Variable inductor with non-magnetic core and method of manufacture therefor

• US 8,248,198 B2
• Filed: 07/22/2009
• Issued: 08/21/2012
• Est. Priority Date: 07/22/2009
• Status: Active Grant

• Current Assignee: Knowles Cazenovia, Inc. (Knowles Corporation)
• Original Assignee: Johanson Manufacturing Corporation
• Inventors: Imbimbo, Mark Alan, Vecchio, Ronald Joseph
• Primary Examiner(s): Musleh, Mohamad
• Assistant Examiner(s): LIAN, MANG TIN BIK
• Application Number:
  US12/507,251
• Publication Number:
  US 20110018668A1
• Time in Patent Office: 1,126 Days
• Field of Search: None
• US Class Current: 336/10
• CPC Class Codes: H01F 21/005 Inductances without magnetic core
• CPC Class Codes: H01F 21/06 by movement of core or part of core relative to the windings as a whole
• CPC Class Codes: Y10T 29/49073 by assembling coil and core

Abstract

A variable inductor is provided. The variable inductor includes a dielectric core having a helical thread on an outer surface thereof for receiving the coil, and a non-magnetic element positioned coaxially within the core. The non-magnetic element could be provided in the form of a bushing or a solid rod, and could be manufactured from any suitable, non-magnetic metal, such as copper, brass, etc.

Claims

1. A variable inductor, comprising:

a dielectric core having a threaded portion on an outer surface thereof and a recess coaxial with the central longitudinal axis of the dielectric core;

a solid, non-magnetic rod positioned within the coaxial recess, the rod extending beyond half the length of the dielectric core; and

a coil received by the threaded portion of the dielectric core,

wherein the dielectric core can be rotated to move the rod and the threaded portion of the dielectric core with respect to the coil from a first position where the entire length of the rod and the threaded portion of the dielectric core are surrounded by the coil to a second position where a portion of the rod extends beyond the coil, to vary the inductance of the variable inductor.

2. The variable inductor of claim 1, wherein the dielectric core comprises a polytetrafluoroethylene dielectric material.

3. The variable inductor of claim 2, wherein the rod comprises a solid copper rod.

4. The variable inductor of claim 1, wherein the coil comprises terminal ends for mounting the variable inductor to a surface.

5. A variable inductor, comprising:

a polytetrafluoroethylene dielectric core having a threaded portion on an outer surface thereof and a recess coaxial with the central longitudinal axis of the dielectric core;

a metallic, non-magnetic element positioned within the coaxial recess, the non-magnetic element extending beyond half the length of the dielectric core; and

a coil received by the threaded portion of the dielectric core,

wherein the dielectric core can be rotated to move the non-magnetic element and the threaded portion of the dielectric core with respect to the coil from a first position where the entire length of the rod and the threaded portion of the dielectric core are surrounded by the coil to a second position where a portion of the rod extends beyond the coil, to vary the inductance of the inductor.

6. The variable inductor of claim 5, wherein the non-magnetic element comprises a solid rod.

7. The variable inductor of claim 5, wherein the non-magnetic element comprises a bushing.

8. The variable inductor of claim 5, wherein the coil comprises terminal ends for mounting the variable inductor to a surface.

9. A method for manufacturing a variable inductor, comprising the steps of:

forming a dielectric core having a helical threaded portion on an outer surface thereof and a recess coaxial with the central longitudinal axis of the dielectric core;

forming a non-magnetic element;

positioning the non-magnetic element within the recess of the dielectric core, the non-magnetic element extending beyond half the length of the dielectric core; and

forming a coil of wire about the dielectric core so that the dielectric core can be rotated to move the non-magnetic element and the threaded portion of the dielectric core from a first position where the entire length of the non-magnetic element and the threaded portion of the dielectric core are surrounded by the coil to a second position where a portion of the rod extends beyond the coil.

10. The method of claim 9, wherein the step of forming the dielectric core comprises drilling the dielectric core to form the recess.

11. The method of claim 9, wherein the step of forming the non-magnetic element comprises forming a solid rod of non-magnetic material.

12. The method of claim 9, wherein the step of forming the non-magnetic element comprises forming a bushing of non-magnetic material.

13. The method of claim 9, further comprising the step of providing an adhesive within the recess prior to positioning the non-magnetic element within the recess.

14. The method of claim 9, further comprising pre-tinning terminal ends of the coil.