Space-efficient PCB-based inductor

• US 10,172,237 B1
• Filed: 08/28/2017
• Issued: 01/01/2019
• Est. Priority Date: 08/28/2017
• Status: Active Grant

• Current Assignee: ABL IP Holding LLC (Acuity Brands, Inc.)
• Original Assignee: OSRAM Sylvania Inc. (Ams-Osram AG)
• Inventors: Safaee, Alireza, Dreeben, Thomas, Cross, John
• Primary Examiner(s): Chen, Xiaoliang
• Application Number:
  US15/687,996
• Time in Patent Office: 491 Days
• Field of Search: 174260, 336180, 336200, 324127, 324210, 324260
• CPC Class Codes: H01F 17/0013 with stacked layers
• CPC Class Codes: H01F 2017/004 with the coil helically wound around an axis without a core
• CPC Class Codes: H01F 27/006 with special arrangement or spacing of turns of the winding(s), e.g. to produce desired self-resonance
• CPC Class Codes: H05K 1/165 incorporating printed inductors

Abstract

A space-efficient Printed Circuit Board (PCB)-based inductor includes a first set of inductor turns formed on the printed circuit board and arranged to form a first toroidal end section, a second set of inductor turns formed on the printed circuit board and arranged to form a first cylindrical side section, a third set of inductor turns formed on the printed circuit board and arranged to form a second toroidal end section, and a fourth set of inductor turns formed on the printed circuit board and arranged to form a second cylindrical side section. The first toroidal end section, first cylindrical side section, second toroidal end section, and second cylindrical side section are connected in series.

Claims

1. An inductor, comprising:

a first set of inductor turns arranged to form a first toroidal end section;

a second set of inductor turns arranged to form a first cylindrical side section;

a third set of inductor turns arranged to form a second toroidal end section; and

a fourth set of inductor turns arranged to form a second cylindrical side section;

wherein;

the first toroidal end section, first cylindrical side section, second toroidal end section, and second cylindrical side section are connected in series; and

the turns of the first and third sets of inductor turns each has a first length, the turns of the second and fourth sets of inductor turns each has a second length, and wherein the second length is longer than the first length.

2. The inductor of claim 1, wherein the first toroidal end section has turns that radiate generally outwardly from a first approximate central focal point, and wherein the second toroidal end section has turns that radiate generally outwardly from a second approximate central focal point.

3. The inductor of claim 2, wherein the turns of the first toroidal end section and the turns of the second toroidal end section extend through an arc encompassing approximately 180 degrees of a circle.

4. The inductor of claim 1, wherein at least some of the turns of the second set of inductor turns are longer than at least some of the turns of the first set of inductor turns.

5. The inductor of claim 1, wherein the first cylindrical side section is connected between the first and second toroidal end sections, and wherein the second cylindrical side section is connected between the second and first toroidal end sections.

6. The inductor of claim 1, wherein each turn is formed from a top wire, a bottom wire, an inner connector, and an outer connector, at least one of the inner connector and the outer connector interconnecting the top wire and bottom wire.

7. The inductor of claim 6, wherein the top and bottom wires of the turns in the first and second cylindrical side sections are longer than top and bottom wires of the turns in the first and second toroidal end sections.

8. The inductor of claim 6, wherein the top wires and bottom wires of the first toroidal end section are the same length as the top wires and bottom wires of the second toroidal end section.