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Bobbin and core assembly configuration and method for E-core and I-core combination

  • US 9,991,045 B1
  • Filed: 10/27/2015
  • Issued: 06/05/2018
  • Est. Priority Date: 11/04/2014
  • Status: Active Grant
First Claim
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1. A magnetic assembly comprising:

  • a bobbin comprising a first end flange and a second end flange, each end flange having a respective outer surface, a passageway extending through the bobbin from the first end flange to the second end flange, the passageway having a passageway height, the passageway including a plurality of crushable passageway ribs extending longitudinally from the first end flange toward the second end flange, and at least one winding wound about the passageway, the bobbin further comprising a channel wall parallel to the outer surface of the first end flange, the channel wall having an inner surface, the inner surface of the channel wall displaced from the outer surface of the first end flange to define an I-core receiving channel between the outer surface of the first end flange and the inner surface of the channel wall, the inner surface of the channel wall having a channel wall height approximately equal to the passageway height, the I-core receiving channel having a channel width between the outer surface of the first end flange and the inner surface of the channel wall, the I-core receiving channel extending longitudinally and vertically with respect to the outer surface of the first end flange;

    an E-core having a main body with an inner surface, and having a first outer leg, a second outer leg, and a middle leg extending from the inner surface of the main body, each of the first outer leg, the second outer leg and the middle leg having a respective end surface displaced away from the inner surface of the main body, the middle leg of the E-core positioned in the passageway of the bobbin with at least a portion of the middle leg in crushing frictional engagement with the passageway ribs, the inner surface of the main body positioned against the outer surface of the second end flange, the respective end surfaces of the first outer leg and the second outer leg substantially flush with the outer surface of the first end flange; and

    an I-core in the form of a rectangular parallelepiped, the I-core having a first longitudinal surface and a second longitudinal surface defining a thickness of the I-core therebetween, the thickness of the I-core substantially equal to the channel width, the I-core positioned in the I-core receiving channel with the first longitudinal surface in frictional engagement with the outer surface of the first end flange and with the second longitudinal surface in frictional engagement with the inner surface of the channel wall, the frictional engagement of the first longitudinal surface with the outer surface of the first end flange and the frictional engagement of the second longitudinal surface with the inner surface of the channel wall sufficient to retain the I-core in a fixed position, both longitudinally and vertically, within the I-core receiving channel.

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