Surface Mountable Planar Magnet for High-Impact Environments

Abstract

A winding assembly, such as a transformer or inductor, includes spring clips and retaining clips for mechanically coupling the winding assembly to a printed circuit board (PCB) or printed wiring board (PWB). The clips provide structural rigidity to the winding assembly, enabling the winding assembly to continue to function during high shock events. Further, the clips compress a thermal pad positioned under the winding assembly, providing a sufficient heat transfer surface area to dissipate heat from the winding assembly.

Description

Technical Field

[0001] The present invention relates to a wound assembly power device, and more particularly, to a mechanical attachment for a wound assembly power device.

[0002] As the power density of electronic power devices (such as transformers, inductors, etc.) increases, custom power devices are designed to provide the power essential for state-of-the-art performance. Conventionally, for large power devices such as DC-DC transformers and inductors, a significant amount of manual assembly is required to heat sink the device and solder it to a circuit board. The manual assembly process is time-consuming, costly, and there is a possibility of thermal expansion stress occurring in the components of the large power device during the heat dissipation and soldering processes. Therefore, there is a need for a reliable and low-cost solution for attaching large custom power devices to circuit boards. Furthermore, there is a need for large custom power devices that can withstand high shock loads while also minimizing the thermal expansion stress conventionally experienced during the assembly process.

Summary of the Invention

[0003] According to one aspect of the present disclosure, a wound assembly configured to be coupled to the surface of a printed wiring board is disclosed. The wound 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 leg and the second leg are positioned adjacent to the surface of the printed wiring board. The spring clip is at least partially positioned on the cover of the ferrite core. The spring clip includes a third leg and a fourth leg, and the third leg and the fourth leg are positioned adjacent to the surface of the printed wiring board.

Brief Description of the Drawings

[0004]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6A

Figure 6B

Figure 7

Mode for Carrying Out the Invention

[0005] FIG. 1 is a perspective view of the first embodiment of the winding assembly 10. FIG. 2 is a cross-sectional view of the winding assembly 10 along the cutting line A-A shown in FIG. 1. FIG. 3 is an exploded view of the first embodiment of the winding assembly 10. FIG. 4 is a perspective view of the ferrite core 14 of the first embodiment of the winding assembly 10. FIG. 5 is a perspective view of the first embodiment of the winding assembly 10 coupled to the printed wiring board 11. FIGS. 1 to 5 are considered 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 holding 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 considered to be coupled to the surface of the printed wiring board 11, it should be understood that this includes, among other things, printed boards, microchips, motherboards, chips, and ultra-small circuits.

[0006] The winding 12 is the electrical center or central component of the winding assembly 10 and includes a current-carrying conductor wound around a central or center component. As such, the winding 12 includes one or more windings (turns) of current-carrying wire that form a continuous coil through which current can pass. In the example shown in FIG. 1, the winding 12 includes three separate layers that are joined together to form the winding 12. The 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. The continuous coil 30 is positioned between the first printed circuit board 26 and the second printed circuit board 28, and the continuous coil 30 is wound around a central or center component (not explicitly shown) of the winding 12. Further, the continuous coil 30 passes through the second printed circuit board 28 such that an end of the continuous coil 30 is electrically coupled to one of the plurality of terminals 32 by a standard electrical connection. As best shown in FIG. 5, each of the plurality of terminals 32 is electrically coupled to the printed wiring board 11 to enable current to pass between the winding 12 and the printed wiring board 11.

[0007] The ferrite core 14 is a magnetic core made of ferrite with the winding 12 formed thereon. As best shown in FIG. 4, the ferrite core 14 includes a base 34, a cover 36, and a cylinder 38. The base 34 has a generally rectangular shape and is coupled to the cover 36 along its short edge. The cover 36 is positioned on and coupled to the base 34 and includes a first notch 40 and a second notch 42. The first notch 40 extends inwardly from the first outer long edge of the cover 36 toward the center of the cover 36. The second notch 42 extends inwardly from the second outer long edge of the cover 36 toward the center of the cover 36. The ferrite core 14 includes the first notch 40 and the second notch 42 such that the continuous coil 30 can pass through the ferrite core 14 without interference. As best shown in FIG. 3, a single continuous coil 30 passes through the second notch 42 and there is no coil passing through the first notch 40. By including both the first notch 40 and the second notch 42, flexibility is provided in the design of the winding assembly 10 and the continuous coil 30 can pass through the ferrite core 14 from either side. The cylinder 38 is positioned at approximately the central position of the base 34 and the cover 36 of the ferrite core 14. The cylinder 38 is characterized by having a circular cross-section that extends from the upper surface of the base 34 to the inner surface of the cover 36. The cylinder 38 of the ferrite core 14 is a component / feature of the winding assembly 10 around which the continuous coil 30 is wound, as described above.

[0008] As best shown in FIGS. 1, 3, and 5, the ferrite core 14 at least partially surrounds the winding 12. More specifically, the central portion of the winding 12 is surrounded and covered by the cover 36, and the four outer corners of the winding 12 extend outwardly beyond the base 34 of the ferrite core 14 and the cover 36. In other words, when the base 34 of the ferrite core 14 and the cover 36 are joined together, a window or opening is formed between the base 34 and the cover 36. The winding 12 is positioned within the window or opening, and since the winding 12 extends outwardly through both the base 34 and the cover 36, the ferrite core 14 surrounds only a portion of the winding 12. Further, by extending beyond the edge of the ferrite core 14, each of the plurality of terminals 32 can be electrically coupled to the printed wiring board 11. In some examples, each of the plurality of terminals 32 may be coupled to an electrical contact on the printed wiring board 11 via a plurality of solders.

[0009] The spacer 16 is positioned between the upper surface of the winding 12 and the lower or inner surface of the cover 36 of the ferrite core 14. Further, the spacer 16 extends beyond the outer edges of the two sides of the cover 36. More specifically, the spacer 16 extends beyond both of the long edges of the cover 36 in a direction perpendicular to the long edges of the cover 36. The spacer 16 extends beyond both of the long edges of the cover 36, whereby the area of the spacer 16 exists beyond both of the long edges of the cover 36. In the example shown, the spacer 16 is a thin rectangular sheet, but in another example, the spacer 16 can have any shape that substantially conforms to the outer periphery of the winding 12. In some examples, the spacer 16 can be composed of G10, FR4, or other composite materials. The spacer 16 is configured to prevent damage to the top surface of the winding 12 due to wear by providing a surface against which the features of the spring clip 24 contact and slide or rub, as will be further considered below. Further, the spacer 16 is configured to provide electrical insulation between the spring clip 24 and the winding 12 to prevent the flow of current between the components.

[0010] In the example shown, there is a small gap between the upper surface of the spacer 16 and the lower or inner surface of the cover 36. Since the gap is small, when the temperature of each component rises, the thermal expansion of the winding 12, the spacer 16, and the ferrite core 14 is allowed, and cracking or damage of the ferrite core 14 due to differences in the coefficient of thermal expansion characteristics between the respective components is also prevented. More specifically, the small gap provides a place where the size of the winding 12 increases in the vertical direction due to thermal expansion without inducing stress in the ferrite core 14. If there were no small gap and the winding 12 was in direct contact with the cover 36, there would be a possibility of cracking in the ferrite core 14 due to the force applied to the ferrite core during the thermal expansion of the components. In other examples where the coefficient of thermal expansion of each component is similar, there may be no small gap.

[0011] As best shown in FIGS. 2-3, the first pad 18 is positioned between the lower surface of the base 34 of the ferrite core 14 and the upper surface of the printed wiring board 11. The second pad 20 is positioned between the upper surface of the cover 36 of the ferrite core 14 and the lower or inner surface of the spring clip 24, as will be further discussed below. In the example shown, both the first pad 18 and the second pad 20 are rectangular in shape and are 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 composed of 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 composed of any material having a maximum operating temperature of at least 235 degrees Celsius. With the first pad 18 and the second pad 20 having a maximum operating temperature of at least 235 degrees Celsius, the winding assembly 10 can perform a reflow process without melting or damaging the first pad 18 and the second pad 20. In other words, if the maximum operating temperature of the first pad 18 and the second pad 20 is less than 235 degrees Celsius, there is a possibility of damage or adverse effects occurring to the first pad 18 and the second pad 20 during the reflow process.

[0012] The first pad 18 is configured to release the heat generated by the winding 12 from the winding 12 through the printed wiring board 11 to the outside from the base plate of the printed wiring board 11. Therefore, in order to ensure the presence of a sufficient heat transfer surface area between the winding assembly 10 and the printed wiring board 11, it is beneficial to compress the first pad 18 under the base 34 of the ferrite core 14. When the first pad 18 is compressed, there will surely be no ridges or voids between the bottom surface of the first pad 18 and the printed wiring board 11, and by maximizing the available heat transfer surface area of the first pad 18, maximum heat transfer is ensured. The second pad 20 can also provide some heat transfer from the ferrite core 14 to the surrounding environment. However, the second pad 20 is mainly configured to evenly disperse the compression force induced by the spring clip 24 and the holding clip 22 onto the ferrite core 14. Therefore, the second pad 20 is configured to provide a surface area that ensures uniform compression of the winding assembly 10 by evenly compressing the surface area of the first pad 18 located below the base 34 of the ferrite core 14, resulting in better heat transfer characteristics.

[0013] Both the retaining clip 22 and the spring clip 24 are positioned over the ferrite core 14, the first pad 18, and the second pad 20, and both the retaining clip 22 and the spring clip 24 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 downward toward the printed wiring board 11. Further, the retaining clip 22 and the spring clip 24 are also configured to apply a downward force to the winding 12, as further discussed below. In the illustrated embodiment, the retaining clip 22 and the spring clip 24 are described 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 can 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.

[0014] The first leg 44 and the second leg 46 are flanges of the retaining clip 22 that are oriented substantially parallel to the upper surface of the printed circuit board 11 and substantially parallel to each other. The first leg 44 and the second leg 46 are configured to directly abut against the upper surface of the printed circuit board 11 when the retaining clip 22 is coupled to the printed circuit 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, by, among other things, a press-fit operation, an external diameter screw connection, or a welding connection. The first threaded insert 54 and the second threaded insert 56 are configured to receive a fastener, such as a threaded fastener, that passes upwardly through the printed circuit board 11 from the underside of the printed circuit board 11 toward the winding assembly 10. Thus, the first threaded insert 54 and the second threaded insert 56 are configured to secure the retaining clip 22 to the printed circuit board 11. In another example, the first leg 44 and the second leg 46 can include openings therethrough such that a fastener can pass through the first leg 44 and the second leg 46 and be coupled to a threaded insert positioned within the printed circuit board 11.

[0015] 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 horizontally, then vertically downward (resulting in 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, thus, the overall retaining clip 22. The upper member 48 can be constructed from sheet metal or other thin metallic material that can withstand a bending operation to form its final shape. The first arm 50 and the second arm 52 extend from the first leg 44, the second leg 46, and the upper member 48.

[0016] More specifically, the first arm 50 extends outwardly from the first leg 44 and the upper member 48 at an angle perpendicular to the vertically extending portion of the upper member 48. Similarly, the second arm 52 extends outwardly from the second leg 46 and the upper member 48 at an angle perpendicular 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 arm 50 and the second arm 52 extend in the same direction. The first arm 50 and the second arm 52, like the upper member 48, can be composed of sheet metal or other thin metal materials. The first arm 50 includes a first hook 58 positioned at the distal free 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 the distal free 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 and couple with the features of the spring clip 24 discussed below.

[0017] The spring clip 24 includes a third leg 62, a fourth leg 64, an upper member 66, a body 68, a lip portion 70, a first contact 72, a second contact 74, a third threaded insert 76, a fourth threaded insert 78, a first fastener 80, a second fastener 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 can include multiple alignment pins 84 to help accurately align the spring clip 24 within the winding assembly 10.

[0018] The third leg 62 and the fourth leg 64 are flanges of the spring clip 24 that are oriented substantially parallel to the upper surface of the printed wiring board 11 and substantially parallel to each other. The third leg 62 and the fourth leg 64 are configured to directly contact 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, by, among other things, a press-fit operation, an external diameter screw connection, or a welding connection. The third threaded insert 76 and the fourth threaded insert 78 are configured to receive a fastener, such as a threaded fastener, that passes upwardly through the printed wiring board 11 from the underside of the printed wiring board 11 toward the winding assembly 10. Thus, the third threaded insert 76 and the fourth threaded insert 78 are configured to secure the spring clip 24 to the printed wiring board 11. In another example, the third leg 62 and the fourth leg 64 can include openings therethrough such that a fastener can pass through the third leg 62 and the fourth leg 64 and be coupled to a threaded insert positioned within the printed wiring board 11.

[0019] The upper member 66 of the spring clip 24 is a generally U-shaped member that extends between the third leg 62 and the fourth leg 64. In other words, the upper member 66 extends vertically upward from the third leg 62, then horizontally, then vertically downward (resulting in a U-shaped member), and then connects to the fourth leg 64. The upper member 66 is configured to provide structure and support between the third leg 62 and the fourth leg 64 and, thus, the overall spring clip 24. The upper member 66 can be constructed from a sheet metal or other thin metal material that can withstand the bending operations to form the final shape of the upper member 66. The body 68 is coupled to and extends from the upper member 66.

[0020] The body 68 has one end coupled to the upper member 66 of the spring clip 24, extends outwardly from the upper member 66, and has a free end positioned on the opposite side of the end coupled to the upper member 66. The body 68 is a substantially flat sheet metal or other thin metal material. The body 68 has a generally rectangular shape similar to the shape of the cover 36 of the ferrite core 14. In some examples, the body 68 can be coupled to the upper member 66 by a welding connection, an adhesive, or other means for joining the metal materials together. In another example, the body 68 and the upper member 66 can be formed from a single material and a bending operation can be used to produce the desired shapes of the upper member 66 and the body 68. The free end of the body 68 includes a lip portion 70 that extends upwardly and angled away from the body 68. In some examples, the angle can be a right angle. The lip portion 70 is configured to provide a location 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 onto the printed wiring board 11, as will be further discussed below.

[0021] As best shown in FIG. 3, the body 68 includes a first contact 72 and a second contact 74 extending from both 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 each extend downwardly toward the third leg 62 and the fourth leg 64. In some examples, the upper portions of the first contact 72 and the second contact 74 coupled to the body 68 can be positioned parallel to the flat upper surface of the body 68. In other examples, the upper portions of the first contact 72 and the second contact 74 coupled to the body 68 can be positioned at an acute angle to the flat upper surface of the body 68. Thus, in some examples, the upper portions of the first contact 72 and the second contact 74 coupled to the body 68 can extend upwardly at a slight angle from the body 68. The first contact 72 and the second contact 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 from the outer edge of the body 68. Next, the first contact 72 and the second contact 74 change direction at the first bend and extend downwardly toward the third leg 62 and the fourth leg 64. Next, the first contact 72 and the second contact 74 change direction again at the second bend and extend outwardly from the body 68 again. In some examples, a respective portion of each of the first contact 72 and the second contact 74 is perpendicular to the body 68, and another respective portion of each of the first contact 72 and the second contact 74 is parallel to the body 68.

[0022] The first contact 72 and the second contact 74 are positioned adjacent to and in direct contact with the spacer 16, inducing a compressive force on the spacer 16. Therefore, when the first contact 72 and the second contact 74 are pressed against the spacer 16, the first contact 72 and the second contact 74 are configured to bend upward from the spacer 16. As a result, a compressive force is generated 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 described above, the size and position of the spacer 16 are set such that the first contact 72 and the second contact 74 are pressed against the spacer 16 and not directly against the winding 12, preventing damage due to wear on the winding 12. As shown in FIG. 3, the first contact 72 includes a notch 86 that completely penetrates the first contact 72 of the spring clip 24. As shown in FIG. 5, the second contact 74 includes a notch 86 that completely penetrates the second contact 74 of the spring clip 24. The notch 86 is an opening that completely penetrates the first contact 72 and the second contact 74, thereby enabling the continuous coil 30 to extend from the inside of the ferrite core 14 to the outside of the ferrite core 14, such that the continuous coil 30 can be coupled to one of the plurality of terminals 32 of the winding 12.

[0023] The spring clip 24 also includes a first fastener 80, a second fastener 82, and an alignment pin 84. The first fastener 80 is coupled to and extends from the third leg 62, and the second fastener 82 is coupled to and extends from the fourth leg 64. The first fastener 80 and the second fastener 82 are upward features configured to engage and couple with the downward 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 engage and couple with the first fastener 80 of the spring clip 24, and the second hook 60 of the retaining clip 22 is configured to engage and couple with the second fastener 82 of the spring clip 24. Therefore, the first hook 58 and the first fastener 80 have mating shapes, and the second hook 60 and the second fastener 82 have mating shapes such that these features can mate and couple together. The coupling of the first hook 58 with the first fastener 80 and the coupling of the second hook 60 with the second fastener 82 fix the retaining clip 22 to the spring clip 24 when the winding assembly 10 is assembled and used. Further, the coupling of the first hook 58 with the first fastener 80 and the coupling of the second hook 60 with the second fastener 82 prevent the retaining clip 22 and the spring clip 24 from being pulled apart or separated from each other during a high-impact event. The alignment pin 84 is positioned adjacent to and extends from the second fastener 82, and the alignment pin 84 extends away from the second fastener 82 and the fourth leg 64. The alignment pin 84 is configured to engage with an opening in the printed circuit board 11 to properly align the winding assembly on the printed circuit board 11 during assembly of the winding assembly 10 to the printed circuit board 11.

[0024] 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 downward toward the printed wiring board 11 to fix 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 utilized to mechanically couple the winding assembly 10 to the printed wiring board 11. The winding assembly 10 serves to couple a large surface mount power device to the printed wiring board 11, thereby minimizing stress on the solder joints previously used to secure the winding 12 to the printed wiring board 11. Further, the winding assembly 10 firmly couples the winding 12 to the printed wiring board 11, enabling the safety and operability of the winding assembly 10 to be maintained during high shock events. The winding assembly 10 provides advantages in fixing a large surface mount power device to a printed wiring board compared to previous soldering methods.

[0025] FIG. 6A is a first perspective view of a second embodiment of the winding assembly 10A. FIG. 6B is a second perspective view of the second embodiment of the winding assembly 10A shown in FIG. 6A. FIG. 7 is an exploded assembly view of the second embodiment of the winding assembly 10A. Consider FIGS. 6A - 7 together. The winding assembly 10A is substantially similar to the winding assembly 10, and it should be understood that the disclosure regarding the winding assembly 10 applies equally to the winding assembly 10A unless otherwise specified. To avoid redundancy, only the differences between the winding assembly 10A and the winding assembly 10 will be considered below.

[0026] The first difference between the winding assembly 10A and the winding assembly 10 is that the retaining clip 22A of the winding assembly 10A includes a first biasing arm 88A and a second biasing arm 90A. As best shown in FIG. 7, the first biasing arm 88A extends inwardly from a first side of the generally U-shaped upper member 48A toward the center of the generally U-shaped upper member 48A. The second biasing arm 90A extends inwardly from a second side of the generally U-shaped upper member 48A toward the center of the generally U-shaped upper member 48A. Further, the first biasing arm 88A and the second biasing arm 90A are positioned above the midpoint of the vertically extending portion of the upper member 48A. The first biasing arm 88A and the second biasing arm 90A are configured to further induce a force on the ferrite core 14A to fix the ferrite core 14A within the 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 horizontally fix the ferrite core 14A within the winding assembly 10A and prevent the ferrite core 14A from sliding or moving within the winding assembly 10A during use and / or during high shock events.

[0027] The second difference between the winding assembly 10A and the winding assembly 10 is that the spring clip 24A of the winding assembly 10A includes a first stopper 92A and a second stopper 94A. As best shown in FIG. 6B, the first stopper 92A extends inwardly from a first side of the generally U-shaped upper member 66A toward the center of the generally U-shaped upper member 66A. The second stopper 94A extends inwardly from a second side of the generally U-shaped upper member 66A toward the center of the generally U-shaped upper member 66A. The first stopper 92A and the second stopper 94A are configured to provide the ferrite core 14A with a contact surface that is pushed toward the first stopper 92A and the second stopper 94A by the first biasing arm 88A and the second biasing arm 90A. Thus, the first stopper 92A and the second stopper 94A help to prevent the ferrite core 14A from sliding or moving within the winding assembly 10A during use and / or during high shock events.

[0028] The winding assembly 10A serves to couple a large surface - mount power device to a printed circuit board, thereby minimizing stress on the solder joints previously used to secure the winding 12A to the printed circuit board. This is another embodiment. Further, the winding assembly 10A securely couples the winding 12A to the printed circuit board, enabling the safety and operability of the winding assembly 10A to be maintained during high - impact events. The winding assembly 10A provides advantages in securing a large surface - mount power device to a printed circuit board compared to previous soldering methods.

[0029] Consideration of possible embodiments The following is a non - exclusive description of possible embodiments of the present invention.

[0030] A winding assembly configured to be coupled to the surface of a printed circuit board, the winding assembly comprising: a winding at least partially surrounded by a ferrite core, the ferrite core including a base and a cover; a holding clip including a first leg and a second leg, the first leg and the second leg being positioned adjacent to the surface of the printed circuit board; and a spring clip at least partially positioned on the cover of the ferrite core, the spring clip including a third leg and a fourth leg, the third leg and the fourth leg being positioned adjacent to the surface of the printed circuit board.

[0031] The winding assembly of the preceding paragraph can optionally further and / or alternatively include any one or more of the following features, configurations, and / or additional components.

[0032] The holding clip further includes an upper member extending between and connecting the first leg and the second leg, the upper member being a generally U - shaped member, and a first arm extending vertically from the upper member and a second arm extending vertically from the upper member, the first arm being positioned parallel to the second arm.

[0033] The first arm includes a first hook positioned at the distal free end of the first arm, and the second arm includes a second hook positioned at the distal free end of the second arm.

[0034] The first biasing arm extends inwardly from the first side of the substantially U-shaped upper member towards the center of the substantially U-shaped upper member, and the second biasing arm extends inwardly from the second side of the substantially U-shaped upper member towards the center of the substantially U-shaped upper member.

[0035] The first threaded insert is coupled to the first leg of the retaining clip, and the second threaded insert is coupled to the second leg of the retaining clip.

[0036] The spring clip includes an upper member extending between and connecting a third leg and a fourth leg, the upper member being a substantially U-shaped member; a body coupled to the upper member and extending from the upper member, the body including an upward lip portion positioned at the distal free end of the body; a first contact extending from a first edge of the body, and a second contact extending from a second edge of the body; and the first contact and the second contact extend from the body towards the third leg and the fourth leg respectively.

[0037] The first stopper extends inwardly from the first side of the substantially U-shaped upper member towards the center of the substantially U-shaped upper member, and the second stopper extends inwardly from the second side of the substantially U-shaped upper member towards the center of the substantially U-shaped upper member.

[0038] A notch penetrates the first contact of the spring clip, and this notch allows the electrical connector to extend from the inside of the ferrite core to the outside of the ferrite core.

[0039] The first contact and the second contact each include a first bend and a second bend, so that a respective portion of each of the first contact and the second contact is perpendicular to the body, and a respective other portion of each of the first contact and the second contact is parallel to the body.

[0040] The spring clip further includes a first fastener extending from the third leg and a second fastener extending from the fourth leg. The alignment pin is positioned adjacent to the second fastener and extends away from the second fastener and the fourth leg.

[0041] The third threaded insert is coupled to the third leg of the spring clip, and the fourth threaded insert is coupled to the fourth leg of the spring clip.

[0042] A first pad is positioned between the surface of the printed circuit board and the bottom surface of the base of the ferrite core.

[0043] A second pad is positioned between the upper surface of the cover of the ferrite core and the inner surface of the spring clip.

[0044] The first pad and the second pad are composed of a material with a maximum operating temperature of at least 235 degrees Celsius.

[0045] A spacer is positioned between the winding and the cover of the ferrite core, and the spacer extends beyond the outer edge of the cover.

[0046] The first contact and the second contact of the spring clip are positioned adjacent to the spacer and in direct contact with the spacer, and the first contact and the second contact are configured to induce a compressive force on the spacer.

[0047] The cover of the ferrite core includes a first notch extending from the first outer edge of the cover towards the center of the cover, and the ferrite core includes a second notch extending from the second outer edge of the cover towards the center of the cover.

[0048] The ferrite core includes a cylinder positioned at approximately the central position of the ferrite core, and the cylinder extends from the upper surface of the base to the inner surface of the cover.

[0049] The winding includes a plurality of coils wound around the cylinder of the ferrite core, and the ends of the plurality of coils are coupled to the terminals of the winding.

[0050] The winding includes a plurality of terminals extending from the winding, and the plurality of terminals are configured to be electrically coupled to a printed wiring board.

[0051] The present invention has been described with reference to exemplary embodiments (s), but those skilled in the art will understand that various changes can be made without departing from the scope of the present invention and equivalents can be used in place of the elements of the embodiments. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present invention without departing from the basic scope of the present invention. Therefore, the present invention is not limited to the specific embodiments (s) disclosed, but is intended to include all embodiments within the scope of the appended claims.

Claims

1. A winding assembly configured to be coupled to a surface of a printed wiring board, comprising: A winding at least partially surrounded by a ferrite core, the ferrite core including a base and a cover, the winding; A retaining clip including a first leg and a second leg, the first leg and the second leg being positioned adjacent to the surface of the printed wiring board, the retaining clip; A spring clip at least partially positioned on the cover of the ferrite core, the spring clip including a third leg and a fourth leg, the third leg and the fourth leg being positioned adjacent to the surface of the printed wiring board, the spring clip; A winding assembly.

2. The retaining clip includes: An upper member extending between and connecting the first leg and the second leg, the upper member being a substantially U-shaped member; A first arm extending vertically from the upper member and a second arm extending vertically from the upper member, the first arm being positioned parallel to the second arm, the first arm and the second arm;

3. The first arm includes a first hook positioned at a distal free end of the first arm, and the second arm includes a second hook positioned at a distal free end of the second arm. The winding assembly according to claim 2.

4. A first biasing arm extends inwardly from a first side of the substantially U-shaped upper member towards the center of the substantially U-shaped upper member, and a second biasing arm extends inwardly from a second side of the substantially U-shaped upper member towards the center of the substantially U-shaped upper member. The winding assembly according to claim 2.

5. A first threaded insert is coupled to the first leg of the retaining clip, and a second threaded insert is coupled to the second leg of the retaining clip. The winding assembly according to claim 1.

6. The spring clip includes: An upper member extending between and connecting the third leg and the fourth leg, the upper member being a substantially U-shaped member; A body coupled to the upper member and extending from the upper member, the body including an upward lip portion positioned at a distal free end of the body; 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 each extend from the body towards the third leg and the fourth leg, further comprising the first contact and the second contact, the winding assembly according to claim 1.

7. The first stopper extends inwardly from a first side of the substantially U-shaped upper member towards the center of the substantially U-shaped upper member, and the second stopper extends inwardly from a second side of the substantially U-shaped upper member towards the center of the substantially U-shaped upper member, the winding assembly according to claim 6.

8. The notch penetrates the first contact of the spring clip, and the notch allows the electrical connector to extend from inside the ferrite core to outside the ferrite core, the winding assembly according to claim 6.

9. 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 winding assembly according to claim 6.

10. The spring clip further includes a first fastener extending from the third leg and a second fastener extending from the fourth leg, and the alignment pin is positioned adjacent to the second fastener and extends away from the second fastener and the fourth leg, the winding assembly according to claim 1.

11. 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, the winding assembly according to claim 1.

12. Further comprising a first pad positioned between the surface of the printed circuit board and the bottom surface of the base of the ferrite core, the winding assembly according to claim 1.

13. Further comprising a second pad positioned between the upper surface of the cover of the ferrite core and the inner surface of the spring clip, the winding assembly according to claim 12.

14. The first pad and the second pad are composed of a material having a maximum operating temperature of at least 235 degrees Celsius, the winding assembly according to claim 13.

15. A spacer is positioned between the winding and the cover of the ferrite core, and the spacer extends beyond the outer edge of the cover. The winding assembly according to claim 1.

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

17. The cover of the ferrite core includes a first notch extending from a first outer edge of the cover toward the center of the cover, and the ferrite core includes a second notch extending from a second outer edge of the cover toward the center of the cover. The winding assembly according to claim 1.

18. The ferrite core includes a cylinder positioned at a substantially central position of the ferrite core, and the cylinder extends from an upper surface of the base to an inner surface of the cover. The winding assembly according to claim 1.

19. The winding includes a continuous coil wound around the cylinder of the ferrite core, and an end of the continuous coil is coupled to a terminal of the winding. The winding assembly according to claim 18.

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

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