ends, a pair of arm sections extending laterally from the opposing ends of the shaped section, respectively, and a plurality of first pins, each first pin extending substantially perpendicular from an end of a respective one of the pair of arm sections.

17. The printed circuit board assembly of claim 16 wherein the winding further includes at least one second pin extending substantially perpendicular from the end of the respective one of the pair of arm sections in a direction opposite the first pin.

18. The printed circuit board assembly of claim 16 wherein the printed circuit board includes a plurality of holes formed therethrough, and wherein the plurality of first pins of the winding are inserted through the plurality of holes in the printed circuit board, respectively.

19. The printed circuit board assembly of claim 18 wherein the magnetic core includes a first core portion having a recessed channel configured to receive at least the shaped section of the winding, and a second core portion having a pair of recessed regions configured to receive the pair of arm sections of the winding, respectively.

20. The printed circuit board assembly of claim 19 wherein the first core portion and the second core portion are coupled in contact to one another to secure at least the shaped section of the winding within the magnetic core, and wherein a surface of the second core portion is positioned against the edge of the printed circuit board so as to align the plurality of first pins of the winding with the plurality of holes in the printed circuit board, respectively.