Surface mount compatible planar magnetics for high shock environments

Abstract

A winding assembly, such as a transformer or an inductor, includes a spring clip and a retaining clip for mechanically coupling the winding assembly to a printed circuit board (PCB) or a printed wiring board (PWB). These clips provide structural rigidity to the winding assembly, allowing it to remain operational during high-impact events. Furthermore, the clips are compressed and positioned beneath a thermal pad below the winding assembly, providing sufficient heat transfer surface area to dissipate heat away from the winding assembly.

Description

Surface mount compatible planar magnets for high shock environments The present invention relates to a winding total work ratio device, and more particularly, to a mechanical attachment for a winding total work ratio device. As the power density of electronic power devices (transformers, inductors, etc.) increases, custom power devices are designed to provide the power required for cutting-edge performance. Traditional high-power devices (such as DC-DC transformers and inductors) require extensive manual assembly of heat sinks and soldering of the devices to circuit boards. The manual assembly process is time-consuming and costly, and thermal expansion stresses can be generated in the components of the high-power device during the heat dissipation and soldering processes. Therefore, a reliable, low-cost solution is needed to attach large custom power devices to circuit boards. In addition, large custom power devices are needed that can withstand high shock loads while minimizing the thermal expansion stresses traditionally experienced during the assembly process. According to one aspect of the present invention, a winding assembly configured to be coupled to a surface of a printed wiring board is disclosed. The winding assembly includes a winding, a ferrite core, a retaining clip, and a spring clip. The winding is at least partially surrounded by the ferrite core. The ferrite core includes a base and a cover. The retaining clip includes a first leg and a second leg, and the first and second legs are positioned adjacent to the surface of the printed wiring board. The spring clip is positioned at least partially above the cover of the ferrite core. The spring clip includes a third leg and a fourth leg, and the third and fourth legs are positioned adjacent to the surface of the printed wiring board. FIG1 is a perspective view of a first embodiment of a winding assembly 10. FIG2 is a cross-sectional view of the winding assembly 10 taken along section line AA shown in FIG1. ​​FIG3 is an exploded view of the first embodiment of the winding assembly 10. FIG4 is a perspective view of the ferrite core 14 of the first embodiment of the winding assembly 10. FIG5 is a perspective view of the first embodiment of the winding assembly 10 coupled to a printed wiring board 11. FIG1 through FIG5 will be discussed together. The winding assembly 10 includes a winding 12, a ferrite core 14, a spacer 16, a first pad 18, a second pad 20, a retaining clip 22, and a spring clip 24. The winding assembly 10 can be a transformer, an inductor, or other electronic device configured to be electrically and mechanically coupled to the printed wiring board 11. Although the winding assembly 10 is discussed as being coupled to a surface of the printed wiring board 11, it should be understood that this also includes printed circuit boards, microchips, motherboards, chips, and microcircuits, among other options. Winding 12 is the core or center component of winding assembly 10 and includes a current-carrying conductor wound around a center or core component. Thus, winding 12 includes one or more turns of a current-carrying conductor forming a continuous coil through which current can flow. In the example shown in FIG. 1 , winding 12 includes three separate layers coupled together to form winding 12. Winding 12 includes a first printed circuit board 26, a second printed circuit board 28, a continuous coil 30, and a plurality of terminals 32. Continuous coil 30 is positioned between first and second printed circuit boards 26, 28 and is wound around a center or core component (not explicitly shown) of winding 12. Furthermore, continuous coil 30 extends through second printed circuit board 28, such that one end of continuous coil 30 is electrically coupled to one of a plurality of terminals 32 via a standard electrical connection. As best shown in FIG. 5 , each of the plurality of terminals 32 is electrically coupled to printed wiring board 11, thereby allowing current to flow between winding 12 and printed wiring board 11. The ferrite core 14 is a magnetic core made of ferrite, on which the windings 12 are formed. As best shown in FIG. 4 , the ferrite core 14 includes a base 34, a cover 36, and a circular post 38. The base 34 is generally rectangular in shape and is coupled to the cover 36 along its shorter edges. The cover 36 is positioned above and coupled to the base 34 and includes a first notch 40 and a second notch 42. The first notch 40 extends inward from a first outer long edge of the cover 36 toward the center of the cover 36. The second notch 42 extends inward from a second outer long edge of the cover 36 toward the center of the cover 36. The first and second notches 40, 42 are included in the ferrite core 14 to allow continuous coils 30 to be routed through the ferrite core 14 without interference. As best shown in FIG. 3 , a single continuous coil 30 is routed through the second notch 42, while no coils are routed through the first notch 40. The inclusion of both the first notch 40 and the second notch 42 allows for flexibility in the design of the winding assembly 10 and provides the ability to route the continuous coil 30 through either side of the ferrite core 14. The circular post 38 is generally located at a central location between the base 34 and the cover 36 of the ferrite core 14. The circular post 38 is a feature having a circular cross-section that extends from an upper surface of the base 34 to an inner surface of the cover 36. The circular post 38 of the ferrite core 14 is a component / feature of the winding assembly 10 in which the continuous coil 30 is wound, as previously discussed. As best shown in Figures 1, 3, and 5, the ferrite core 14 at least partially surrounds the winding 12. More specifically, a central portion of the winding 12 is surrounded and covered by the cover 36, and the outer four corners of the winding 12 extend outward beyond the base 34 and cover 36 of the ferrite core 14. In other words, when the base 34 and cover 36 of the ferrite core 14 are coupled together, a window or opening is formed between the base 34 and cover 36. The winding 12 is positioned within the window or opening and extends through and outward from both the base 34 and cover 36, such that the ferrite core 14 only surrounds a portion of the winding 12. Furthermore, the winding 12 extending beyond the edge of the ferrite core 14 allows each of the plurality of terminals 32 to be electrically coupled to the printed wiring board 11. In some examples, each of the plurality of terminals 32 can be coupled to electrical contacts on the printed wiring board 11 via a plurality of solders. The spacer 16 is positioned between an upper surface of the winding 12 and a lower or inner surface of the cover 36 of the ferrite core 14. Furthermore, the spacer 16 extends beyond both outer edges of the cover 36. More specifically, the spacer 16 extends beyond both long edges of the cover 36 in a direction perpendicular to the long edges of the cover 36. The spacer 16 extends beyond both long edges of the cover 36 such that an area of ​​the spacer 16 exists outside both long edges of the cover 36. In the illustrated example, the spacer 16 is a rectangular sheet, but in other embodiments, the spacer 16 can have any shape that substantially conforms to the outer perimeter of the winding 12. In some examples, the spacer 16 can be constructed from G10, FR4, or other composite materials. The spacer 16 is configured to prevent abrasive damage to the top surface of the winding 12 by providing a surface for the features of the spring clip 24 to contact and slide or rub against, as discussed further below. Furthermore, the spacer 16 is configured to provide electrical insulation between the spring clip 24 and the winding 12 , thereby preventing the flow of electrical current between the components. In the example shown, a small gap exists between one of the upper surfaces of spacer 16 and the lower or inner surface of cover 36. As the temperature of the components increases, the small gap allows for thermal expansion of winding 12, spacer 16, and ferrite core 14, while also preventing cracking or damage to ferrite core 14 due to the different thermal expansion coefficient characteristics between the components. More specifically, the small gap provides a location for winding 12 to increase in size vertically due to thermal expansion without inducing stress in ferrite core 14. If the small gap were not present and winding 12 were directly adjacent to cover 36, ferrite core 14 could crack due to the forces applied to the ferrite core during thermal expansion of the components. In other examples where the thermal expansion coefficients of the components are similar, the small gap may not be present. As best shown in Figures 2-3, the first pad 18 is positioned between a lower surface of the base 34 of the ferrite core 14 and an upper surface of the printed wiring board 11. The second pad 20 is positioned between an upper surface of the cover 36 of the ferrite core 14 and a lower or inner surface of the spring clip 24, as discussed further below. In the illustrated example, both the first pad 18 and the second pad 20 have a rectangular shape and are sized to be approximately the same size as the outer perimeter of the base 34 and the cover 36, respectively. In another example, the first pad 18 and the second pad 20 can have any shape that substantially conforms to the outer perimeter of the base 34 and the cover 36, respectively. In some examples, the first pad 18 and the second pad 20 are constructed from a graphite material having a maximum operating temperature of at least 235 degrees Celsius. In other examples, the first pad 18 and the second pad 20 can be constructed from any material having a maximum operating temperature of at least 235 degrees Celsius. The first and second pads 18, 20 having a maximum operating temperature of at least 235 degrees Celsius allow the winding assembly 10 to pass through the reflow process without melting or damaging the first and second pads 18, 20. In other words, the first and second pads 18, 20 having a maximum operating temperature below 235 degrees Celsius may result in damage or negative impact to the first and second pads 18, 20 during the reflow process. First pad 18 is configured to transfer heat generated by winding 12 away from winding 12, through printed wiring board 11, and out through one of the substrates of printed wiring board 11. Thus, first pad 18 is advantageously compressed beneath substrate 34 of ferrite core 14 to ensure sufficient heat transfer surface area between winding assembly 10 and printed wiring board 11. Compressing first pad 18 ensures that no ridges or air gaps exist between the bottom surface of first pad 18 and printed wiring board 11, and also ensures maximum heat transfer by utilizing the maximum amount of available heat transfer surface area of ​​first pad 18. Second pad 20 may also provide some heat transfer from ferrite core 14 outward to the surrounding environment. However, second pad 20 is primarily configured to evenly distribute the compressive forces induced by spring clip 24 and retaining clip 22 onto ferrite core 14. Thus, the second pad 20 is configured to provide a surface area that ensures equal compression of the winding assembly 10 by evenly compressing the surface area of ​​the first pad 18 positioned beneath the base 34 of the ferrite core 14 to produce better heat transfer characteristics. Both the retaining clip 22 and the spring clip 24 are positioned above the ferrite core 14, the first pad 18, and the second pad 20, and are coupled to the printed wiring board 11. Together, the retaining clip 22 and the spring clip 24 are configured to compress the ferrite core 14, the first pad 18, and the second pad 20 downwardly toward the printed wiring board 11. Furthermore, the retaining clip 22 and the spring clip 24 are also configured to exert a downward force on the winding 12, as discussed further below. In the illustrated embodiment, the retaining clip 22 and the spring clip 24 are depicted as separate components that interface with each other to secure the winding 12 to the printed wiring board 11. In another embodiment, the retaining clip 22 and the spring clip 24 may be a single component configured to secure the winding 12 to the printed wiring board 11. The retaining clip 22 includes a first leg 44 , a second leg 46 , an upper member 48 , a first arm 50 , a second arm 52 , a first threaded insert 54 , a second threaded insert 56 , a first hook 58 , and a second hook 60 . The first leg 44 and the second leg 46 are flanges of the retaining clip 22 and are oriented generally parallel to the upper surface of the printed wiring board 11 and generally parallel to each other. The first leg 44 and the second leg 46 are configured to directly abut the upper surface of the printed wiring board 11 when the retaining clip 22 is coupled to the printed wiring board 11. More specifically, the first leg 44 includes a first threaded insert 54 coupled to the first leg 44, and the second leg 46 includes a second threaded insert 56 coupled to the second leg 46. In some examples, the first threaded insert 54 and the second threaded insert 56 can be coupled to the first leg 44 and the second leg 46, respectively, through a press-fit operation, an outer diameter threaded connection, or a solder connection, among other options. The first threaded insert 54 and the second threaded insert 56 are configured to receive fasteners (e.g., threaded fasteners) that extend through the printed wiring board 11 from the bottom side thereof upward toward the winding assembly 10. Thus, the first threaded insert 54 and the second threaded insert 56 are configured to secure the retention clip 22 to the printed wiring board 11. In another example, the first leg 44 and the second leg 46 may include apertures extending through the first leg 44 and the second leg 46, thereby allowing a fastener to extend through the first leg 44 and the second leg 46 to couple with the threaded inserts positioned within the printed wiring board 11. The upper member 48 of the retaining clip 22 is a generally U-shaped member that extends between and connects the first leg 44 and the second leg 46. In other words, the upper member 48 extends vertically upward from the first leg 44, then extends horizontally, then extends vertically downward (creating a U-shaped member), and then connects to the second leg 46. The upper member 48 is configured to provide structure and support between the first leg 44 and the second leg 46, and therefore the entire retaining clip 22. The upper member 48 can be constructed from sheet metal or other thin metal material that can withstand bending operations to form the final shape of the upper member 48. A first arm 50 and a second arm 52 extend from the first leg 44, the second leg 46, and the upper member 48. More specifically, the first arm 50 extends outward from the first leg 44 and the upper member 48 at a perpendicular angle relative to the vertically extending portion of the upper member 48. Similarly, the second arm 52 extends outward from the second leg 46 and the upper member 48 at a perpendicular angle relative to the vertically extending portion of the upper member 48. The first arm 50 is positioned parallel to the second arm 52 so that the first and second arms 50, 52 extend in the same direction. The first and second arms 50, 52 can be constructed from sheet metal or other thin metal materials, similar to the upper member 48. The first arm 50 includes a first hook 58 positioned at a free distal end of the first arm 50. In other words, the end of the first arm 50 not coupled to the first leg 44 includes the first hook 58. The second arm 52 includes a second hook 60 positioned at a free distal end of the second arm 52. In other words, the end of the second arm 52 not coupled to the second leg 46 includes the second hook 60. The first hook 58 and the second hook 60 are configured to mate with and couple to features of the spring clip 24 , which are discussed below. The spring clip 24 includes a third leg 62, a fourth leg 64, a top member 66, a body 68, a lip 70, a first contact 72, a second contact 74, a third threaded insert 76, a fourth threaded insert 78, a first detent 80, a second detent 82, and an alignment pin 84. Although the spring clip 24 is described as having one alignment pin 84, it should be understood that in another embodiment, the spring clip 24 may include more than one alignment pin 84 to help properly align the spring clip 24 within the winding assembly 10. The third leg 62 and the fourth leg 64 are flanges of the spring clip 24 and are oriented generally parallel to the upper surface of the printed wiring board 11 and generally parallel to each other. The third leg 62 and the fourth leg 64 are configured to directly abut the upper surface of the printed wiring board 11 when the spring clip 24 is coupled to the printed wiring board 11. More specifically, the third leg 62 includes a third threaded insert 76 coupled to the third leg 62, and the fourth leg 64 includes a fourth threaded insert 78 coupled to the fourth leg 64. In some examples, the third threaded insert 76 and the fourth threaded insert 78 can be coupled to the third leg 62 and the fourth leg 64, respectively, through a press-fit operation, an outer diameter threaded connection, or a solder connection, among other options. The third threaded insert 76 and the fourth threaded insert 78 are configured to receive fasteners (e.g., threaded fasteners) that extend through the printed wiring board 11 from the bottom side thereof upward toward the winding assembly 10. Thus, the third and fourth threaded inserts 76, 78 are configured to secure the spring clip 24 to the printed wiring board 11. In another example, the third and fourth legs 62, 64 may include apertures extending through the third and fourth legs 62, 64, thereby allowing a fastener to extend through the third and fourth legs 62, 64 to couple with the threaded inserts positioned within the printed wiring board 11. The top member 66 of the spring clip 24 is a generally U-shaped member that extends between and connects the third leg 62 and the fourth leg 64. In other words, the top member 66 extends vertically upward from the third leg 62, then extends horizontally, then extends vertically downward (creating a U-shaped member), and then connects to the fourth leg 64. The top member 66 is configured to provide structure and support between the third leg 62 and the fourth leg 64, and therefore the entire spring clip 24. The top member 66 can be constructed from sheet metal or other thin metal material that can withstand bending operations to form the final shape of the top member 66. The body 68 is coupled to and extends from the top member 66. The body 68 is coupled to the top member 66 of the spring clip 24 at one end, extends outward from the top member 66, and has a free end located opposite the end coupled to the top member 66. The body 68 is a generally flat sheet of metal or other thin metallic material. The body 68 has a generally rectangular shape, similar to the shape of the cap 36 of the ferrite core 14. In some examples, the body 68 can be coupled to the top member 66 via a welded connection, an adhesive, or other means for coupling metallic materials together. In another example, the body 68 and the top member 66 can be formed from a single piece of material, and a bending operation can be used to produce the desired shape of the top member 66 and the body 68. The free end of the body 68 includes a lip 70 that extends upward at an angle away from the body 68. In some examples, the angle can be a vertical angle. The lip 70 is configured to provide a position for securing and holding the upper member 48 of the retaining clip 22 to the spring clip 24 when the winding assembly 10 is assembled on the printed wiring board 11 , as discussed further below. As best shown in FIG. 3 , the body 68 includes a first contact 72 and a second contact 74 extending from opposite sides of the body 68. More specifically, the first contact 72 extends from a first edge of the body 68, and the second contact 74 extends from a second edge of the body 68. The first contact 72 and the second contact 74 extend downward toward the third leg 62 and the fourth leg 64, respectively. In some examples, the upper portions of the first and second contacts 72, 74 coupled to the body 68 may be positioned parallel to the flat top surface of the body 68. In other examples, the upper portions of the first and second contacts 72, 74 coupled to the body 68 may be positioned at an acute angle relative to the flat top surface of the body 68. Thus, in some examples, the upper portions of the first and second contacts 72, 74 coupled to the body 68 may extend upward away from the body 68 at a slight angle. The first and second contacts 72, 74 each include a first bend and a second bend. More specifically, the first contact 72 and the second contact 74 each include a portion extending outwardly away from the outer edge of the body 68. The first contact 72 and the second contact 74 then change direction at a first bend and extend downwardly toward the third leg 62 and the fourth leg 64. The first contact 72 and the second contact 74 then change direction again at a second bend and again extend outwardly away from the body 68. In some examples, a portion of each of the first contact 72 and the second contact 74 is perpendicular to the body 68, and another portion of each of the first contact 72 and the second contact 74 is parallel to the body 68. The first and second contacts 72, 74 are positioned adjacent to and in direct contact with the spacer 16 to induce a compressive force on the spacer 16. Thus, the first and second contacts 72, 74 are configured to flex upward away from the spacer 16 when the first and second contacts 72, 74 are pressed downward onto the spacer 16. This creates a compressive force that pushes the spacer 16, the winding 12, the ferrite core 14, and the first pad 18 downward toward the printed wiring board 11. As discussed, the spacer 16 is sized and positioned so that the first and second contacts 72, 74 press against the spacer 16 without pressing directly onto the winding 12, thereby preventing abrasive damage to the winding 12. As shown in FIG. 3 , the first contact 72 includes a cutout 86 for the first contact 72 that extends completely through the spring clip 24. As shown in FIG. 5 , the second contact 74 includes a cutout 86 for the second contact 74 that extends completely through the spring clip 24. The cutout 86 extends completely through the aperture of the first contact 72 and the second contact 74 , allowing the continuous coil 30 to extend from inside the ferrite core 14 to outside the ferrite core 14 so that the continuous coil 30 can be coupled to one of the plurality of terminals 32 of the winding 12 . The spring clip 24 also includes a first detent 80, a second detent 82, and an alignment pin 84. The first detent 80 is coupled to and extends from the third leg 62, and the second detent 82 is coupled to and extends from the fourth leg 64. The first detent 80 and the second detent 82 are upward-facing features that are configured to mate with and couple to the downward-facing first hook 58 and second hook 60 of the retaining clip 22. More specifically, the first hook 58 of the retaining clip 22 is configured to mate with and couple to the first detent 80 of the spring clip 24, and the second hook 60 of the retaining clip 22 is configured to mate with and couple to the second detent 82 of the spring clip 24. Thus, the first hook 58 and the first detent 80 have mating geometries, and the second hook 60 and the second detent 82 have mating geometries, allowing these features to mate and couple together. When the winding assembly 10 is assembled and in use, the coupling of the first hook 58 with the first detent 80 and the coupling of the second hook 60 with the second detent 82 secures the retaining clip 22 to the spring clip 24. Furthermore, the coupling of the first hook 58 with the first detent 80 and the coupling of the second hook 60 with the second detent 82 prevents the retaining clip 22 and the spring clip 24 from pulling apart or away from each other during high-shock events. An alignment pin 84 is positioned adjacent to and extends from the second detent 82, and extends away from the second detent 82 and the fourth leg 64. The alignment pin 84 is configured to mate with an aperture within the printed wiring board 11 to properly align the winding assembly 10 on the printed wiring board 11 during assembly of the winding assembly to the printed wiring board 11. When assembled, the retaining clip 22 and the spring clip 24 are configured to compress the winding 12, the ferrite core 14, the first pad 18, and the second pad 20 downwardly toward the printed wiring board 11 to secure the winding 12 during use. The first leg 44, the second leg 46, the third leg 62, and the fourth leg 64, together with the first threaded insert 54, the second threaded insert 56, the third threaded insert 76, and the fourth threaded insert 78, are used to mechanically couple the winding assembly 10 to the printed wiring board 11. The winding assembly 10 helps couple large surface-mount power devices to the printed wiring board 11, which minimizes stress on the solder joints previously used to secure the winding 12 to the printed wiring board 11. In addition, the winding assembly 10 securely couples the winding 12 to the printed wiring board 11, allowing the winding assembly 10 to remain secured and operable during high-shock events. The winding assembly 10 provides advantages over previous solder coupling methods for securing large surface mount power devices to printed wiring boards. FIG6A is a first perspective view of a second embodiment of winding assembly 10A. FIG6B is a second perspective view of the second embodiment of winding assembly 10A shown in FIG6A. FIG7 is an exploded view of the second embodiment of winding assembly 10A. FIG6A and FIG7 will be discussed together. Winding assembly 10A is substantially similar to winding assembly 10, and it should be understood that the disclosure regarding winding assembly 10 also applies to winding assembly 10A unless otherwise stated. To avoid redundancy, only the differences between winding assembly 10A and winding assembly 10 will be discussed below. A first difference between winding assembly 10A and winding assembly 10 is that the retaining clip 22A of winding assembly 10A includes a first biasing arm 88A and a second biasing arm 90A. As best shown in FIG. 7 , first biasing arm 88A extends inward from a first side of the generally U-shaped upper member 48A toward a center of the generally U-shaped upper member 48A. Second biasing arm 90A extends inward from a second side of the generally U-shaped upper member 48A toward the center of the generally U-shaped upper member 48A. Furthermore, first biasing arm 88A and second biasing arm 90A are positioned above the midpoint of the vertically extending portion of upper member 48A. First biasing arm 88A and second biasing arm 90A are configured to induce a force on ferrite core 14A to further help secure ferrite core 14A within winding assembly 10A. More specifically, the first biasing arm 88A and the second biasing arm 90A induce a force on the ferrite core 14A to secure the ferrite core 14A horizontally within the winding assembly 10A, preventing the ferrite core 14A from sliding or moving within the winding assembly 10A during use and / or during high shock events. A second difference between winding assembly 10A and winding assembly 10 is that spring clip 24A of winding assembly 10A includes a first stop 92A and a second stop 94A. As best shown in FIG. 6B , first stop 92A extends inward from a first side of generally U-shaped top member 66A toward a center of generally U-shaped top member 66A. Second stop 94A extends inward from a second side of generally U-shaped top member 66A toward the center of generally U-shaped top member 66A. First stop 92A and second stop 94A are configured to provide an abutment surface for ferrite core 14A, which is urged toward first stop 92A and second stop 94A by first biasing arm 88A and second biasing arm 90A. Thus, the first stop 92A and the second stop 94A help prevent the ferrite core 14A from sliding or moving within the winding assembly 10A during use and / or during high shock events. Winding assembly 10A is another embodiment that helps couple large surface-mount power devices to printed wiring boards, minimizing stress on the solder joints previously used to secure winding 12A to the printed wiring board. Furthermore, winding assembly 10A securely couples winding 12A to the printed wiring board, allowing winding assembly 10A to remain secured and operational during high-shock events. Winding assembly 10A offers advantages over previous solder coupling methods for securing large surface-mount power devices to printed wiring boards. Discussion of Possible Implementations The following is a non-exclusive description of possible embodiments of the present invention. A winding assembly configured to be coupled to a surface of a printed wiring board, the winding assembly comprising: a winding at least partially surrounded by a ferrite core, the ferrite core comprising a base and a cover; a retaining clip comprising a first leg and a second leg, wherein the first leg and the second leg are positioned adjacent to the surface of the printed wiring board; and a spring clip at least partially positioned over the cover of the ferrite core, the spring clip comprising a third leg and a fourth leg, wherein the third leg and the fourth leg are positioned adjacent to the surface of the printed wiring board. The winding assembly of the preceding paragraph may optionally include (in addition and / or alternatively) any one or more of the following features, configurations and / or additional components: The retaining clip further includes an upper member extending between and connecting the first leg and the second leg, wherein the upper member is a generally U-shaped member; and a first arm extending perpendicularly from the upper member, and a second arm extending perpendicularly from the upper member, wherein the first arm is positioned parallel to the second arm. The first arm includes a first hook positioned at a free distal end of the first arm, and wherein the second arm includes a second hook positioned at a free distal end of the second arm. A first biasing arm extends inwardly from a first side of the generally U-shaped upper member toward a center of the generally U-shaped upper member, and wherein a second biasing arm extends inwardly from a second side of the generally U-shaped upper member toward the center of the generally U-shaped upper member. A first threaded insert is coupled to the first leg of the retaining clip, and wherein a second threaded insert is coupled to the second leg of the retaining clip. The spring clip further includes: a top member extending between and connecting the third leg and the fourth leg, wherein the top member is a generally U-shaped member; a body coupled to and extending from the top member, the body including an upward-facing lip positioned at a free distal end of the body; and a first contact extending from a first edge of the body, and a second contact extending from a second edge of the body, wherein the first contact and the second contact extend from the body toward the third leg and the fourth leg, respectively. A first stop extends inwardly from a first side of the generally U-shaped top member toward the center of the generally U-shaped top member, and wherein a second stop extends inwardly from a second side of the generally U-shaped top member toward the center of the generally U-shaped top member. A cutout extends through the first contact of the spring clip, wherein the cutout allows an electrical connector to extend from within the ferrite core to outside the ferrite core. The first contact and the second contact each include a first bent portion and a second bent portion, so that a portion of each of the first contact and the second contact is perpendicular to the body, and another portion of each of the first contact and the second contact is parallel to the body. The spring clip further includes a first detent extending from the third leg and a second detent extending from the fourth leg, and wherein an alignment pin is positioned adjacent to the second detent and extends away from the second detent and the fourth leg. A third threaded insert is coupled to the third leg of the spring clip, and a fourth threaded insert is coupled to the fourth leg of the spring clip. A first pad is positioned between the surface of the printed wiring board and a bottom surface of the base of the ferrite core. A second pad is positioned between an upper surface of the cap of the ferrite core and an inner surface of the spring clip. The first pad and the second pad are constructed of a material having a maximum operating temperature of at least 235 degrees Celsius. A spacer is positioned between the winding and the cover of the ferrite core, and wherein the spacer extends beyond an outer edge of the cover. A first contact and a second contact of the spring clip are positioned adjacent to and in direct contact with the spacer, and wherein the first contact and the second contact are configured to induce a compressive force on the spacer. The cover of the ferrite core includes a first notch extending from a first outer edge of the cover toward a center of the cover, and wherein the ferrite core includes a second notch extending from a second outer edge of the cover toward a center of the cover. The ferrite core includes a circular column positioned substantially at a center location of the ferrite core, and wherein the circular column extends from an upper surface of the base to an inner surface of the cover. The winding includes a plurality of coils wound around the circular column of the ferrite core, and wherein one end of the plurality of coils is coupled to a terminal of the winding. The winding includes a plurality of terminals extending from the winding, and wherein the plurality of terminals are configured to be electrically coupled to the printed wiring board. Although the present invention has been described with reference to one (or several) exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope of the invention. Therefore, it is intended that the present invention not be limited to the particular embodiment (s) disclosed, but that the invention include all embodiments coming within the scope of the appended claims. 10: Winding assembly 10A: Winding assembly 11: Printed wiring board 12: Winding 12A: Winding 14: Ferrite core 14A: Ferrite core 16: Spacer 18: First pad 20: Second pad 22: Retaining clip 22A: Retaining clip 24: Spring clip 24A: Spring clip 26: First printed circuit board 28: Second printed circuit board 30: Continuous coil 32: Terminal 34: Base 36: Cover 38: Circular column 40: First notch 42: Second notch 44: First leg 46: Second leg 48: Upper component 48A: Upper Part 50: First Arm 52: Second Arm 54: First Threaded Insert 56: Second Threaded Insert 58: First Hook 60: Second Hook 62: Third Leg 64: Fourth Leg 66: Top Part 66A: Top Part 68: Body 70: Lip 72: First Contact 74: Second Contact 76: Third Threaded Insert 78: Fourth Threaded Insert 80: First Detent 82: Second Detent 84: Alignment Pin 86: Cutout 88A: First Biasing Arm 90A: Second Biasing Arm 92A: First Stop 94A: Second Stop FIG1 is a perspective view of a first embodiment of a winding assembly. FIG. 2 is a cross-sectional view of the winding assembly taken along section line AA of FIG. 1 . FIG3 is an exploded view of the first embodiment of the winding assembly. FIG4 is a perspective view of a ferrite core of the first embodiment of the winding assembly. 5 is a perspective view of a first embodiment of a winding assembly coupled to a printed wiring board. FIG6A is a first perspective view of a second embodiment of a winding assembly. FIG. 6B is a second perspective view of the second embodiment of the winding assembly of FIG. 6A . FIG. 7 is an exploded view of the second embodiment of the winding assembly. 10: Winding assembly 12: Winding 14: Ferrite core 16: Spacer 18: First Pad 20: Second pad 22: Retention clip 24: Spring clip 26: First printed circuit board 28: Second printed circuit board 30: Continuous coil 32:Terminal

Claims

1. A winding assembly configured to be coupled to a surface of a printed wiring board, the winding assembly comprising: A winding at least partially surrounded by a ferrite core, the ferrite core including a substrate and a cap; a retaining clip including a first leg and a second leg, wherein the first leg and the second leg are positioned adjacent to the surface of the printed wiring board; and a spring clip at least partially positioned above the cap of the ferrite core, the spring clip including a third leg and a fourth leg, wherein the third leg and the fourth leg are positioned adjacent to the surface of the printed wiring board, wherein the retaining clip further includes: an upper member extending between and connecting the first leg and the second leg, wherein the upper member is a generally U-shaped member; a first arm extending vertically from the upper member; and a second arm extending vertically from the upper member, wherein the first arm is positioned parallel to the second arm.

2. The winding assembly of claim 1, wherein the first arm includes a first hook located at a free distal end of the first arm, and wherein the second arm includes a second hook located at a free distal end of the second arm.

3. The winding assembly of claim 1, wherein a first bias arm extends inwardly from a first side of one of the generally U-shaped upper components toward the center of one of the generally U-shaped upper components, and wherein a second bias arm extends inwardly from a second side of one of the generally U-shaped upper components toward the center of the generally U-shaped upper component.

4. The winding assembly of claim 1, wherein a first threaded insert is coupled to the first foot of the retainer, and a second threaded insert is coupled to the second foot of the retainer.

5. The winding assembly of claim 1, wherein the spring clip further comprises: A top component extending between and connecting the third and fourth feet, wherein the top component is a generally U-shaped component; a body coupled to and extending from the top component, the body including an upper lip-facing portion located at a free distal end of the body; and a first contact extending from a first edge of the body, and a second contact extending from a second edge of the body, wherein the first contact and the second contact extend from the body toward the third and fourth feet, respectively.

6. The winding assembly of claim 5, wherein a first stop member extends inwardly from a first side of one of the generally U-shaped top members toward the center of one of the generally U-shaped top members, and wherein a second stop member extends inwardly from a second side of one of the generally U-shaped top members toward the center of the generally U-shaped top member.

7. The winding assembly of claim 5, wherein a cut extends through the first contact of the spring clip, and wherein the cut allows an electrical connector to extend from inside the ferrite core to outside the ferrite core.

8. The winding assembly of claim 5, wherein the first contact and the second contact each include a first bend and a second bend, such that a portion of each of the first contact and the second contact is perpendicular to the body, and another portion of each of the first contact and the second contact is parallel to the body.

9. The winding assembly of claim 1, wherein the spring clip further includes a first tug extending from the third foot and a second tug extending from the fourth foot, and wherein an alignment pin is positioned adjacent to the second tug and extends away from the second tug and the fourth foot.

10. The winding assembly of claim 1, wherein a third threaded insert is coupled to the third pin of the spring clip, and wherein a fourth threaded insert is coupled to the fourth pin of the spring clip.

11. The winding assembly of claim 1, further comprising a first pad positioned between the surface of the printed wiring board and a bottom surface of the substrate of the ferrite core.

12. The winding assembly of claim 11, further comprising a second pad positioned between an upper surface of the cap of the ferrite core and an inner surface of the spring clip.

13. The winding assembly of claim 12, wherein the first pad and the second pad are constructed of a material having a maximum operating temperature of at least 235 degrees Celsius.

14. The winding assembly of claim 1, wherein a spacer is positioned between the winding and the cover of the ferrite core, and wherein the spacer extends beyond one outer edge of the cover.

15. The winding assembly of claim 14, wherein a first contact and a second contact of the spring clip are positioned adjacent to and in direct contact with the spacer, and wherein the first contact and the second contact are configured to generate a compressive force on the spacer.

16. The winding assembly of claim 1, wherein the cover of the ferrite core includes a first recess extending from a first outer edge of the cover toward a center of the cover, and wherein the ferrite core includes a second recess extending from a second outer edge of the cover toward a center of the cover.

17. The winding assembly of claim 1, wherein the ferrite core includes a circular post generally located at a central position of the ferrite core, and wherein the circular post extends from an upper surface of the substrate to an inner surface of the cover.

18. The winding assembly of claim 17, wherein the winding comprises a continuous coil of the cylindrical part wound around the ferrite core, and wherein one end of the continuous coil is coupled to a terminal of the winding.

19. The winding assembly of claim 1, wherein the winding includes a plurality of terminals extending from the winding, and wherein the plurality of terminals are configured to be electrically coupled to the printed wiring board.

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