Extended E matrix integrated magnetics (MIM) core

• US 7,633,369 B2
• Filed: 10/02/2007
• Issued: 12/15/2009
• Est. Priority Date: 04/18/2002
• Status: Expired due to Term

• Current Assignee: Flextronics International USA Incorporated (Flex, Ltd.)
• Original Assignee: Flextronics International USA Incorporated (Flex, Ltd.)
• Inventors: Chandrasekaran, Sriram, Mehrotra, Vivek
• Primary Examiner(s): NGUYEN, TUYEN T
• Application Number:
  US11/866,152
• Publication Number:
  US 20080024259A1
• Time in Patent Office: 805 Days
• Field of Search: 336/65, 336/83, 336/170, 336180-186, 336/212, 336214-215, 336220-223
• US Class Current: 336/212
• CPC Class Codes: H01F 17/04 with magnetic core
• CPC Class Codes: H01F 2038/006 matrix transformer consisting of several interconnected individual transformers working as a whole
• CPC Class Codes: H01F 27/24 Magnetic cores
• CPC Class Codes: H01F 27/255 made from particles H01F27/26 takes precedence
• CPC Class Codes: H01F 3/08 made from powder powder coatings on sheets H01F3/02; on strips or ribbons H01F3/04; on wires H01F3/06
• CPC Class Codes: H01F 30/06 characterised by the structure
• CPC Class Codes: H02M 7/043 using transformers or inductors only
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

Abstract

A matrix integrated magnetics (MIM) “Extended E” core in which a plurality of outer legs are disposed on a base and separated along a first outer edge to define windows therebetween. A center leg is disposed on the top region of the base and separated from the outer legs to define a center window. The center leg is suitably positioned along a second outer edge opposite the first or between outer legs positioned along opposing outer edges. A plate is disposed on the outer legs opposite the base.

Claims

1. A matrix integrated magnetic (MIM) core, comprising:

a base having first and second outer edges separated by a top region;

a plurality of outer legs on top of said base along two opposite edges of said base defining windows therebetween;

a center leg on said top region of said base disposed along a center of said base between said outer legs, separated from and spanning said outer legs to define two center windows; and

a plate opposite said base that covers said outer legs and windows therebetween, said center leg and said center windows.

2. The MIM core of claim 1, wherein said plurality of outer legs exceeds two.

3. The MIM core of claim 1, wherein said plurality of outer legs are disposed parallel to each other and perpendicular to said center leg.

4. The MIM core of claim 1, wherein a width of said center windows is constant between said center leg and each of said plurality of outer legs.

5. The MIM core of claim 1, wherein said base is rectangular.

6. The MIM core of claim 1, wherein ones of said plurality of outer legs have a winding coupled thereto.

7. The MIM core of claim 1, wherein said plurality of outer legs have primary and second windings coupled thereto.

8. The MIM core of claim 1, wherein said center leg has a winding coupled thereto.

9. The MIM core of claim 1, wherein said center leg is one piece.

10. The MIM core of claim 1, wherein said center leg is shorter than said plurality of outer legs and forms an air gap between said center leg and said plate.

11. A method of forming a matrix integrated magnetic (MIM) core, comprising:

forming a base having first and second outer edges separated by a top region;

forming a plurality of outer legs on top of said base along two opposite edges of said base defining windows therebetween;

forming a center leg on said top region of said base disposed along a center of said base between said outer legs, separated from and spanning said outer legs to define two center windows; and

placing a plate opposite said base that covers said outer legs and windows therebetween, said center leg and said center windows.

12. The method of claim 11, wherein said plurality of outer legs exceeds two.

13. The method of claim 11, wherein said plurality of outer legs are disposed parallel to each other and perpendicular to said center leg.

14. The method of claim 11, wherein a width of said center windows is constant between said center leg and each of said plurality of outer legs.

15. The method of claim 11, wherein said base is rectangular.

16. The method of claim 11, wherein ones of said plurality of outer legs have a winding coupled thereto.

17. The method of claim 11, wherein said plurality of outer legs have primary and second windings coupled thereto.

18. The method of claim 11, wherein said center leg has a winding coupled thereto.

19. The method of claim 11, wherein said center leg is one piece.

20. The method of claim 11, wherein said center leg is shorter than said plurality of outer legs and forms an air gap between said center leg and said plate.