LOW PROFILE LAYERED COIL AND CORES FOR MAGNETIC COMPONENTS

• US 20100259351A1
• Filed: 04/23/2010
• Published: 10/14/2010
• Est. Priority Date: 09/12/2006
• Status: Active Grant

• Current Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: Cooper Technologies Company (Eaton Corporation PLC.)
• Inventors: Bogert, Robert James, Yan, Yipeng, Doljack, Frank Anthony, Kamath, Hundi Panduranga
• Granted Patent: US 8,466,764 B2
• Time in Patent Office: Days
• US Class Current: 336/200
• CPC Class Codes: H01F 17/0006 Printed inductances printed coils for dynamo-electric machines H02K3/26; printed circuits H05K
• CPC Class Codes: H01F 17/04 with magnetic core
• CPC Class Codes: H01F 2027/2819 Planar transformers with printed windings, e.g. surrounded by two cores and to be mounted on printed circuit
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 5/003 Printed circuit coils

Abstract

A low profile magnetic component includes at least one coil layer defining a generally planar coil winding having a center area and a number of turns extending about the center area. A body encloses the coil layer, and is fabricated from one of a dielectric material and a magnetic material. A magnetic core material occupies at least the center area of the coil layer.

Claims

1. A magnetic component assembly comprising:

at least one coil defining a coil winding having a center area and a number of turns extending about the center area;

a body enclosing and embedding the coil layer, wherein the body is fabricated from one of a dielectric material and a magnetic material, and

a magnetic core material occupying at least the center area of the coil layer and a center area of the body, wherein the electrical and magnetic properties of the body and the magnetic core material are different from one another.

2. The magnetic component assembly of claim 1, wherein the body includes a first layer, the first layer including a core opening defining a receptacle for the introduction of a magnetic core material.

3. The magnetic component assembly of claim 2, wherein the body further comprises a second layer, and both of the first and second layers comprise a core opening extending therethrough.

4. The magnetic component assembly of claim 3, wherein the at least one coil layer includes a core opening extending therethrough in the center area.

5. The magnetic component assembly of claim 4, wherein the magnetic core material comprise a magnetic core element separately provided from the first and second layers, the magnetic core element extending through the core openings of the first and second magnetic sheets and the core opening of the at least one coil layer.

6. The magnetic component assembly of claim 5, wherein the magnetic core material is formed into one of a drum core and a rod core.

7. The magnetic component assembly of claim 6, wherein the body comprises a coil portion fabricated from a first magnetic material and outer portions fabricated from a second magnetic material, the second magnetic material having different magnetic properties than the first magnetic material.

8. The magnetic component assembly of claim 7, wherein the magnetic core material is fabricated from a third magnetic material, the third magnetic material having different magnetic properties than the first and second magnetic materials.

9. The magnetic component assembly of claim 6, wherein the magnetic core material includes a center portion that is substantially entirely embedded between the outer portions of the magnetic body.

10. The magnetic component assembly of claim 5, wherein both of the first and second layers comprise a magnetic material, the magnetic core material of the first and second layers having different magnetic properties from the magnetic core element.

11. The component of claim 1, wherein the at least one coil layer comprises a double sided coil.

12. The magnetic component assembly of claim 1, wherein the at least coil layer comprises a flexible circuit coil.

13. The magnetic component assembly of claim 12, wherein the flexible circuit coil includes at least one termination pad.

14. The magnetic component assembly of claim 1, wherein the at least coil comprises a plurality of spaced apart coil layers.

15. The magnetic component assembly of claim 14, wherein the spaced apart coil layers are connected by at least one via.

16. The magnetic component assembly of claim 1, wherein the body includes a first layer, the first layer comprising a polymer-based film.

17. The magnetic component assembly of claim 16, wherein the polymer-based film is a polyimide film.

18. The magnetic component assembly of claim 1, wherein the body includes a first layer, the first layer comprising a liquid crystal polymer.

19. The magnetic component assembly of claim 1, wherein the at least one coil layer comprises an electroformed coil winding formed independently of the first and second layers.

20. The magnetic component assembly of claim 1, wherein the body includes a first layer, the first layer comprising a moldable magnetic material.

21. The magnetic component assembly of claim 20, wherein the moldable magnetic material comprises at least one of Ferrite particles, Iron (Fe) particles, Sendust (Fe—

Si—

Al) particles, MPP (Ni—

Mo—

Fe) particles, HighFlux (Ni—

Fe) particles, Megaflux (Fe—

Si Alloy) particles, iron-based amorphous powder particles, cobalt-based amorphous powder particles, and equivalents and combinations thereof.

22. The magnetic component assembly of claim 21, wherein the body includes a second layer, the second layer comprising a moldable magnetic material.

23. The magnetic component assembly of claim 22, wherein the moldable magnetic material of the second layer has different magnetic properties from the moldable magnetic material of the first layer.

24. The magnetic component assembly of claim 1, further comprising surface mount terminations.

25. The magnetic component assembly of claim 1, wherein the component is an inductor.

26. The magnetic component assembly of claim 1, wherein the inductor is a miniaturized inductor.

27. The magnetic component assembly of claim 1, wherein the body comprises stacked magnetic layers, and wherein the magnetic core material is provided integrally with the magnetic layers.