Magnetic element having improved transformers and common mode chokes

• US 9,101,071 B2
• Filed: 11/22/2010
• Issued: 08/04/2015
• Est. Priority Date: 11/20/2009
• Status: Active Grant

• Current Assignee: Hon Hai Precision Industry Co., Ltd.
• Original Assignee: Hon Hai Precision Industry Co., Ltd.
• Inventors: Wu, Li-Chun, Xu, Yong-Chun, Huang, Chao-Tung, Lin, Chih-Min, Hu, Jian-She, Huang, Kuo-Chuan
• Primary Examiner(s): Pape, Zachary M
• Assistant Examiner(s): BURTNER, DOUGLAS R
• Application Number:
  US12/951,099
• Publication Number:
  US 20110122589A1
• Time in Patent Office: 1,716 Days
• Field of Search: 336/200, 439/607.1, 439/620.05
• US Class Current: 1/1
• CPC Class Codes: H01F 27/28 Coils; Windings; Conductive connections
• CPC Class Codes: H01F 27/2804 Printed windings
• CPC Class Codes: H01R 12/526 the printed circuits being on the same board with plated through holes H05K3/42
• CPC Class Codes: H01R 13/6633 with inductive component, e.g. transformer
• CPC Class Codes: H05K 1/165 incorporating printed inductors
• CPC Class Codes: H05K 1/181 associated with surface mounted components
• CPC Class Codes: H05K 2201/086 for inductive purposes, e.g. printed inductor with ferrite core
• CPC Class Codes: H05K 2201/097 Alternating conductors, e.g. alternating different shaped pads, twisted pairs; Alternating components
• CPC Class Codes: H05K 2201/1003 Non-printed inductor
• CPC Class Codes: H05K 2201/1034 Edge terminals, i.e. separate pieces of metal attached to the edge of the printed circuit board [PCB]
• CPC Class Codes: Y10T 29/4913 Assembling to base an electrical component, e.g., capacitor, etc.

Abstract

A magnetic element (100) includes a board unit (2) including a paddle board (21) having a row of first conductive vias (251) and a row of second conductive vias (252) for insertion of terminals (3), a number of embedded magnetic components (22), and a number of SMDs (surface mount devices) (23) mounted on the paddle board by SMT (surface mount technology). Each embedded magnetic component includes a magnetic core (221) embedded in the paddle board, and a number of PCB (printed circuit board) layout traces (222) disposed in the paddle board. Each PCB layout trace includes a first PCB layout trace (222a) encircling around the magnetic core and connecting with the first conductive via, and a second PCB layout trace (222b) encircling around the magnetic core and connecting with the SMD.

Claims

1. A magnetic element for being mounted onto a printed circuit board, comprising:

an insulative housing having a base portion and two pairs of periphery walls upwardly surrounding the base portion to define a receiving cavity, the receiving cavity sealed by the base portion and the two pairs of periphery walls and having an opening facing upwardly;

two rows of terminals respectively fixed to two of the periphery walls, each of the terminals having a body portion fixed by corresponding periphery wall, a connecting portion extending from one end of the body portion into the receiving cavity and bent upward to form a pin end, and a soldering portion connected to an opposite end of the body portion and extending outwardly to form a horizontal soldering pad;

a board unit comprising a paddle board and a plurality of embedded transformers, each embedded transformer including a magnetic core, the paddle board having a first side face, a second side face, a row of first conductive vias, and a row of second conductive vias, the conductive vias extending through the first side face and the second side face, the transformer embedded between the first side face and the second side face and connected to the conductive vias; and

plural SMD type common mode chokes;

wherein

the board unit is mounted into the receiving cavity through the opening and the pin ends of the terminals penetrate and are soldered in the conductive vias; and

wherein

the soldering pads of the terminals are set in a horizontal plane; and

the first side face of the paddle board is proximal to the base portion, the common mode chokes are mounted on the first side face of the paddle board, and each embedded transformer is electrically connected with a corresponding SMD type common mode choke through the paddle board between the two rows of terminals.

2. The magnetic element as claimed in claim 1, wherein the two rows of terminals are insert-molded to the two periphery walls of said insulative housing.