Orthogonal-junction plate windings for toroidal magnetics.

Abstract

An electromagnetic core and winding assembly is proposed. The assembly may include a core having a body and an opening defined by an inner surface of the body. The assembly may also include a plurality of plate windings configured to operate electromagnetically with the core, the plurality of plate windings being arranged to intersect and partially surround the body of the core. A portion of each of the plurality of plate windings may extend through the opening in the core. The 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 junction plate windings for toroidal magnetics. [Brief explanation of the drawings]

[0002] The foregoing and other features of the present disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings, in which: The present disclosure will be described with additional specificity and detail through the use of the accompanying drawings, with the understanding that these drawings illustrate only some embodiments in accordance with the present disclosure and should not be considered as limiting its scope.

[0003] [Figure 1] FIG. 1 illustrates an exemplary orthogonal plate toroidal winding assembly, according to some embodiments.

[0004] [Figure 2] FIG. 2 is a 3D electrical model diagram of the orthogonal plate toroidal winding assembly of FIG. 1 in accordance with some embodiments.

[0005] [Figure 3A] FIG. 1 illustrates another exemplary orthogonal plate toroidal winding assembly, according to some embodiments. [Figure 3B] FIG. 1 illustrates another exemplary orthogonal plate toroidal winding assembly, according to some embodiments. [Figure 3C] FIG. 1 illustrates another exemplary orthogonal plate toroidal winding assembly, according to some embodiments. [Figure 3D] FIG. 1 illustrates another exemplary orthogonal plate toroidal winding assembly, according to some embodiments.

[0006] [Figure 4A] 10A-10C illustrate process steps for combining plates with a core housing into a core winding assembly according to some embodiments. [Figure 4B] 10A-10C illustrate process steps for combining plates with a core housing into a core winding assembly according to some embodiments. [Figure 4C] 10A-10C illustrate process steps for combining plates with a core housing into a core winding assembly according to some embodiments. [Figure 4D] 10A-10C illustrate process steps for combining plates with a core housing into a core winding assembly according to some embodiments. [Figure 4E] 10A-10C illustrate process steps for combining plates with a core housing into a core winding assembly according to some embodiments. [Figure 4F] 10A-10C illustrate process steps for combining plates with a core housing into a core winding assembly according to some embodiments. [Figure 4G] 10A-10C illustrate process steps for combining plates with a core housing into a core winding assembly according to some embodiments.

[0007] [Figure 5A] 3E is a different view of the core winding assembly of FIG. 3D according to some embodiments. [Figure 5B] 3E is a different view of the core winding assembly of FIG. 3D according to some embodiments. [Figure 5C] 3E is a different view of the core winding assembly of FIG. 3D according to some embodiments. [Figure 5D] 3E is a different view of the core winding assembly of FIG. 3D according to some embodiments.

[0008] [Figure 6A] 10A-10C illustrate alternative edge-to-edge butt weld joints with combined plates according to some embodiments.

[0009] [Figure 6B]10A-10C illustrate cross-sectional images of an exemplary interactive spatial awareness core, housing, and U-shaped busbar tight fitment, according to some embodiments.

[0010] [Figure 6C] 1A-1C illustrate types of weld joints, according to some embodiments.

[0011] [Figure 7A] 1A-1C illustrate exemplary existing magnetic core materials made by plate stamping. [Figure 7B] 1A-1C illustrate exemplary existing magnetic core materials made by plate stamping. [Figure 7C] 1A-1C illustrate exemplary existing magnetic core materials made by plate stamping.

[0012] [Figure 7D] FIG. 1 illustrates an example of a progressive plate stamping format for a conductor, according to some embodiments. [Figure 7E] FIG. 1 illustrates an example of a progressive plate stamping format for a conductor, according to some embodiments.

[0013] [Figure 8A] 1A-1C illustrate exemplary orthogonal plate toroidal winding assemblies with different numbers of parts and unique part geometries, according to some embodiments. [Figure 8B] 1A-1C illustrate exemplary orthogonal plate toroidal winding assemblies with different numbers of parts and unique part geometries, according to some embodiments.

[0014] [Figure 8C] FIG. 10 illustrates that, according to some embodiments, conductor stampings can be augmented by stacking and connecting other stampings that can be partially or completely sized to double or multiple the local current carrying capacity, reduce electrical resistance, and enhance the thermal path of the conductor.

[0015] [Figure 9A] 1A-1C illustrate an exemplary welding and fastening method for welding plates together, according to some embodiments. [Figure 9B] 1A-1C illustrate an exemplary welding and fastening method for welding plates together, according to some embodiments.

[0016] [Figure 10A] 1 illustrates another exemplary welding method for welding plates together, according to some embodiments. [Figure 10B] 1 illustrates another exemplary welding method for welding plates together, according to some embodiments. [Figure 10C] 1 illustrates another exemplary welding method for welding plates together, according to some embodiments.

[0017] [Figure 11A] FIG. 10 illustrates another exemplary orthogonal plate toroidal winding assembly in which exposed support points or electrical connection points are staggered to prevent electrical shorting. [Figure 11B] 1 illustrates another exemplary orthogonal plate toroidal winding assembly in which exposed support or electrical connection points are staggered to prevent electrical shorting. According to some embodiments, the stampings may be insulated from each other by other dielectric materials, such as sheets or films, that are separate individual components from the core structure.

[0018] [Figure 11C] FIG. 10 illustrates a comparative core winding assembly having windings disposed on only one side of the core.

[0019] [Figure 11D] FIG. 10 illustrates another exemplary orthogonal plate toroidal winding assembly that may have windings above or below each other or side by side, according to some embodiments.

[0020] [Figure 11E] FIG. 11E is a cross-sectional view of the orthogonal plate toroidal winding assembly of FIG. 11D according to some embodiments.

[0021] [Figure 11F] FIG. 11B is an enlarged view of FIG. [Figure 11G] FIG. 11B is an enlarged view of FIG. 11C.

[0022] [Figure 12A] FIG. 1 illustrates how an exemplary orthogonal plate toroidal winding assembly can present a surface designated to serve as a gripping area for an automated gripper, according to some embodiments. [Figure 12B] FIG. 1 illustrates how an exemplary orthogonal plate toroidal winding assembly can present a surface designated to serve as a gripping area for an automated gripper, according to some embodiments.

[0023] [Figure 13A] 1 illustrates an exemplary PCB layout on which an exemplary orthogonal plate toroidal winding assembly is arranged, according to some embodiments. [Figure 13B] 1 illustrates an exemplary PCB layout on which an exemplary orthogonal plate toroidal winding assembly is arranged, according to some embodiments.

[0024] [Figure 13C] FIG. 13C illustrates a portion of FIG. 13B with a perspective PCB view and heat dissipation cutouts highlighted, according to some embodiments.

[0025] [Figure 14] FIG. 10 illustrates another exemplary orthogonal plate toroidal winding assembly including an interleaved lead design, according to some embodiments.

[0026] [Figure 15A]FIG. 1 illustrates a top view of an exemplary orthogonal plate toroidal winding assembly mounted on a PCB, according to some embodiments.

[0027] [Figure 15B] FIG. 15B is a front view of the orthogonal plate toroidal winding assembly of FIG. 15A according to some embodiments.

[0028] [Figure 15C] FIG. 15B is a bottom view of the orthogonal plate toroidal winding assembly of FIG. 15A according to some embodiments.

[0029] [Figure 15D] FIG. 15B is a side view of the orthogonal plate toroidal winding assembly of FIG. 15A according to some embodiments. [Figure 15E] FIG. 15B is a side view of the orthogonal plate toroidal winding assembly of FIG. 15A according to some embodiments.

[0030] [Figure 16A] FIG. 1 illustrates a stand-alone choke design according to some embodiments.

[0031] [Figure 16B] 1A-1C illustrate how connectors are integrated into a quadrature plate toroidal winding assembly according to some embodiments. [Figure 16C] 1A-1C illustrate how connectors are integrated into a quadrature plate toroidal winding assembly according to some embodiments. [Figure 16D] 1A-1C illustrate how connectors are integrated into a quadrature plate toroidal winding assembly according to some embodiments.

[0032] [Figure 16E] 10A-10C illustrate bus bars used as connector terminals insert molded into a housing according to some embodiments.

[0033] [Figure 16F] FIG. 1 illustrates an internal ribbon-based nanocrystalline core embedded within a housing, according to some embodiments.

[0034] [Figure 16G] 10A-10C illustrate methods for adjusting power flow across a choke in orthogonal stamping, according to some embodiments.

[0035] [Figure 17A-B] 10 illustrates how a connector housing with insert molded terminals is fed into a core assembly housing according to some embodiments.

[0036] [Figure 17C] 1A-1C illustrate how the choke core and housing are assembled according to some embodiments.

[0037] [Figure 17D] 10A-10C illustrate how the remainder of the winding structure is assembled to the main housing, according to some embodiments. [Figure 17E] 10A-10C illustrate how the remainder of the winding structure is assembled to the main housing, according to some embodiments. [Figure 17F] 10A-10C illustrate how the remainder of the winding structure is assembled to the main housing, according to some embodiments.

[0038] [Figure 18A] 10A-10C illustrate an assembled U-shaped busbar with connector tab extensions installed for connector insertion, according to some embodiments.

[0039] [Figure 18B] FIG. 10 illustrates a U-shaped bus bar installed directly above the 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 like reference numerals have been used to identify like elements shown in one or more of the figures, and that the elements shown in these figures are intended to illustrate embodiments of the present disclosure and not to limit the disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0041] Provided herein are various embodiments of orthogonally joined plate windings for toroidal magnetics, including separated vertical plate stacks, which may enable several advantages to replace drawn round enameled magnetic wire for toroidal windings of magnetic components such as inductors, chokes, and transformers. Some embodiments include an electromagnetic core and winding assembly including a core and multiple plate windings orthogonally surrounding the core.

[0042] Various embodiments can provide one or more of the following non-limiting electrical and mechanical advantages, including but not limited to: 1) reduced total footprint size compared to continuous wire wound or flat wire edge wound toroidal cores; 2) rectangular or preferred footprint shape desired for printed circuit board (PCB) components for optimal layout density; 3) winding plates double as heat sink fins for natural convection cooling; 4) adjustable inter-turn capacitance; 5) controlled creepage distance between windings; 6) controlled winding spacing for uniformity unaffected by variability in winding pattern, wire tension effects, and bunching; 7) joining techniques such as laser welding that provide manufacturing cycle times of only a few seconds; 8) vertical plate ends that act as PCB solder leads or feet, eliminating the circular magnetic wire terminals typically required to convert wire ends to those suitable for 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, which may be easily scaled for higher current carrying capacity, heat dissipation, low electrical and thermal resistance, interwinding capacitance, and intrawinding volume, among other desired objectives of the assembly.

[0043] Existing toroidal windings are primarily enameled wire structures that are manually pulled, sometimes semi-automated. For example, continuous edge-wound flat copper can be spiraled into a toroidal core shape for installation. Exemplary wound toroid shapes can be formed by enameled wire that is manually and / or mechanically pulled and wound, and the wire can come into physical contact with the core, making both the core and wire susceptible to damage. Furthermore, high-current applications may use or require multiple parallel windings, such as bifilar winding arrangements, which often require sequential winding of successive lengths of wire conductor around the core to follow and match the helical path and pitch. Variable wire positioning and overall wire winding components in industrial practice can variably increase the shape and size of core winding assemblies, resulting in irregularities when compared to each other.

[0044] Noncircular spirals can be threaded into closed toroids. However, assembly requires helical rotation into a toroidal cross-sectional shape, reducing the ability to achieve a tight fit. Most cores are manufactured with a fixed rectangular cross-sectional shape for microstructural uniformity, and some specific cores, such as nanocrystalline types, are constructed from fixed-width ribbons wound continuously in layers (like a spool of tape), thus resulting in rectangular cross-sections with acute angles, as shown in Figure 2D. In the design of Figure 2D, edgewise-wound or wire-wound conductors have difficulty bending or conforming to such acute angles due to the conductor's minimum internal bend radius.

[0045] According to various embodiments, the cross-sectional size of the core can be increased without increasing the total winding length in each winding unit. For example, parallel-arranged and joined plates oriented perpendicular to the core equator form an unconventional helical winding structure. Thin plate conductors can be stacked or aligned with each other along a toroidal shape, allowing for aspect ratios comparable to round, square, and flat magnetic wire windings because they are not limited in size radially or perpendicularly along the core axis. Therefore, a wide range of customizable conductor cross-sectional areas, including desired non-uniform cross-sectional areas and aspect ratios, can be achieved with little or no impact on the toroidal size. Such winding shape customization can be for various combinations of purposes, such as thermal shielding, ambient field effects, electrical interface, strength, stiffness, winding current flow, and heat flow along sections of the winding. A thermal advantage of plate-shaped conductors is that they behave like heat sink fins for convective heat transfer, or conductive edge cooling methods are also possible. Plates can be shaped to follow the core contour as well as the external envelope. This optimized fitment is advantageous compared to edge-wound spiral windings, which must be helically threaded onto a rectangular cross-section toroid or the toroidal core must be cut and the rectangularly shaped wire spiral assembled. Shape-matching orthogonal plates allow for optimization of the overall footprint and volume of magnetic components such as chokes, inductors, or transformers. This level of volume optimization is not currently available for this type of wound component. Plate elements can be joined using processes such as laser welding and, depending on the embodiment, can have distinct shapes and thicknesses, even within a single continuous winding.

[0046] According to some embodiments, orthogonal conductor plates can provide one or more of the following additional advantages: The edges of the plates can be soldered directly onto the surface of the PCB for electrical connection and / or mechanical and / or thermal interface. Each winding turn can have a close-contact cooling path to the PCB surface, and optional PCB cutouts can allow thermal interface to cool each winding from an underlying heat sink. The plate structure can be similar to a convection heat sink for cooling. The plates can be shaped for customized mounting, cooling, and conductor cross-section optimization (geometric, resistive, thermal) within the dimensional envelope. Inter-plate / inter-turn capacitance can be tailored by surface area and / or pitch spacing. Plates and plate subsections can be stacked and welded together locally or completely for double / triple / multiple conductive cross-sections. Electrical isolation between turns can also be achieved by housing combs with variable thickness and spacing, or by grooves added for desired electrical creepage distances. The conductors that extend to the PCB, unlike magnetic wires, can be manufactured and processed as flat, regularly shaped objects, making them more suitable for automated assembly. The positions of the leads and weld joints can be fixed, reducing distortion and variability, a manufacturing consideration for high-volume automated PCB assemblies (PCBAs).

[0047] Controlled plate spacing can eliminate the need for enameling of the magnetic wires, which typically requires insulating coated conductors to be directly above or side by side in contact with each other.

[0048] The novel crossover link can allow power flow entering the toroid winding to exit through the other side without interaction with the PCB, which can have the advantage of electromagnetic compatibility (EMC) immunity. Some embodiments allow for many ways to customize designs within rectangular footprints, spatial volumes, planar cooling paths, and simplification of electrical layout or linear power flow not available with conventional wire-wound and edge-wound designs.

[0049] Some embodiments may be applied to one or more of EMC chokes, conductors, transformers, or current sensors. Other advantages may be realized in through-hole, pin-in-paste, and SMD lead structures. Some embodiments may be applied to molded housings for surface mount device (SMD) applications that require high-temperature grade resins to retain their shape during soldering / reflow. Some embodiments may also be applied to industrial development of fully automated assembly (tooth comb insertion, fixturing, laser welding) required for cost competitiveness and manufacturing speed. Furthermore, some embodiments may be applied to replace edge-wound conductors that require an inside bend radius that cannot follow the sharp cross-sectional shape of nanocrystalline cores made from fixed-width ribbons.

[0050] According to some embodiments, orthogonally arranged conductors can add multiple dimensional customization for high density. Furthermore, novel crossover conductors can enable new linear power flow-through. With orthogonal plates, crossover conductors can naturally be similar to other winding elements in terms of structure, handling, and packaging. Some embodiments can enable winding core assemblies that meet spatial densities comparable to other SMD components (previously, such assemblies would be separated from PCBAs with other electrical and mechanical attachments). FIG. 1 illustrates an exemplary orthogonal-plate toroidal winding assembly 300 according to some embodiments. The assembly 300 may include a core 310 and multiple winding plates, including first through fourth groups of winding plates 322-328. The size and cross-sectional aspect ratio of the core 310 may be adjusted, modified, or customized as needed to match the width, height, thickness, spacing, and assembly volume of each winding. Each of the groups of winding plates 322-328 may have tight, uniform spacing between the winding plates, or may instead have wider spacing for other desired purposes. The first and third groups of winding plates 322 and 326 may be spaced apart by a first distance. The second and fourth groups of winding plates 324 and 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, wider spacing between the winding plates may be used if higher voltage isolation is required or if greater free convection cooling is thermally desirable. Core 310 may include an air core comprising any material, including a gaseous state or vacuum, that has the desired magnetic properties.

[0051] While FIG. 1 illustrates each group of winding plates 322-328 including six winding plates, the present disclosure is not limited thereto. For example, fewer than six (e.g., 1-5 plates) or more than six (e.g., 10-20 plates) winding plates may be used. Furthermore, the first through fourth groups of winding plates 322-328 may have the same number of winding plates or different numbers of winding plates, depending on the embodiment. 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. While FIG. 1 illustrates two units, the present disclosure is not limited thereto. For example, the winding assembly 300 may have one winding unit or more than two winding units.

[0052] Additional lead or foot connections within the beginning and end of each winding unit may be present for electrical connection purposes such as taps. Additional lead or foot connections beyond the electrical connections may provide a thermal path for conducting heat or adding strength.

[0053] Each side of the core 310 may be provided with winding plates of different thicknesses. For example, on 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. Further, on the rear 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, a thinner group of winding plates may conduct less current than a thicker group of winding plates. Groups of winding plates 322-328 may be connected across other sides of the core 310. Groups of winding plates 322-328 may completely or substantially surround the core 310 and may be various shapes in addition to the rectangular footprint shown.

[0054] 2 is an expanded view of the orthogonal plate toroidal winding assembly 300 of FIG. 1, according to some embodiments. Each group of winding plates 322 and 324 includes an opening 435 through which a portion of the core 310 passes.

[0055] Each of the thinner winding plates 322 may have a thickness in the range of approximately 0.25 mm or greater. Each of the thicker winding plates 324 may have a thickness in the range of approximately 0.50 mm or greater. These thicknesses are merely examples, and the present disclosure is not limited thereto. For example, each of the thinner winding plates 322 may have a thickness of less than approximately 0.25 mm. Furthermore, each of the thicker winding plates 324 may have a thickness of less than approximately 0.50 mm. In some embodiments, the winding plates may be thickened by doubling up two or more thinner plates and then joining them for desired electrical and thermal functions. The first and last winding plates may have different dimensions for connection purposes, while the middle winding plates may have the same dimensions. For example, the first and last winding plates may be longer, wider, and / or thicker, and the middle winding plates may be relatively recessed.

[0056] The groups of thicker winding plates 322 and the groups of thinner winding plates 324 can be spaced apart from one another by a distance ranging from about 0.5 mm to about 4 mm to 5 mm (see spacing "420" in FIG. 2). Adjacent pairs of each of the thinner winding plates 322 and each of the thicker winding plates 324 can be spaced apart by a distance ranging from about 0.5 mm to about 1 mm to 2 mm (see spacing "425" in FIG. 2). The spacing between adjacent pairs of thinner winding plates 322 can be the same as or different from adjacent pairs of thicker winding plates 324. Spacing can be used to adjust certain electrical characteristics, such as capacitance. For example, smaller spacing between winding plates can reduce capacitance and increase creepage or clearance of voltage surfaces. The above spacing ranges are merely examples, and the present disclosure is not limited thereto.

[0057] The winding assembly 300 can have a core cross-sectional aspect ratio ranging from 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 over the width of the cross-section of the core 310. The above ranges of core cross-sectional aspect ratios are merely examples, and the present disclosure is not limited thereto. For example, core cross-sectional aspect ratios less than about 0.5 or greater than about 1.5 are also possible.

[0058] 3A-3D illustrate another exemplary quadrature-plate toroidal winding assembly according to some embodiments. Figures 3A and 3C illustrate an exemplary quadrature-plate toroidal winding assembly with an interleaved quadrature winding design. Figure 3B illustrates a top view of Figure 3A. Figure 3D illustrates a bottom view of Figure 3C.

[0059] 4A-4G illustrate how plates can be combined with a core housing to form a core winding assembly, according to some embodiments. FIG. 4A illustrates a substantially U-shaped plate 610, according to some embodiments. FIG. 4B illustrates the substantially U-shaped plate 610 being placed in a core housing 620. FIG. 4C illustrates a substantially I-shaped plate 630, according to some embodiments. FIG. 4D illustrates a bottom view of the core winding assembly shown in FIG. 4B. FIG. 4E illustrates the substantially I-shaped plate 630 being placed at the bottom of the core winding assembly shown assembled to the core and housing in FIG. 4D. FIG. 4F provides a more detailed view showing how the substantially I-shaped plate 630 fits into the bottom of the core winding assembly shown in FIG. 4D and connects to many or all of the U-shaped plates. Eight winding units of U-shaped and I-shaped plates are shown in FIG. 4F. Winding units across opposite sides of the core can be electrically joined to combine them into one larger winding unit, which can have, for example, twice the number of turns. In FIG. 4F, reference numeral 640 represents a crossover bus bar or stamping. FIG. 4G is an example of a crossover stamping that can link windings or conductive elements from one side of the core to the other. This crossover can also be formed to connect winding units along the same side of the core, like a split winding. This crossover can also be formed or used in multiples to branch from one winding unit to multiple other winding units, or it may primarily link winding units wound on different cores. The number and unique features of the bus bars forming the I-shaped plates shown in FIGS. 4A-4G are merely examples, and the present disclosure is not limited thereto.

[0060] Figures 5A-5D are different views of the core winding assembly of Figure 3D according to some embodiments. Figure 5C is a wireframe diagram of the core winding assembly of Figure 5A according to some embodiments. The core winding assembly shown in Figure 5A is substantially the same as the core winding assembly of Figure 4E. Figure 5D shows a cover provided with a core housing including a core comb. Figure 5B is an empty core without a housing. Figure 5C is a top view of the core winding assembly of Figure 5A.

[0061] FIG. 6A illustrates an exemplary winding assembly 800 including an alternative butt-welded joint between plates according to some embodiments. FIG. 6 illustrates an inverted L-shaped edge 810 or an L-shaped edge 820, compared to the linear edge shown in FIG. 2. In FIG. 6A, the plate with the inverted L-shaped edge 810 and the plate with the L-shaped edge 820 overlap at the interface, so this design can provide a thinner interface between the plates. Because the interface can be thinner (e.g., about half) than that of FIG. 5A, the spacing between the plates can be reduced, thereby reducing the size of the winding unit.

[0062] Figure 6B shows a cross-sectional image of an exemplary interactive spatial awareness core, housing, and U-shaped busbar tight fitment. Figure 6C shows exemplary types of weld joints according to some embodiments. Figure 6C illustrates multiple joint types possible as a basis for metal plate joining. The types of weld joints shown in Figure 6C are merely examples, and the present disclosure is not limited thereto.

[0063] For industrial understanding and handling purposes, Figures 7A-7C illustrate an exemplary existing plate stamping format used to create magnetic cores. Figures 7D and 7E illustrate another exemplary progressive stamping format, according to some embodiments, intended to optimize material usage. Compared to the individually fabricated plates of Figures 7A-7C, the plates shown in Figures 7D and 7E illustrate an example of a progressive stamping arrangement on raw sheet conductor material. Figure 7D has a slanted nested design, while Figure 7E illustrates a vertical design.

[0064] 8A and 8B show exemplary orthogonal-plate toroidal winding assemblies 1010 and 1020 having different numbers of components, according to some embodiments. The orthogonal-plate toroidal winding assembly 1010 of FIG. 8A includes four more components per winding unit than the perpendicular-plate toroidal winding assembly 1020 shown in FIG. 8B. For example, the winding assembly 1010 of FIG. 8A includes a U-shaped plate 1012, an I-shaped plate 1014, a side plate 1016, and a side plate 1018 per winding. In the example of FIG. 8A, the height of the side plate 1016 is different from the heights of the U-shaped plate 1012 and the I-shaped plate 1014, and the side plates 1018, 1016, 1018 protrude further from the surrounding windings to establish a dedicated mounting surface. In the winding assembly 1020 of FIG. 8B, each combined plate includes a U-shaped plate 1022 and an I-shaped plate 1024. In the example of Figure 8B, the combined plates have the same height. In the example of Figure 8A, two more parts (plates) are required per winding, resulting in the assembly of Figure 8A requiring four more plates than the example of Figure 8B. Figures 8A and 8B merely illustrate example winding assemblies and exemplary reduced number of parts, and the disclosure is not limited thereto.

[0065] 8C shows that, according to some embodiments, conductor stampings can be augmented by stacking and connecting other stampings that can be partially or completely sized to double or multiple the local current carrying capacity, reduce electrical resistance, and enhance the thermal path of the conductor. These doublers can be an option with stamped wire windings for higher current carrying capacity, lower resistance, and heat conduction.

[0066] 9A and 9B illustrate an exemplary welding method for welding plates of an exemplary orthogonal-plate toroidal winding assembly 1110, according to some embodiments. FIG. 9A shows the assembled plates, with a U-shaped plate 1112 and an I-shaped plate 1114 bonded together. The plates 1112 and 1114 may be bonded by welding. The joining method may include various types, including, but not limited to, laser welding, high-temperature soldering, ultrasonic, or resistance welding. However, the present disclosure is not limited thereto, and other joining methods may also be used.

[0067] 9B shows a laser welding fixture in which an upper spring 1130 can be used to perform precise positioning of the plates 1112 and 1114 of the winding assembly 1110 before welding. FIG. 9B shows only an exemplary positioning fixture; other precision positioning devices can be used. For example, the upper spring 1130 can be omitted, and instead, gravity can be adequate to position the plates 1112 and 1114.

[0068] 10A-10C illustrate another exemplary welding method for welding plates together, according to some embodiments. FIG. 10A shows the assembled plates, with a U-shaped plate 1210 and an I-shaped plate 1220 bonded together. FIG. 10B shows an exemplary laser weld spot feature, demonstrating that welding can be performed even if the plate surfaces are not smooth or contain slight gaps. In FIG. 10C, the I-shaped plate 1220 can be positioned adjacent to the top of the U-shaped plate 1210 or a feature on the core housing held in place by a fixture without the use of an upper spring, while a lower spring 1230 can be used to push the core and I-shaped plate upward to fit flush with the upper fixture plate 1250.

[0069] 11A-11D show another exemplary orthogonal-plate toroidal winding assembly 1310 according to some embodiments. FIG. 11B shows a top view of the orthogonal-plate toroidal winding assembly 1310 of FIG. 11A. In FIGS. 11A and 11B, a U-shaped plate 1312 and an I-shaped plate 1314 surrounding a core 1318 are separated by film or sheet insulation 1316. The film or sheet insulation 1316 may be disposed between the plates 1312 and 1314 to insulate adjacent plates and thereby avoid short circuits. The winding assembly 1310 is similar to the winding assembly 800 shown in FIG. 6A, except that the film or sheet insulation 1316 is further provided in FIGS. 11A and 11B.

[0070] FIG. 11C shows a comparative core winding assembly 1320 having windings 1312 disposed on only one side of the core 1314.

[0071] 11D shows another exemplary orthogonal plate toroidal winding assembly 1330, according to some embodiments. The exemplary assembly 1330 of FIG. 11C includes windings 1332 and 1336 disposed on opposite sides of a core 1336.

[0072] Figure 11E is a cross-sectional view of the quadrature-plate toroidal winding assembly 1330 of Figure 11D, according to some embodiments. Figure 11E illustrates that the stampings can be integrated for handling and assembly, and can later be separated from one another for electrical function by removal of break-off tabs or other selected cutting methods for individualization. The quadrature-plate toroidal winding assembly 1330 includes a U-shaped plate 1338 and an I-shaped plate 1340. The quadrature-plate toroidal winding assembly 1330 can also include break-off tabs 1342 used to attach the U-shaped plate 1338 and the I-shaped plate 1340 for handling during assembly.

[0073] 11F and 11G are enlarged views of FIGS. 11B and 11C, respectively.

[0074] 12A and 12B show how an exemplary orthogonal-plate toroidal winding assembly is gripped by a gripper 1420, according to some embodiments. The surface may be substantially flat or may include other features to assist with self-alignment, clamping, fastening, lifting, or identification marking, for example. The gripper may be an SMD gripper. The SMD gripper may grip the core or the winding, or any combination. The opposing side surfaces of the core housing may be substantially flat or may be reinforced with features for lifting or positioning during clamping, lifting, or setting into place.

[0075] 13A and 13B illustrate an example PCB layout 1500 in which an example orthogonal plate toroidal winding assembly is arranged, according to some embodiments. FIG. 13A is a top view of the PCB layout 1500 including example orthogonal plate toroidal winding assemblies 1510 and 1520. FIG. 13B is a bottom view of the PCB layout 1500 including cutouts (or openings) 1530 and 1540 that can be used as paths for placing structures, thermal interface materials, or air passages to cool perpendicular plate toroidal winding assemblies such as assemblies 1510 and 1520 by thermally dissipating heat generated in the winding assemblies 1510 and 1520. FIG. 13C illustrates a perspective PCB view and a portion of FIG. 13B with the heat dissipation cutouts highlighted, according to some embodiments.

[0076] FIG. 14 illustrates another exemplary orthogonal plate toroidal winding assembly 1610 including an alternating lead design, according to some embodiments. The orthogonal plate toroidal winding assembly 1610 includes plates 1612 and 1614 having alternating protrusions that can serve as electrical connection leads to one another. The plates 1612 and 1614 are similar to those of the winding assembly 800 shown in FIG. 6A or the winding assembly 1310 shown in FIG. 11B in that alternating plates are provided. The plates 1612 and 1614 can each include laser welds that form alternating loops (A, B) during assembly and manufacturing to provide distance between attachment and welding points and prevent accidental electrical shorts between winding turns.

[0077] Figure 15A is a top view of an exemplary orthogonal plate toroidal winding assembly as viewed from above a PCB, according to some embodiments. Figure 15B is a side elevational view of the vertical plate toroidal winding assembly of Figure 15A, according to some embodiments. Figure 15C is a bottom view of the orthogonal plate toroidal winding assembly of Figure 15A, according to some embodiments. Figure 15D is a cross-sectional view, and Figure 15E is an end view of the vertical plate toroidal winding assembly of Figure 15A, according to some embodiments.

[0078] Figure 16A shows a standalone choke design according to some embodiments. Figures 16B-16D show how connectors are integrated into a quadrature-plate toroidal winding assembly according to some embodiments. Figure 16B shows a practical application using insert-molded busbars acting as connector terminals. These are welded directly to the main quadrature-stamped windings. Figure 16C shows alternative connector locations on either side of the choke depending on the embodiment. The terminal orientation can be aligned toward the center (see Figure 16B) or rotated as shown in Figure 16C depending on the mating connector configuration. Figure 16D shows how the installation orientation can be adjusted as needed if integration requires exposing terminals or adjusting the assembly orientation on the quadrature axis compared to the previous embodiment.

[0079] FIG. 16E shows a busbar used as a connector terminal integrated into a housing by insert molding, according to some embodiments. FIG. 16F shows an internal ribbon-based nanocrystalline core embedded inside the housing, according to some embodiments. FIG. 16G shows a method of adjusting power flow across a choke in an orthogonal stamping, according to some embodiments. FIG. 16E shows a purple busbar used as a connector terminal insert molded into a housing. Reference numerals 1810-1840 refer to four stampings. Reference numeral 1850 represents a thin stamped busbar (e.g., a U-shaped busbar) that can be used to carry low amperage currents. Thin stamped busbar 1850 can be made of sheet metal. The thickness of thin sheet metal 1850 can be approximately 0.8 mm. Reference numeral 1870 represents a thick stamped busbar (e.g., a U-shaped busbar) that can be used to carry higher amperage currents. Thick stamped busbar 1860 can be made of sheet metal. The thickness of thick sheet metal 1860 can be approximately 1.3 mm. The above thicknesses of busbars 1850 and 1860 are merely examples, and other thicknesses may be used. Reference numeral 1870 represents a nanocrystalline ribbon core, which may be the inductor core (shown in dark gray) in FIG. 16F. Nanocrystalline ribbon core 1870 may be composed of wound nanocrystalline ribbon. Reference numeral 1880 represents a gasket that acts as a dust seal for the product's enclosure and is molded directly onto the housing to seal the interior volume from the outside world.

[0080] Figure 16G shows that orthogonal stamping allows for easy tailoring of the way power flows across the choke. In Figure 16G, the windings are split across the centerline, and the top winding operates similarly to Figure 4G, with power flowing from left to right. In Figure 16G, in the bottom two windings, shown in orange, the windings are adjusted to ensure that the direction of power flow is aligned along a vertical direction 90 degrees orthogonal to the two windings due north, shown in dark teal. This consolidation allows for the number of windings to be maintained while minimizing the overall footprint driven by high-voltage creepage.

[0081] Figures 17A and 17B show how a connector housing with insert-molded terminals is fed into the core assembly housing according to some embodiments. Figure 17C shows how the choke core and housing are assembled according to some embodiments. Figures 17D-17F show how the remaining portions of the winding structure are assembled to the main housing according to some embodiments. Figures 17A-17F show that connector-choke integration can be implemented using two assemblies that can be welded together. For example, the two assemblies include a connector housing with insert-molded terminals (Figures 17A and 17B) and a secondary half (Figures 17C-17F) that surrounds the choke core and aligns the remaining stamping and welding operations. Key benefits of this integration include integrating the connector and optimizing power flow into and out of the connector. Furthermore, integrating the connector terminals allows for a direct current path from the connector to the choke, eliminating contact with the PCBA if necessary. This design also significantly reduces the overall footprint of the choke, allowing for improved layout density (power density) using these components. Easier connector integration as the stamped structure of the busbar can lend itself to a more integrated solution for blade-style connectors.

[0082] FIG. 18A shows an assembled U-shaped busbar (with connector tab extensions installed for connector insertion) according to some embodiments. FIG. 18B shows a U-shaped busbar installed directly above a core assembly housing according to some embodiments. Some embodiments provide easier connector integration by converting a round-profile wire, an oval-profile bar into a blade for connector mating, soldering, crimping, or insulation displacement without requiring one or more intermediate parts to penetrate a varnish-like dielectric coating. FIG. 18B uses a busbar structure stamped onto the windings, providing much easier / more efficient integration because male blades for connectors, which are traditionally stamped, can be stamped directly onto the windings. In some embodiments, the geometry of the U-shaped busbars can be modified to add interfaces directly on them, if spacing allows.

[0083] It should be understood that a feature, material, characteristic, or group described in connection with a particular aspect, embodiment, or example is applicable to any other aspect, embodiment, or example described in this section or elsewhere in this specification, unless inconsistent therewith. All features disclosed in this specification (including the accompanying claims, abstract, and drawings), and / or all steps of any method or process so disclosed, may be combined in any combination, except where at least some of such features and / or steps are mutually exclusive. Protection is not limited to the details of any of the foregoing embodiments. Protection extends to any novel, or any novel combination of, features disclosed in this specification (including the accompanying claims, abstract, and drawings), or any novel, or any novel combination of steps of any method or process so disclosed.

[0084] Furthermore, certain features that are described in this disclosure in the context of separate embodiments can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Furthermore, while features may be described above as acting in a particular combination, one or more features from a claimed combination can, in some cases, be deleted from the combination, and the combination can be claimed as a subcombination or a variation of the subcombination.

[0085] Furthermore, while operations may be depicted in the figures or described herein in a particular order, such operations need not be performed in the particular order shown, or in sequential order, or even all operations need to be performed to achieve desirable results. Other operations not shown or described may be incorporated into the example methods and processes. For example, one or more additional operations may be performed before, after, simultaneously with, or between any of the described operations. Furthermore, operations may be rearranged or reordered in other implementations. Those skilled in the art will appreciate that in some embodiments, the actual steps performed in the illustrated and / or disclosed processes may differ from those shown in the figures. Depending on the embodiment, certain of the steps described above may be omitted and other steps may be added. Furthermore, the features and attributes of the specific embodiments disclosed above may be combined in different ways to form additional embodiments, all of which are within the scope of the present disclosure. It should also be understood that the separation of various system components in the above implementations is not to be understood as requiring such separation in all implementations, and the described components and systems may generally be integrated together in a single product or packaged in multiple products. For example, any of the components of the energy storage system described herein may be provided separately or may be integrated (e.g., packaged together or attached together) to form an energy storage system.

[0086] For purposes of this disclosure, certain aspects, advantages, and novel features are described herein. Not necessarily all such advantages may be achieved in accordance with any particular embodiment. Thus, for example, one skilled in the art will recognize that the present disclosure may be embodied or implemented to achieve one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.

[0087] Unless specifically stated otherwise or understood otherwise within the context in which it is used, conditional language such as "can," "could," "might," or "may" is generally intended to suggest that certain embodiments include certain features, elements, and / or steps, while other embodiments do not. Thus, such conditional language generally does not intend that features, elements, and / or steps are in any way required by one or more embodiments, or that one or more embodiments necessarily include logic for determining whether those features, elements, and / or steps should be included in or performed in any particular embodiment, with or without user input or prompting for input.

[0088] Conjunctions such as the phrase "at least one of X, Y, and Z," unless otherwise specified, are understood in the context in which they are generally used to convey that an item, term, etc. can be either X, Y, or Z. Thus, such conjunctions are generally not intended to imply that a particular embodiment requires the presence of at least one of X, at least one of Y, and at least one of Z.

[0089] As used herein, language of degree, such as "approximately," "about," "generally," and "substantially," denotes a value, amount, or characteristic that approaches a stated value, amount, or characteristic that still performs a desired function or achieves a desired result.

[0090] The scope of the present disclosure is not intended to be limited by the specific disclosure of embodiments in this section or elsewhere herein, but may be defined by the claims, as presented in this section or elsewhere herein, or as presented in the future. Claim language is to be interpreted broadly based on the language used in the claims, and not limited to the examples described in this specification or during prosecution of the application, which examples are to be construed as non-exclusive.

[0091] While specific embodiments have been described, these embodiments are presented by way of example only and are not intended to limit the scope of the present disclosure. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions, and changes may be made in the systems and methods described herein without departing from the spirit of the disclosure. The appended claims and their equivalents are intended to cover such forms or modifications as are within the scope and spirit of the present disclosure. Accordingly, the scope of the present invention is defined solely by reference to the appended claims.

Claims

1. a core having a body and an opening defined by an inner surface of the body; a plurality of plate windings configured to be in electromagnetic operation with the core, the plurality of plate windings being positioned to intersect and partially surround the body of the core, a portion of each of the plurality of plate windings extending through the opening in the core; 1. An electromagnetic core and winding assembly comprising:

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

4. 4. The assembly of claim 1, further comprising a core housing that houses the core therein, the core housing having a plurality of vertical grooves formed on an outer surface thereof, the plurality of vertical grooves configured to house the plurality of plate windings therein, respectively.

5. 5. The assembly of claim 1, wherein each of the plurality of plate windings comprises a first plate having two opposing ends and at least partially surrounding the body of the core, and a second or more plates configured to couple to the two opposing ends of the first plate in an arrangement coupled in series with other like plates.

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

7. 7. An assembly according to claim 1, wherein the plurality of plate windings are substantially U-shaped or contoured to surround the cross-sectional shape of the core.

8. 8. The assembly of claim 1, wherein the plurality of plate windings comprises 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 opposite the first side.

9. 9. An assembly according to claim 1, wherein the one or more first groups of plate windings comprise a first group and a second group spaced apart from one another, the first group comprising a first number of plate windings and the second group comprising 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. 10. The assembly of claim 9, wherein at least one of the first group of plate windings or the second group of plate windings comprises a plurality of plates equally spaced apart from one another.

13. 10. The assembly of claim 9, wherein the first group of plate windings is spaced apart from the second group of plate windings by a distance in the range of about 0.5 mm to about 4 mm-5 mm.

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

15. 14. An assembly according to any one of claims 1 to 13, wherein at least one of the plates has sections of electrical or thermal conductors mounted parallel to the current flow to increase current carrying capacity, reduce resistance and / or improve heat distribution or dissipation.

16. 10. The assembly of claim 9, wherein the first group of plate windings comprises a plurality of plates spaced apart a first distance, and the second group of plate windings comprises a plurality of plates spaced apart a second distance different from the first distance.

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

18. 18. The assembly of claim 1, wherein at least one of the plates has bending features or additionally attached elements, including those used to connect winding assemblies, configured to extend for one or more of thermal, mechanical, or electrical connections, or other functional purposes.

19. 19. The assembly of claim 1, wherein the core has a cross-section, and wherein a core aspect ratio is defined as the length of the cross-section of the core across the width of the cross-section of the core, and wherein the core aspect ratio can vary.

20. 20. The assembly of claim 1, wherein the plates are configured to join or branch winding units along the same side, other side, or opposite side of an electrically connected main core or other core winding unit.

21. 21. The assembly of any one of claims 1 to 20, wherein the core comprises any material, including a gaseous state or vacuum, that has desired magnetic properties.

22. 22. The assembly of claim 1, further comprising a plurality of connector terminals coupled to the plurality of plate windings.

23. 23. The assembly of claim 22, wherein the core and the plurality of plate windings are contained within a housing, and the plurality of connector terminals are integrated into the housing by insert molding.

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