Wire-less inductive devices and methods

• US 8,860,543 B2
• Filed: 11/13/2007
• Issued: 10/14/2014
• Est. Priority Date: 11/14/2006
• Status: Active Grant

• Current Assignee: Pulse Electronics Incorporated (Yageo Corporation)
• Original Assignee: Pulse Electronics Incorporated (Yageo Corporation)
• Inventors: Schaffer, Christopher P., Gutierrez, Aurelio J.
• Primary Examiner(s): NGUYEN, TUYEN T
• Application Number:
  US11/985,156
• Publication Number:
  US 20080186124A1
• Time in Patent Office: 2,527 Days
• Field of Search: 336/65, 336/192, 336/200, 336220-223, 336/232, 336205-208, 257/531
• US Class Current: 336/200
• CPC Class Codes: H01F 17/0033 with the coil helically wound around a magnetic core
• CPC Class Codes: H01F 27/2895 Windings disposed upon ring cores
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

Abstract

A wire-less inductive device and methods of manufacturing and use are disclosed. In one embodiment, the inductive device comprises a plurality of through-hole vias which act to replace windings disposed around a magnetically permeable core. In another embodiment, the inductive device comprises a plurality of connection elements disposed or formed within channels which act as windings disposed around a magnetically permeable core. In a second aspect of the invention, a method of manufacturing the aforementioned inductive devices is disclosed. In a third aspect of the invention, an electronics assembly and circuit comprising the wire-less inductive devices are disclosed.

Claims

1. An inductive device, comprising:

a plurality of substrates, said substrates collectively having a plurality of conductive pathways formed therein comprised of a first conductive pathway and a second conductive pathway, each of said plurality of conductive pathways defined by a plurality of vias comprised of a plurality of outer vias and a plurality of inner vias; and

a plurality of magnetically permeable cores comprising a first magnetically permeable core and a second magnetically permeable core, said cores disposed at least partly between said plurality of substrates;

wherein said magnetically permeable cores are stacked in a substantially vertical fashion such that at least a portion of said magnetically permeable cores are substantially parallel yet not co-extensive; and

wherein said first magnetically permeable core is associated with said first conductive pathway and said second magnetically permeable core is associated with said second conductive pathway, said first and second conductive pathways being distinct from one another.

2. The inductive device of claim 1, wherein said inductive device comprises a plurality of transformers, and said magnetically permeable cores comprise a toroidal shape situated about a central axis, said toroidal shape further comprising an outer and an inner radial diameter extending radially from said central axis.

3. The inductive device of claim 2, wherein at least a portion of said plurality of conductive pathways comprises an outer winding diameter and an inner winding diameter, said outer winding diameter being larger then said outer radial diameter and said inner winding diameter being smaller than said inner radial diameter.

4. The inductive device of claim 3, wherein said plurality of conductive pathways collectively comprise a plurality of traces disposed on at least two total surfaces of said plurality of substrates.

5. The inductive device of claim 4, wherein said first conductive pathway comprises at least two windings, said at least two windings comprising a uniform pitch spacing.

6. The inductive device of claim 3, wherein said outer winding diameter comprises a first outer winding diameter and a second outer winding diameter and said inner winding diameter comprises a first inner winding diameter and a second inner winding diameter, said first and second outer and inner winding diameters each being unequal in radial diameter.

7. The inductive device of claim 1, wherein at least one of said plurality of substrates comprises a plurality of plated pads, said plurality of plated pads adapted for surface mounting said inductive device to an external substrate.

8. The inductive device of claim 1, wherein said plurality of conductive pathways are disposed so as to be orientation-agnostic during assembly.

9. A multiple core inductive device, comprising:

a plurality of substrates comprising a pair of outer substrates and one or more inner substrates, said substrates having a plurality of conductive pathways, said plurality of conductive pathways defined by a plurality of vias comprised of a plurality of outer vias and a plurality of inner vias; and

a plurality of magnetically permeable cores, said plurality of cores each disposed at least partly between adjacent ones of each of said plurality of substrates;

wherein a first one of said plurality of magnetically permeable cores has a first conductive pathway associated therewith and a second one of said plurality of magnetically permeable cores has a second conductive pathway associated therewith, said first and second conductive pathways being distinct from one another.

10. The multiple core inductive device of claim 9, wherein at least one of said plurality of substrates further comprises one or more electronic component receiving pads.

11. The multiple core inductive device of claim 9, wherein each of said plurality of magnetically permeable cores comprises a toroidal shape situated about a respective central axis;

and

wherein each said toroidal shape further comprises an outer and an inner radial diameter extending radially from said respective central axis.

12. The multiple core inductive device of claim 11, wherein at least a portion of said plurality of conductive pathways associated with a first of said toroidal shapes comprises an outer winding diameter and an inner winding diameter, said outer winding diameter being larger then said outer radial diameter of said first of said toroidal shapes and said inner winding diameter being smaller than said inner radial diameter of said first of said toroidal shapes.

13. The multiple core inductive device of claim 12, wherein said plurality of conductive pathways collectively comprise a plurality of traces disposed on at least two total surfaces of said plurality of substrates and a plurality of conductive vias disposed within said plurality of substrates.

14. The multiple core inductive device of claim 9, wherein at least one of said plurality of substrates comprises a plurality of plated pads, said plurality of plated pads adapted for surface mounting said multiple core inductive device to an external substrate.