High-frequency, low-profile inductor
First Claim
1. A low-profile magnetic component, comprising:
- a Z-folded film including an elongated dielectric film defining first and second ends and a length dimension between said ends, and first and second edges, said dielectric film having a predetermined width between said first and second edges, said dielectric film supporting an electrical conductor having at least a first portion defining a second width which is less than said predetermined width, said first portion of said electrical conductor extending in a zig-zag manner from said first end of said dielectric film to a location near said second end of said dielectric film, said elongated dielectric film also defining a plurality of pairs of core apertures, each said pair of core apertures including first and second core apertures spaced apart from each other and from said first and second edges of said dielectric film, said pairs of first and second core apertures being spaced in a regular pattern along said length of said dielectric film, said regular pattern being selected so that, when said dielectric film is Z-folded to form said Z-folded film, said first and second core apertures of each of said pairs of core apertures are registered with corresponding ones of said first and second core apertures of the other pairs of core apertures, said first core apertures of each of said pairs of core apertures being located adjacent said first portion of said electrical conductor, and between said first portion of said electrical conductor and said first edge of said dielectric film, and said second core apertures of each of said pairs of core apertures being located adjacent said first portion of said electrical conductor, and between said first portion of said electrical conductor and said second edge of said dielectric film;
a thin, fiat, magnetically permeable top plate defining at least one peripheral edge;
a thin, fiat, magnetically permeable bottom plate defining at least one peripheral edge, and lying substantially parallel to, and spaced away from said first plate by a predetermined separation;
a first magnetically permeable core post having a length less than said predetermined separation, and extending through said first core apertures of said Z-folded film, and between said top and bottom plates, so as to be magnetically coupled to said top and bottom plates at first locations spaced away from said peripheral edges of said top and bottom plates, whereby said first core post is magnetically coupled to said top and bottom plates by a magnetic path including a first gap resulting from the difference between said predetermined separation and said length of said first core post;
a second magnetically permeable core post having a length less than said predetermined separation, and extending through said second core apertures of said Z-folded film, and between said top and bottom plates, so as to be magnetically coupled to said top and bottom plates at second locations spaced away from said peripheral edges of said top and bottom plates, whereby said second core post is magnetically coupled to said top and bottom plates by a magnetic path including a second gap resulting from the difference between said predetermined separation and said length of said second core post;
whereby, when electrical current flows through said first portion of said electrical conductor, the magnetic flux direction through said first and second apertures, and through said first and second core posts, respectively, extending therethrough, is mutually parallel but oppositely directed.
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Accused Products
Abstract
A multi-pole magnetic component, such as an inductor, includes z-folded conductive film windings and a core having a plurality of pairs of spaced apart core posts extending between a base plate and a top plate of the core. The core includes an air gap that is distributed substantially evenly along the flux path. Magnetic flux flows through the core posts in a series manner so as to have an opposite flux direction in adjacent poles. Preferably, the air gap is determined such that the ratio of the distance between each adjacent core post and the distance between the base and top plates results in magnetic fields that are substantially tangential to the surface of the conductive film winding. Furthermore, the core posts are preferably shaped to have a larger cross sectional area at the base portion of the posts than at the top portion thereof. Alternatively, the core posts are attached to the bottom plate and are inserted into suitably shaped cut-out portions of the top plate. In either case, the air gap between each core post and the respective core plate is smaller around the center of the core post than at the outer edges thereof. As a result, flux is concentrated near the center of the core posts, thereby reducing fringing fields which, in turn, minimizes high-frequency winding losses.
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Citations
13 Claims
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1. A low-profile magnetic component, comprising:
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a Z-folded film including an elongated dielectric film defining first and second ends and a length dimension between said ends, and first and second edges, said dielectric film having a predetermined width between said first and second edges, said dielectric film supporting an electrical conductor having at least a first portion defining a second width which is less than said predetermined width, said first portion of said electrical conductor extending in a zig-zag manner from said first end of said dielectric film to a location near said second end of said dielectric film, said elongated dielectric film also defining a plurality of pairs of core apertures, each said pair of core apertures including first and second core apertures spaced apart from each other and from said first and second edges of said dielectric film, said pairs of first and second core apertures being spaced in a regular pattern along said length of said dielectric film, said regular pattern being selected so that, when said dielectric film is Z-folded to form said Z-folded film, said first and second core apertures of each of said pairs of core apertures are registered with corresponding ones of said first and second core apertures of the other pairs of core apertures, said first core apertures of each of said pairs of core apertures being located adjacent said first portion of said electrical conductor, and between said first portion of said electrical conductor and said first edge of said dielectric film, and said second core apertures of each of said pairs of core apertures being located adjacent said first portion of said electrical conductor, and between said first portion of said electrical conductor and said second edge of said dielectric film; a thin, fiat, magnetically permeable top plate defining at least one peripheral edge; a thin, fiat, magnetically permeable bottom plate defining at least one peripheral edge, and lying substantially parallel to, and spaced away from said first plate by a predetermined separation; a first magnetically permeable core post having a length less than said predetermined separation, and extending through said first core apertures of said Z-folded film, and between said top and bottom plates, so as to be magnetically coupled to said top and bottom plates at first locations spaced away from said peripheral edges of said top and bottom plates, whereby said first core post is magnetically coupled to said top and bottom plates by a magnetic path including a first gap resulting from the difference between said predetermined separation and said length of said first core post; a second magnetically permeable core post having a length less than said predetermined separation, and extending through said second core apertures of said Z-folded film, and between said top and bottom plates, so as to be magnetically coupled to said top and bottom plates at second locations spaced away from said peripheral edges of said top and bottom plates, whereby said second core post is magnetically coupled to said top and bottom plates by a magnetic path including a second gap resulting from the difference between said predetermined separation and said length of said second core post; whereby, when electrical current flows through said first portion of said electrical conductor, the magnetic flux direction through said first and second apertures, and through said first and second core posts, respectively, extending therethrough, is mutually parallel but oppositely directed. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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Specification