Orthogonal combined plate type winding for annular magnetism

Abstract

An electromagnetic core and a winding assembly are presented. The assembly may include a core including a body and an aperture defined by an inner surface of the body. The assembly may also include a plurality of plate windings configured to electromagnetically operate with the core, the plurality of plate windings disposed through and at least partially around the body of the core. A portion of each of the plurality of plate windings may pass through the aperture of the core. A plurality of plate windings may at least partially orthogonally surround the body of the core.

Description

Technical Field

[0001] The present disclosure relates to orthogonal bonded plate windings for toroidal magnetics. BRIEF DESCRIPTION OF THE DRAWINGS

[0002] The foregoing and other features of the present disclosure will become more apparent through the following description and the appended claims in conjunction with the accompanying drawings. It is to be understood that these drawings depict only several embodiments according to the present disclosure and are not to be considered as limiting the scope thereof, and the present disclosure will utilize additional specificity and detailed description through the use of the accompanying drawings.

[0003] Figure 1 An example orthogonal plate toroidal winding assembly is illustrated in accordance with some embodiments.

[0004] Figure 2 According to some embodiments Figure 1 Electrical 3D model view of an orthogonal plate toroidal winding assembly.

[0005] FIG. 3A to FIG. 3D Another example orthogonal plate toroidal winding assembly is illustrated in accordance with some embodiments.

[0006] FIG. 4A to FIG. 4G Illustrated are steps in a process of how a plate is combined with a core housing into a core winding assembly according to some embodiments.

[0007] FIG. 5A to FIG. 5D According to some embodiments Figure 3D Different views of the core winding assembly.

[0008] Fig. 6A An alternative edge-to-edge butt weld joint of a plate assembly according to some embodiments is illustrated.

[0009] Figure 6B Illustrated is a cross-sectional image of an example conversational spatial understanding core, shell, U-shaped busbar close fitting according to some embodiments.

[0010] Figure 6C Illustrated are types of weld joints according to some embodiments.

[0011] 7A to 7C An example prior art magnetic core material manufactured by a plate stamping method is illustrated.

[0012] Fig.7D and Fig. 7E An example of a progressive plate stamping format for a conductor according to some embodiments is illustrated.

[0013] Fig. 8A and Figure 8B Example orthogonal plate toroidal winding assemblies having different numbers of components and unique component shapes are illustrated in accordance with some embodiments.

[0014] Figure 8C It is illustrated that conductor stampings according to some embodiments may be reinforced by stacking and connecting other stampings, which may be partially or fully sized, to double or multiply local current carrying capacity, reduce resistance, and enhance thermal paths for conductors.

[0015] Fig. 9A and Fig. 9B Illustrated are example welding and securing methods for welding plates according to some embodiments.

[0016] FIG. 10A to FIG. 10C Another example welding method for welding plates according to some embodiments is illustrated.

[0017] Fig.11A and Fig. 11B Another example orthogonal plate toroidal winding assembly is illustrated in accordance with some embodiments, wherein exposed supports or electrical connection points are staggered to prevent electrical shorts.The stampings may be insulated from each other by other dielectric materials, such as sheets or films as individual components separated from the core structure.

[0018] Fig. 11C A comparative example core winding assembly having windings disposed on only one side of the core is illustrated.

[0019] Fig.11D Another example orthogonal plate toroidal winding assembly is illustrated, which may have windings above each other, below each other, or alongside each other, in accordance with some embodiments.

[0020] Fig.11E According to some embodiments Fig.11D Cross-sectional view of an orthogonal plate toroidal winding assembly.

[0021] Fig.11F and Fig.11G They are Fig. 11B and Fig. 11C Magnified image of .

[0022] Fig. 12A and Fig. 12B Shown is how an example orthogonal plate toroidal winding assembly may present a surface designated to act as a clamping area for an automated clamper in accordance with some embodiments.

[0023] Fig.13A and Fig. 13B An example PCB layout is illustrated in which an example orthogonal plate toroidal winding assembly is provided, according to some embodiments.

[0024] Fig. 13C The diagram illustrates a method according to some embodiments Fig. 13BA portion of the PCB with the transparent PCB view and heat sink cutouts highlighted.

[0025] Fig.14 Another example orthogonal plate toroidal winding assembly including a staggered lead design is illustrated in accordance with some embodiments.

[0026] Fig.15A is a top view of an example orthogonal plate toroidal winding assembly mounted in a PCB in accordance with some embodiments.

[0027] Fig. 15B According to some embodiments Fig.15A Front view of an orthogonal plate toroidal winding assembly.

[0028] Fig. 15C According to some embodiments Fig.15A Bottom view of the orthogonal plate toroidal winding assembly.

[0029] Fig.15D and Fig.15E According to some embodiments Fig.15A Side view of an orthogonal plate toroidal winding assembly.

[0030] Fig.16A An independent choke design according to some embodiments is illustrated.

[0031] FIG. 16B to FIG. 16D Illustrated is how a connector may be integrated into an orthogonal plate toroidal winding assembly according to some embodiments.

[0032] Fig.16E Illustrated is a bus bar being used as a connector terminal insert molded into a housing according to some embodiments.

[0033] Fig.16F An internal ribbon-based nanocrystalline core embedded within a shell is illustrated in accordance with some embodiments.

[0034] Figure 16G Illustrated is how the power flow through a choke is regulated in quadrature stamping according to some embodiments.

[0035] Fig.17A and Fig. 17B Illustrated is how a connector housing with insert molded terminals is supplied to a core assembly housing according to some embodiments.

[0036] Fig. 17C Illustrated is how a choke core and housing may be assembled according to some embodiments.

[0037] Figures 17D to 17F It illustrates how the rest of the winding structure is assembled to the main housing according to some embodiments.

[0038] Fig.18A An assembled U-shaped bus bar is shown with connector tabs grown for connector insertion to be installed according to some embodiments.

[0039] Fig.18B A U-shaped bus bar is shown mounted directly over a core assembly housing according to some embodiments.

[0040] Embodiments of the present disclosure and their advantages are best understood by referring to the following detailed description. It should be understood that similar reference numerals are used to identify similar elements illustrated in one or more of the accompanying drawings, wherein the illustrations in the drawings are for illustrating embodiments of the present disclosure, rather than for limiting embodiments of the present disclosure. DETAILED DESCRIPTION

[0041] Various embodiments of orthogonally bonded plate windings for toroidal magnetics are provided herein, including separate vertical plate stacks, which can achieve several advantages to replace drawn round enameled magnet wire for toroidal windings in magnetic components such as inductors, chokes, and transformers. Some embodiments include an electromagnetic core and a winding assembly including a core and a plurality of plate windings orthogonally around the core.

[0042] Various embodiments may provide one or more of the following non-limiting electrical and mechanical advantages, including but not limited to: 1) reduced overall footprint size compared to continuous wire wound or flat wire edge wound toroidal cores, 2) desired rectangular or favorable footprint shape for printed circuit board (PCB) assemblies to achieve optimal layout density, 3) winding plates doubling as heat sinks for natural convection cooling, 4) adjustable turn-to-turn capacitance, 5) winding-to-winding surface leakage control, 6) controlled winding spacing for uniformity independent of winding pattern, wire tension effects, and bunching variability, 7) bonding techniques such as laser welding provide manufacturing cycle times in just seconds, 8) vertical plate ends acting as PCB solder leads or feet, which can eliminate round magnet wire terminals that are typically required to convert the wire ends to fit onto surface mount technology (SMT) feet and other printed circuit board connection methods, and 9) conductor plate thickness, cross-section and aspect ratio, and overall assembly shape can be easily scaled to achieve other desired goals of the assembly such as higher current carrying capacity, heat dissipation, low electrical and thermal resistance, inter-winding and intra-winding capacitance.

[0043] Existing toroidal windings are primarily hand-drawn enameled wire constructions, sometimes semi-automated. For example, a continuous edge-wound flat copper may be spiraled into a toroidal core shape for installation. The example winding toroidal shape may be formed by enameled wire that is passed and wrapped by hand and / or machine, and these wires may physically contact the core, so both the core and the wire are susceptible to damage. In addition, high current applications may employ or require multiple parallel windings, such as a bifilar winding arrangement, which typically requires sequentially wrapping continuous lengths of wire conductors in an attempt to follow and match the path and pitch of the spiral around the core. Variable wire positioning and integral wire winding assemblies in industrial practice can variably increase the shape and size of the core winding assembly, resulting in irregularities when compared to each other.

[0044] Non-circular helices can be threaded onto closed rings. However, since assembly requires the helix to be rotated onto a ring cross-sectional shape, the ability to fit tightly is reduced. Most cores are manufactured with a constant rectangular cross-sectional shape to achieve microstructural uniformity, and some specialized cores (such as nanocrystalline types) consist of fixed-width ribbons that are continuously wrapped one above the other (like a roll of tape), thus having Figure 2 The rectangular cross section with sharp corners shown in D. Figure 2 In Design D, edgewound or wirewound conductors have difficulty bending or conforming to such sharp corners due to the conductor's minimum internal bend radius.

[0045] According to various embodiments, the cross-sectional dimensions of the core can be large without increasing the length of the total winding in each winding unit. For example, the plates oriented vertically to the core equator are arranged in parallel and combined together to form an unconventional spiral winding structure. The thin plate conductor allows an aspect ratio comparable to circular, square and flat magnetic wire windings because they can be stacked together or arranged side by side along an annular shape, and the radial or vertical dimensions along the axis of the core are not limited. In this way, a wide range of customizable conductor cross-sectional areas can be achieved, including desired non-uniform cross-sectional areas and aspect ratios, with almost no effect on the annular size. This winding shape customization can be used for various combined purposes, such as heat removal, surrounding field effects, electrical interfaces, strength, stiffness, current in the winding, and heat flow along the winding portion. A thermal benefit of plate-shaped conductors is that they behave like heat sinks for convection heat transfer, or conductive edge cooling methods can also be used. The shape of the plate can follow the core contour and the outer envelope. This optimized fitting is advantageous compared to edge wound spiral windings that must be screwed onto a toroid of rectangular cross section, or where a toroidal core must be cut to assemble a rectangular formed spiral. Shape matching orthogonal plates allow the overall footprint and volume of magnetic components such as chokes, inductors or transformers to be optimized. This level of volume optimization is currently not available for this type of wound components. Depending on the embodiment, the plate elements can be joined using processes such as laser welding and are allowed to have different shapes and thicknesses, even within a continuous single winding.

[0046] According to some embodiments, orthogonal conductor plates may provide one or more of the following additional benefits. It may be possible to weld the edge of the plate directly to the surface of the PCB for electrical connection and / or mechanical and / or thermal interface. Each winding turn may have a cooling path close to the PCB surface, and an optional PCB cutout may allow a thermal interface to cool each winding from a lower side heat sink. The plate structure may be similar to a convection heat sink for cooling. The shape of the plate may be customized for mounting, cooling, and conductor cross-section optimization (geometry, resistance, heat) within a size envelope. Inter-board / inter-turn capacitance may be tuned by surface area and / or pitch. Plates and sub-sections of the plate may be stacked together and partially or completely welded into dual / triple / multi-conductive cross-sections. Inter-turn electrical isolation may also be achieved by housing combs with variable thickness and spacing or grooves added for desired electrical surface creepage. Unlike magnetic wires, conductors extending to the PCB may be made and handled as flat, regularly shaped objects and are more suitable for automated assembly. The positions of leads and solder joints may be fixed, and deformation and variability may be reduced to achieve high-volume automated PCB assembly (PCBA) production considerations.

[0047] Control board spacing can eliminate the need for magnet wire enamels, which typically assume that the insulation-coated conductors are directly in contact with each other and are laid on top of or beside each other.

[0048] A novel cross-link can enable power flow into a toroidal winding to be exhausted through the opposite side without PCB interaction and can have electromagnetic compatibility (EMC) immunity benefits. Some embodiments allow for multiple ways to customize the design within a rectangular footprint, spatial volume, planar cooling paths, and electrical layout, or direct power flow simplifications not available with conventional wirewound and edgewound configurations.

[0049] Some embodiments may be applied to one or more of EMC chokes, conductors, transformers, or current sensors. Other benefits may be realized in through-hole, pin-in-solder paste, and SMD lead configurations. Some embodiments may also be applied to molded housings for surface mount device (SMD) applications that require high temperature grade resins to maintain shape during soldering / reflow. Some embodiments may also be applied to industrial development of fully automated assemblies (comb insertion, fixation, laser welding) required for cost competitiveness and manufacturing speed. In addition, some embodiments may also be applied to replace edge-wound conductors that require internal bend radiuses that cannot follow the sharp cross-sectional shape of nanocrystalline cores made from fixed width tapes.

[0050] According to some embodiments, the orthogonal arrangement of conductors can add multiple size customization for high density. In addition, the new cross conductor can realize new straight-through power penetration. With orthogonal plates, the cross conductor can be naturally similar to other winding components in terms of structure, processing and implementation. Some embodiments can enable wound core components to meet spatial densities comparable to other SMD component parts (previously such components used other electrical and mechanical mounting outside the PCBA).

[0051] Figure 1 An example orthogonal plate toroidal winding assembly 300 according to some embodiments is illustrated. Assembly 300 may include a core 310 and a plurality of winding plates, including a first group of winding plates 322 to a fourth group of winding plates 328. The size and cross-sectional aspect ratio of core 310 may be adjusted, modified or customized as needed to match the width, height, thickness, spacing and assembly volume of each winding. Each group of winding plates 322 to 328 may have a tight uniform spacing between the winding plates, or alternatively have a wide spacing for other desired goals. The winding plates of the first group 322 and the third group 326 may be spaced apart by a first distance. The winding plates of the second group 324 and the fourth group 328 may be spaced apart by a second distance different from the first distance. The second distance may be greater than the first distance. For example, when higher voltage isolation or greater free convection cooling is required for heat, a wider spacing may be used between the winding plates. Core 310 may include an air core, which includes any material having desired magnetic properties, including gaseous or vacuum.

[0052] although Figure 1 Each group of winding plates 322 to 328 is shown to include six winding plates, but the present disclosure is not limited to this. For example, less than (e.g., 1 to 5 plates) or more than (e.g., 10 to 20 plates) six winding plates may be used. In addition, depending on the embodiment, the first group of winding plates 322 to the fourth group of winding plates 328 may have the same number of winding plates or a different number of winding plates. The first group of winding plates 322 and the third group of winding plates 326 may form one unit. The second group of winding plates 324 and the fourth group of winding plates 328 may form another unit. Although Figure 1 Two units are shown, but the present disclosure is not limited thereto. For example, the winding assembly 300 may have one winding unit or more than two winding units.

[0053] There may be additional leads or pin connections within the start and end of each winding unit for electrical connections, such as tabs. The additional leads or pin connections present in addition to the electrical connections may provide thermal pathways to conduct heat or increase strength.

[0054] On each side of the core 310, winding plates with different thicknesses may be provided. For example, for the front side of the core 310, the first group of winding plates 322 may be thinner than the second group of winding plates 324, and vice versa. For example, for the back side of the core 310, the third group of winding plates 326 may be thinner than the fourth group of winding plates 328, and vice versa. Here, the thinner winding plate group may conduct less current than the thicker winding plate. The groups of winding plates 322 to 328 may be connected across the other sides of the core 310. The groups of winding plates 322 to 328 may completely or substantially surround the core 310, and the core 310 may also be various shapes in addition to the rectangular footprint shown.

[0055] Figure 2 According to some embodiments Figure 1 1 is an enlarged view of the orthogonal plate toroidal winding assembly 300. Each set of winding plates 322 and 324 includes an opening 435 through which a portion of the core 310 passes.

[0056] The thickness of each group of thinner winding plates 322 can be in the range of about 0.25mm or more. The thickness of each group of thicker winding plates 324 can be in the range of about 0.50mm or more. These thicknesses are merely examples, and the present disclosure is not limited thereto. For example, the thickness of each thinner winding plate 322 can be less than about 0.25mm. In addition, the thickness of each thicker winding plate 324 can be less than about 0.50mm. In some embodiments, the winding plate can be thickened by stacking two or more thinner plates in a double layer and then combining to achieve the desired electrical function and thermal function. The first winding plate and the last winding plate can have different sizes for connection purposes, and the middle winding plate can have the same size. For example, the first winding plate and the last winding plate can be longer, wider and / or thicker, and the middle winding plate can be relatively concave.

[0057] The thinner set of winding plates 322 and the thicker set of winding plates 324 may be about 0.5 mm to about 4 mm to 5 mm (see Figure 2 The two adjacent winding plates in each thinner winding plate 322 and each thicker winding plate 324 may be spaced apart in a range of about 0.5 mm to about 1 mm to 2 mm (see Figure 2 4. The spacing between adjacent winding plates in the thinner set of winding plates 322 may be the same or different than the spacing between adjacent winding plates in the thicker set of winding plates 324. The spacing may be used to adjust specific electrical properties, such as capacitance. For example, smaller spacing between winding plates may create smaller capacitance, increasing voltage surface leakage or clearance. The above spacing ranges are merely examples, and the present disclosure is not limited thereto.

[0058] The winding assembly 300 can have a core cross-sectional aspect ratio in the range of about 0.5 to about 1.5. The core cross-sectional aspect ratio can be defined as the height of the cross section of the core 310 multiplied by the width of the cross section of the core 310. The above core cross-sectional aspect ratio ranges are only examples, and the present disclosure is not limited thereto. For example, it is also possible that the core cross-sectional aspect ratio is less than about 0.5 or greater than about 1.5.

[0059] FIG. 3A to FIG. 3D Another example orthogonal plate toroidal winding assembly is illustrated in accordance with some embodiments. Figure 3A and Figure 3C An example orthogonal plate toroidal winding assembly having an intercalated orthogonal winding design is shown. Figure 3B Shows Figure 3A Top view. Figure 3D Shows Figure 3C Bottom view of the .

[0060] FIG. 4A to FIG. 4GIllustrated is how a plate is combined with a core housing to form a core winding assembly according to some embodiments. Figure 4A A generally U-shaped plate 610 is shown according to some embodiments. Figure 4B A generally U-shaped plate 610 is shown placed on a core housing 620 . Figure 4C A generally I-shaped plate 630 is shown according to some embodiments. Figure 4D Shows Figure 4B Bottom view of the core winding assembly shown. Figure 4E The generally I-shaped plate 630 is shown placed in Figure 4D The bottom portion of the core winding assembly is shown assembled to the core and housing. Figure 4F shows how to combine a generally I-shaped plate 630 into Figure 4D A more detailed view of the bottom portion of the core winding assembly shown connected to many or all of the U-shaped plates. Figure 4F , 8 winding units of U-shaped plates and I-shaped plates are shown. Winding units across opposite sides of the core can be electrically combined to unify into a larger winding unit, for example, the number of turns can be doubled. Figure 4F , reference numeral 640 denotes a cross bus bar or a stamping. Figure 4G is an example of a cross stamping that can link a winding or conductive element from one side of the core to the other. This cross can also be formed to connect winding elements along the same side of the core, such as in a split winding. This cross can be formed or used in multiples, branching from one winding element to multiple other winding elements, and even possibly linking to a winding element that is primarily wound on another core. FIG. 4A to FIG. 4G The number and unique features of the busbars forming the I-shaped plates shown are examples only, and the present disclosure is not limited in this regard.

[0061] FIG. 5A to FIG. 5D According to some embodiments Figure 3D Different views of the core winding assembly. Figure 5C According to some embodiments Figure 5A Wireframe view of the core winding assembly. Figure 5A The core winding assembly shown is Figure 4E Basically the same. Figure 5D A cover is shown covered by a core housing including a core comb. Figure 5B It is a hollow core without a shell. Figure 5C yes Figure 5A Top view of the core winding assembly.

[0062] Fig. 6A An example winding assembly 800 is illustrated, according to some embodiments, which includes an alternative butt weld joint of a combined plate. Figure 2 The linear edge shown is compared to the Shaped edge 810 or Shaped edge 820. Fig. 6A In, due to the The plate having the shaped edge 810 and having The panels with the shaped edges 820 overlap in the joint portion, so this design can provide a thinner panel joint. Figure 5A The joint portion is thinner (e.g., about half), so the spacing between the plates can be reduced, potentially reducing the size of the winding unit.

[0063] Figure 6B Illustrated is a cross-sectional image of an example conversational spatial understanding core, shell, and U-shaped busbar tight fitting. Figure 6C Illustrated are example types of welded joints according to some embodiments. Figure 6C In the reference for metal sheet joining, various joint types are possible. Figure 6C The types of weld joints shown are examples only, and the present disclosure is not limited in this regard.

[0064] 7A to 7C An example prior art sheet stamping format for manufacturing magnetic cores is illustrated for reference by industry familiarity and similar processes. Fig.7D and Fig. 7E Another example progressive stamping format designed to optimize material usage according to some embodiments is illustrated. 7A to 7C Compared with those panels manufactured separately, Fig.7D and Fig. 7E The plate shown in shows an example of a progressive stamping arrangement on raw sheet conductor material. Fig.7D Has a tilted nesting design, and Fig. 7E A vertical design is shown.

[0065] Fig. 8A and Figure 8B Example orthogonal plate toroidal winding assemblies 1010 and 1020 are illustrated having different numbers of components in accordance with some embodiments. Fig. 8A The orthogonal plate toroidal winding assembly 1010 has a ratio of Figure 8B The vertical plate-type toroidal winding assembly 1020 shown includes four components. For example, Fig. 8A The winding assembly 1010 includes a U-shaped plate 1012, an I-shaped plate 1014, a side plate 1016, and a side plate 1018 for each winding. Fig. 8A In the example, the height of the side plate 1016 is different from the height of the U-shaped plate 1012, the I-shaped plate 1014, and the side plate 1018. 1016 and 1018 further protrude from the surrounding windings to establish a dedicated mounting surface. Figure 8B In the winding assembly 1020, each combined plate includes a U-shaped plate 1022 and an I-shaped plate 1024. Figure 8B In this example, the combined panels have the same height. Fig. 8A The example requires two more parts (plates) per winding, so Fig. 8A Components will be Figure 8B The examples require up to four boards. Fig. 8A and Figure 8B Only example winding assemblies and an example number of reduced components are shown, and the present disclosure is not limited thereto.

[0066] Figure 8C It is illustrated that conductor stampings according to some embodiments can be reinforced by stacking and connecting other stampings, which can be partially or fully sized to double or multiply the local current carrying capacity, reduce resistance, and enhance the thermal path of the conductor. These doublers can be optionally utilized with stamped windings to achieve higher current carrying capacity, lower resistance, and thermal conductivity.

[0067] Fig. 9A and Fig. 9B An example welding method for welding plates of an example orthogonal plate toroidal winding assembly 1110 is illustrated in accordance with some embodiments. Fig. 9A An assembled plate is shown in which a U-shaped plate 1112 and an I-shaped plate 1114 are coupled to each other. Plates 1112 and 1114 may be coupled via welding. The bonding method may include various types, including but not limited to laser welding, high temperature welding, ultrasound (ultrasonic) or resistance welding. However, the present disclosure is not limited thereto, and other coupling methods may also be used.

[0068] Fig. 9B A laser welding fixture is shown in which an upper spring 1130 can be used to perform fine positioning of the plates 1112 and 1114 of the winding assembly 1110 prior to welding. Fig. 9B Only an example positioning fixture is shown, and other fine positioning devices may also be used. For example, the upper spring 1130 may be omitted, and gravity may be sufficient to position the plates 1112 and 1114.

[0069] FIG. 10A to FIG. 10C Another example welding method for welding plates according to some embodiments is illustrated. Fig. 10A An assembled plate is shown in which a U-shaped plate 1210 and an I-shaped plate 1220 are coupled to each other. Fig. 10B Example laser spot welding capabilities are shown, demonstrating that welds can be performed even if the surface of the board is not smooth or contains tiny gaps. Fig. 10C In the embodiment, the I-shaped plate 1220 can be positioned near the top of the U-shaped plate 1210, or a feature secured to the core housing by a clamp without the use of an upper spring, and the lower spring 1230 can be used to push the core and I-shaped plate upward to fit flush with the upper clamp plate 1250.

[0070] Fig.11A and Fig. 11B Another example orthogonal plate toroidal winding assembly 1310 is illustrated in accordance with some embodiments. Fig. 11B Shows Fig.11A A top view of an orthogonal plate toroidal winding assembly 1310. Fig.11A and Fig. 11B 13, U-shaped plates 1312 and I-shaped plates 1314 surrounding core 1318 are separated by a film or sheet insulator 1316. The film or sheet insulator 1316 may be disposed between plates 1312 and 1314 to prevent short circuits by insulating adjacent plates. Fig. 6A The winding assembly 800 shown, except for the Fig.11A and Fig. 11B A thin film or sheet insulator 1316 is additionally provided.

[0071] Fig. 11C A comparative example core winding assembly 1320 is illustrated having windings 1312 disposed on only one side of a core 1314 .

[0072] Fig.11D Another example orthogonal plate toroidal winding assembly 1330 is illustrated in accordance with some embodiments. Fig. 11C The example assembly 1330 includes windings 1332 and 1336 disposed on either side of a core 1336 .

[0073] Fig.11E According to some embodiments Fig.11D A cross-sectional view of an orthogonal plate toroidal winding assembly 1330 . Fig.11E Indicates that the stampings can be processed uniformly and the components can also be disconnected from each other later by removing the break tabs or other selected cutting methods to achieve personalized electrical functions. The orthogonal plate toroidal winding assembly 1330 includes a U-shaped plate 1338 and an I-shaped plate 1340. The orthogonal plate toroidal winding assembly 1330 can also include a break tab 1342, which is used to attach the U-shaped plate 1338 and the I-shaped plate 1340 for handling during assembly.

[0074] Fig.11F and Fig.11G They are Fig. 11B and Fig. 11C Magnified image of .

[0075] Fig. 12A and Fig. 12B14 shows how an example orthogonal plate toroidal winding assembly according to some embodiments may be clamped by a clamp 1420. The surface may be substantially flat or contain other features, such as aiding self-alignment, clamping, fastening, lifting or identification markings. The clamp may be an SMD clamp. The SMD clamp may clamp the core or the winding or any combination. The two end side surfaces of the core housing may be substantially flat or enhanced with features for lifting or positioning during clamping or lifting or setting in place.

[0076] Fig.13A and Fig. 13B An example PCB layout 1500 is shown in which an example orthogonal plate toroidal winding assembly is provided, according to some embodiments. Fig.13A is a top view of a PCB layout 1500 including example orthogonal plate toroidal winding assemblies 1510 and 1520 . Fig. 13B is a bottom view of a PCB layout 1500 including cutouts (or openings) 1530 and 1540 which may be used as passages for placement of structures, thermal interface materials, or air channels to cool vertical plate toroidal winding assemblies, such as assemblies 1510 and 1520, by dissipating heat generated in winding assemblies 1510 and 1520. Fig. 13C According to some embodiments Fig. 13B A portion of the PCB with the transparent PCB view and heat sink cutouts highlighted.

[0077] Fig.14 Another example orthogonal plate toroidal winding assembly 1610 including a staggered lead design according to some embodiments is illustrated. Orthogonal plate toroidal winding assembly 1610 includes plates 1612 and 1614 having staggered protrusions that can act as electrical connection leads relative to each other. Plates 1612 and 1614 are connected to Fig. 6A The winding assembly 800 or Fig. 11B The plates of the winding assembly 1310 shown are similar in that staggered plates are provided. Plates 1612 and 1614 may each include laser welded portions forming loops (A, B) that alternate during assembly and manufacturing to provide distances between mounting points and welding points to prevent accidental electrical shorts between winding turns.

[0078] Fig.15A is a top view of an example orthogonal plate toroidal winding assembly viewed from the top of a PCB according to some embodiments. Fig. 15B According to some embodiments Fig.15A Side elevation view of a vertical plate toroidal winding assembly. Fig. 15C According to some embodiments Fig.15A Bottom view of the orthogonal plate toroidal winding assembly. Fig.15D According to some embodiments Fig.15AA cross-sectional view of a vertical plate toroidal winding assembly, and Fig.15E is an end view of the vertical plate toroidal winding assembly.

[0079] Fig.16A An independent choke design according to some embodiments is illustrated. FIG. 16B to FIG. 16D Illustrated is how a connector may be integrated into an orthogonal plate toroidal winding assembly according to some embodiments. Fig. 16B A practical application is shown with insert molded busbars acting as connector terminals. These are welded directly to the main orthogonal stamped windings. Fig. 16C There are alternative connector locations shown on either side of the choke depending on the embodiment. The terminal orientation can be rotated so that it is either aligned toward the center (see Fig. 16B ), or Fig. 16C as shown, depending on mating connector preference. Fig.16D It shows how, compared to the above embodiments, if the integration requires exposure of terminals or assembly orientation in an orthogonal axis, the mounting orientation can be adjusted as needed.

[0080] Fig.16E Illustrated is a bus bar used as a connector terminal integrated into a housing by insert molding according to some embodiments. Fig.16F An internal ribbon-based nanocrystalline core embedded within a shell is illustrated in accordance with some embodiments. Figure 16G Illustrated is how the power flow through a choke may be regulated in quadrature stamping according to some embodiments. Fig.16E A purple busbar is shown being used as a connector terminal insert molded into a housing. Reference numerals 1810 to 1840 indicate four stampings. Reference numeral 1850 indicates a thin stamped busbar (e.g., a U-shaped busbar) that can be used to carry light ampere currents. The thin stamped busbar 1850 can be made of a metal sheet. The thickness of the thin metal sheet 1850 can be approximately 0.8 mm. Reference numeral 1870 indicates a thick stamped busbar (e.g., a U-shaped busbar) that can be used to carry high ampere currents. The thick stamped busbar 1860 can be made of a metal sheet. The thickness of the thick metal sheet 1860 can be approximately 1.3 mm. The above thicknesses of the busbars 1850 and 1860 are examples only, and other thicknesses can also be used. Reference numeral 1870 indicates a nanocrystalline ribbon core, which can be Fig.16F The inductor core in (shown in dark grey). The nanocrystalline ribbon core 1870 may be made of wound nanocrystalline ribbon. Reference numeral 1880 indicates a gasket that is molded directly onto the housing to act as a dust seal for the product housing and seal the internal volume from the outside world.

[0081] Figure 16G It is shown that by using orthogonal stamping, the way power flows through the choke can be easily adjusted. Figure 16GIn the case of a winding split across the centerline, the upper winding acts similarly to Figure 4G , where power flows from left to right. Figure 16G In the bottom two windings shown in (orange), the windings are aligned to ensure the power flow direction is aligned along the vertical direction, which is 90 degrees directly north of the two windings shown in cyan. This integration allows the number of windings to be maintained while minimizing the overall footprint of the high voltage leakage drive.

[0082] Fig.17A and Fig. 17B Illustrated is how a connector housing with insert molded terminals is supplied to a core assembly housing according to some embodiments. Fig. 17C Illustrated is how a choke core and housing may be assembled according to some embodiments. FIG. 17D to FIG. 17F It illustrates how the rest of the winding structure is assembled to the main housing according to some embodiments. FIG. 17A to FIG. 17F It is shown that the connector-choke integration can be achieved with two components that can be welded together. For example, the two components include a connector housing with insert-molded terminals ( Fig.17A and Fig. 17B ) and the secondary half that surrounds the choke core and aligns with the remaining stampings and welding operations ( FIG. 17C to FIG. 17F ). The main benefits of this integration include integrating the connector and optimizing the power flow into and out of the connector. In addition, the integrated connector terminals allow for a DC path from the connector to the choke and do not contact the PCBA as required. This design can also significantly reduce the overall footprint of the choke and increase layout density (power density) using these components. Connector integration is easier due to the stamped structure of the busbar, which can provide a more integrated solution for blade-type connectors.

[0083] Fig.18A An assembled U-shaped bus bar is shown (wherein connector tabs grown for connector insertion will be mounted) according to some embodiments. Fig.18B A U-shaped busbar is shown mounted directly over a core assembly housing according to some embodiments. Some embodiments provide easier connector integration without the need for one or more intermediate components to convert a rounded profile wire, a rounded profile bar into a blade for connector mating, soldering, crimping, or insulation displacement to bite through a painted dielectric coating. Fig.18B Use stamped busbar construction for windings to provide easier / more efficient integration, as the male blades of traditionally stamped connectors can be stamped directly onto the windings. In some embodiments, if spacing permits, the geometry of the U-shaped busbar can be modified to add interfaces directly onto it.

[0084] Features, materials, characteristics or groups described in conjunction with a particular aspect, embodiment or example should be understood to be applicable to any other aspect, embodiment or example described in this section or elsewhere in this specification, unless incompatible therewith. All features disclosed in this specification (including any accompanying claims, abstract and drawings) and / or all steps of any method or process so disclosed may be combined in any combination, except for at least some mutually exclusive combinations of such features and / or steps. Protection is not limited to the details of any preceding embodiments. The protection extends to any novel one or any novel combination of features of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or any novel one or any novel combination of steps of any method or process so disclosed.

[0085] In addition, certain features described in the present disclosure in the context of separate implementations may also be implemented in combination in a single implementation. Conversely, various features described in the context of a single implementation may also be implemented in multiple implementations, either individually or in any suitable subcombination. Moreover, although features may be described above as functioning in certain combinations, one or more features from a claimed combination may in some cases be excised from the combination, and the combination may be claimed as a subcombination or a variation of a subcombination.

[0086] Moreover, although the operations may be depicted in the drawings or described in a particular order in the specification, such operations do not need to be performed in the particular order shown or in a sequential order, or all operations need not be performed to achieve the desired results. Other operations not depicted or described may be incorporated into the example methods and processes. For example, one or more additional operations may be performed before, after, at the same time, or between any of the described operations. In addition, the operations may be re-stepped or re-ordered in other implementations. Those skilled in the art will appreciate that in some embodiments, the actual steps taken in the illustrated and / or disclosed processes may be different from those shown in the drawings. Depending on the embodiment, some of the above steps may be removed, or other steps may be added. In addition, the features and attributes of the specific embodiments disclosed above may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure. Moreover, the separation of various system components in the above implementations should not be understood as requiring such separation in all implementations, and it should be understood that the components and systems described may generally be integrated together in a single software product or packaged into multiple products. For example, any component of the energy storage system described herein may be provided separately, or may be integrated together (e.g., packaged together or attached together) to form an energy storage system.

[0087] For the purposes of the present disclosure, certain aspects, advantages and novel features are described herein. According to any particular embodiment, not all such advantages may be achieved. Thus, for example, those skilled in the art will recognize that the present disclosure may be implemented or performed in a manner that achieves one advantage or a group of advantages taught herein without necessarily achieving other advantages that may be taught or suggested herein.

[0088] Unless specifically stated otherwise or otherwise understood to be used within the context, conditional language (such as "can," "could," "possibly," or "may") is generally intended to convey that some embodiments include and other embodiments do not include certain features, elements, and / or steps. Thus, such conditional language is generally not intended to imply that features, elements, and / or steps are in any way required for one or more embodiments, or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether such features, elements, and / or steps are included or to be performed in any particular embodiment.

[0089] Unless specifically stated otherwise, connective language, such as the phrase "at least one of X, Y, and Z," otherwise utilizes the contextual understanding that is generally used to convey that an item, term, etc. can be X, Y, or Z. Thus, such connective language is not generally intended to imply that certain embodiments require the presence of at least one X, at least one Y, and at least one Z.

[0090] Language of degree as used herein, such as the terms "approximately," "about," "generally," and "substantially" as used herein, refers to a value, amount or characteristic that is close to a stated value, amount or characteristic, which still performs a desired function or achieves a desired result.

[0091] The scope of the present disclosure is not limited by the specific disclosure of the embodiments in this section or elsewhere in this specification, and may be defined by the claims in this section or elsewhere in the specification or in the future. The language of the claims should be interpreted broadly based on the language used in the claims, and not limited to the examples described in this specification or examples described during the prosecution of the application, which examples should be interpreted as non-exclusive.

[0092] Although certain embodiments have been described, these embodiments are presented only by way of example and are not intended to limit the scope of the present disclosure. In fact, the novel methods and systems described herein may be implemented in various other forms. In addition, various omissions, substitutions, and changes may be made to the systems and methods described herein without departing from the spirit of the present disclosure. The attached claims and their equivalents are intended to cover such forms or modifications that fall within the scope and spirit of the present disclosure. Therefore, the scope of the present invention is limited only by reference to the attached claims.

Claims

1. An electromagnetic core and winding assembly, comprising: a core including a body and a hole defined by an inner surface of the body; as well as A plurality of plate windings are configured to electromagnetically operate with the core, the plurality of plate windings being disposed through and at least partially surrounding the body of the core, a portion of each of the plurality of plate windings passing through the hole of the core.

2. The assembly of claim 1, wherein the plurality of plate windings perpendicular to the equatorial plane of the core at least partially surround the body of the core.

3. An assembly according to claim 1 or 2, wherein the plurality of plate windings completely surround the body of the core.

4. The assembly according to any one of claims 1 to 3, further comprising a core housing in which the core is accommodated, the core housing comprising a plurality of vertical grooves formed on an outer surface thereof, the plurality of vertical grooves being configured to respectively accommodate the plurality of plate windings therein.

5. A component according to any one of claims 1 to 4, wherein each of the plurality of plate windings comprises a first plate and a second plate or more plates, the first plate comprising two opposite ends and at least partially surrounding the body of the core, the second plate or more plates being configured to be coupled to the two opposite ends of the first plate in a series chain arrangement with other similar plates.

6. The assembly of claim 5, wherein the first plate has a generally U-shape and the second plate has a generally I-shape.

7. The assembly of any one of claims 1 to 6, wherein the plurality of plate windings are generally U-shaped or shaped to surround the cross-sectional shape of the core.

8. A component according to any one of claims 1 to 7, wherein the plurality of plate windings include one or more first groups of plate windings surrounding a first side of the body of the core and one or more second groups of plate windings surrounding a second side of the body of the core, the second side being opposite to the first side.

9. A component according to any one of claims 1 to 8, wherein the one or more first groups of plate windings include a first group and a second group spaced apart from each other, wherein the first group includes a first number of plate windings, and wherein the second group includes a second number of plate windings.

10. The assembly of claim 9, wherein the first number and the second number are the same.

11. The assembly of claim 9, wherein the first number and the second number are different.

12. The assembly of claim 9, wherein at least one of the first set of plate windings or the second set of plate windings comprises a plurality of plates evenly spaced from one another.

13. The assembly of claim 9, wherein the first set of plate windings are spaced apart from the second set of plate windings in a range of about 0.5 mm to about 4 mm to 5 mm.

14. The assembly of claim 9, wherein at least one of the first set of plate windings or the second set of plate windings comprises a plurality of winding plates spaced apart from one another in a range of about 0.5 mm to about 1 mm to 2 mm.

15. An assembly according to any one of claims 1 to 13, wherein at least one of the plates has an electrical or thermal conductor section attached in parallel with the current flow to increase current carrying capacity, reduce electrical resistance and / or improve heat distribution or heat dissipation.

16. The assembly of claim 9, wherein the first set of plate windings includes a plurality of plates spaced apart from one another by a first distance, and wherein the second set of plate windings includes a plurality of plates spaced apart from one another by a second distance, the second distance being different from the first distance.

17. The assembly of claim 9, wherein at least one of the plate windings in the first set has a different thickness than at least one of the plate windings in the second set.

18. An assembly according to any one of claims 1 to 17, wherein at least one of the plates has a bending feature or additionally attached elements, including a bending feature or additionally attached elements for connecting a winding assembly, configured to extend for one or more of a thermal connection, a mechanical connection or an electrical connection or other functional purposes.

19. The assembly of any one of claims 1 to 18, wherein the core has a cross-section, wherein a core aspect ratio is defined as the length of the cross-section of the core divided by the width of the cross-section of the core, and wherein the core aspect ratio can vary.

20. An assembly according to any one of claims 1 to 19, wherein the plate is configured to join or branch winding units along the same side, other side or opposite side of the main core or one or more other core winding units to be electrically connected.

21. An assembly according to any one of claims 1 to 20, wherein the core comprises any material possessing desired magnetic properties, including a gas or a vacuum.

22. The assembly of any one of claims 1 to 21, further comprising a plurality of connector terminals coupled to the plurality of plate windings. 23 . The assembly of claim 22 , wherein the core and the plurality of plate-type windings are accommodated in a housing, and wherein the plurality of connector terminals are integrated into the housing by insert molding.

Images