Multi-part reactive device and method

• US 6,362,714 B1
• Filed: 06/30/1999
• Issued: 03/26/2002
• Est. Priority Date: 06/30/1999
• Status: Expired due to Fees

• Current Assignee: Temic Automotive of North America, Incorporated (Continental AG)
• Original Assignee: Motorola, Inc. (Motorola Solutions, Inc.)
• Inventors: Budniak, Mitchell, Hopman, Nick, Rice, Amy
• Primary Examiner(s): Donovan, Lincoln
• Assistant Examiner(s): NGUYEN, TUYEN T
• Application Number:
  US09/345,619
• Time in Patent Office: 1,000 Days
• Field of Search: 336/55, 336/61, 336/200, 336/223, 336/232, 336/179, 361/270
• US Class Current: 336/179
• CPC Class Codes: H01F 17/0033 with the coil helically wound around a magnetic core
• CPC Class Codes: H01F 17/06 with core substantially closed in itself, e.g. toroid

Abstract

A multi-part reactive device preferably includes a substrate with a first conductive area and a second conductive area. A first conductive element with a first terminal is connected to the first conductive area. The first conductive element has a second terminal connected to the second conductive area. A current loop is formed extending from the first conductive area, through the first terminal, through the second terminal, to the second conductive area. A magnetically-effective core member is captivated by the first conductive element to the substrate between the first conductive area and the second conductive area and encircles the current loop. The first conductive area, the first conductive element, the magnetically-effective core member, and the second conductive area form a first magnetic circuit. Additional magnetic circuits can be formed by adding additional conductive patterns and additional conductive elements.

Claims

1. A multi-part reactive device comprising:

a substrate having a first conductive area and a second conductive area disposed thereon;

a first conductive element having a first terminal connected to the first conductive area, and a second terminal connected to the second conductive area, wherein a first current loop is formed extending from the first conductive area, through the first terminal, through the first conductive element, through the second terminal, to the second conductive area;

a magnetically-effective core member captivated by the first conductive element to the substrate between the first terminal and the second terminal and encircling the current loop wherein the first conductive area, the first conductive element, the magnetically-effective core member, and the second conductive area form a first magnetic circuit;

wherein the first conductive element comprises a surface-mountable component;

wherein the substrate has a major surface and an opposing major surface, the multi-part reactive device further comprising at least one via connecting the major surface to the opposing major surface, wherein the first conductive area is disposed on the first major surface coinciding with the at least one via and wherein the first terminal is connected to a portion of the first conductive area coinciding with the at least one via.

2. A multi-part reactive device in accordance with claim 1 wherein the magnetically-effective core member has a doughnut geometry with a first side and an opposing second side.

3. A multi-part reactive device in accordance with claim 2 wherein the first conductive element faces the first side of the magnetically-effective core member and the second conductive area faces the second side of the magnetically-effective core member.

4. A multi-part reactive device in accordance with claim 1 further comprising:

a thermally conductive baseplate connected to the at least one via coincident with the opposing major surface.

5. A multi-part reactive device comprising:

a substrate having a first conductive area and a second conductive area disposed thereon;

a first conductive element having a first terminal connected to the first conductive area, and a second terminal connected to the second conductive area, wherein a first current loop is formed extending from the first conductive area, through the first terminal, through the first conductive element, through the second terminal, to the second conductive area;

a magnetically-effective core member captivated by the first conductive element to the substrate between the first terminal and the second terminal and encircling the current loop wherein the first conductive area, the first conductive element, the magnetically-effective core member, and the second conductive area form a first magnetic circuit;

a third conductive area electrically connected to and extending apart from the second conductive area;

a fourth conductive area disposed on the substrate electrically isolated from the first conductive area, the second conductive area and the third conductive area;

a second conductive element having a third terminal connected to the third conductive area and a fourth terminal connected to the fourth conductive area, wherein the third conductive area, the second conductive element, the magnetically-effective core member, and the fourth conductive area form a second magnetic circuit coupled to the first magnetic circuit;

wherein the substrate has a first major surface and a second major surface opposing the first major surface, the multi-part reactive device further comprising;

at least one via connecting the major surface to the opposing major surface, wherein the first conductive area is disposed on the first major surface coinciding with the at least one via and wherein the first terminal is connected to a portion of the first conductive area coinciding with the at least one via.

6. A multi-part reactive device comprising:

a substrate having a first conductive area and a second conductive area disposed thereon;

a first conductive element having a first terminal connected to the first conductive area, and a second terminal connected to the second conductive area, wherein a first current loop is formed extending from the first conductive area, through the first terminal, through the first conductive element, through the second terminal, to the second conductive area;

a magnetically-effective core member captivated by the first conductive element to the substrate between the first terminal and the second terminal and encircling the current loop wherein the first conductive area, the first conductive element, the magnetically-effective core member, and the second conductive area form a first magnetic circuit;

a third conductive area electrically connected to and extending apart from the second conductive area;

a fifth conductive area disposed on the substrate electrically isolated from the first conductive area, and extending between the second conductive area, and the third conductive area;

a sixth conductive area disposed on the substrate electrically isolated from the fifth conductive area; and

a capacitor connected between the fifth conductive area, and the sixth conductive area.

7. A multi-part reactive device comprising:

a substrate having a first conductive area and a second conductive area disposed on a first major surface and an opposing conductive area disposed on a second major surface opposing the first major surface, wherein the opposing conductive area is electrically connected to the second conductive area by at least one via, and wherein the opposing conductive area is at least in part coincident with the first conductive area;

a first conductive element having a first terminal connected to the first conductive area, and a second terminal, connected to the second conductive area, wherein a current loop is formed extending from the first conductive area, to the first terminal, to the first conductive element to the second terminal, to the second conductive area to the at least one via to the opposing conductive area; and

a magnetically-effective core member captivated by the first conductive element to the substrate between the first terminal and the second terminal and encircling the current loop wherein the first conductive area, the first conductive element, the magnetically-effective core member, the second conductive area the at least one via and the opposing conductive area form a first magnetic circuit.

8. A multi-part reactive device in accordance with claim 7 wherein the first conductive element comprises a surface-mountable component.

9. A multi-part reactive device in accordance with claim 7 wherein the first conductive element comprises a through hole component, and wherein a portion of the first conductive element extends through the at least one via electrically connecting the second conductive area to the opposing conductive area.

10. A multi-part reactive device comprising:

a first molded thermoplastic device having a first conductive area disposed extending from a first surface to a fourth surface positioned apart from the first surface, and a second conductive area disposed extending from the first surface to a second surface positioned apart from the first surface, wherein the first conductive area and the second conductive area are electrically isolated;

a second molded thermoplastic device having major surface with a third conductive area and a fourth conductive area disposed thereon, wherein the third conductive area and the fourth conductive area are electrically isolated; and

a magnetically-effective core member captivated between the first surface and the second surface by the second molded thermoplastic device, wherein a first portion of the first conductive area is connected to a first portion of the third conductive area and a first portion of the second conductive area is connected to a second portion of the third conductive area.

11. A multi-part reactive device in accordance with claim 10 wherein the first molded thermoplastic device further comprises a third surface, a fourth surface, and a fifth surface, wherein the first surface, the third surface, and the fifth surface are positioned in a substantially coplanar orientation, and the second surface and the fourth surface are positioned in a substantially coplanar orientation.

12. A multi-part reactive device in accordance with claim 11 wherein the first conductive area extends from the third surface to the fourth surface to the first surface, and the second conductive area extends from the first surface to the second surface to the fifth surface, wherein the major surface of the second molded thermoplastic device abuts the third surface, the fifth surface, and the first surface of the first molded thermoplastic device.

13. A multi-part reactive device in accordance with claim 12 wherein a second portion of the second conductive area is connected to a first portion of the fourth conductive area.