Inductive component and tapped transformer therewith

Abstract

An inductive component includes a first edgewise coil formed of a first wire having a first thickness and a first number of turns, a second edgewise coil formed of a second wire having a second thickness and a second number of turns, and a core material disposed about the first edgewise coil and the second edgewise coil. The first thickness may be different from the second thickness, or the first number of turns may be different from the second number of turns. The inductive component may include a third edgewise coil.

Description

PER-584-PCT 61658.160W001INDUCTIVE COMPONENT AND TAPPED TRANSFORMER THEREWITHCROSS-REFERENCES TO RELATED APPLICATION

[0001] This patent application claims priority to and is related to and expressly incorporates by reference in their entirety the following United States Provisional Patent Applications:

[0002] Application No. 63 / 735,814 filed on December 18, 2024, entitled “INDUCTIVE COMPONENTS, SYSTEMS, AND METHODS; ”

[0003] Application No. 63 / 735,816 filed on December 18, 2024, entitled “INDUCTIVE COMPONENTS, SYSTEMS, AND METHODS;’’

[0004] Application No. 63 / 735,820 filed on December 18, 2024, entitled “INDUCTIVE COMPONENTS, SYSTEMS, AND METHODS;’’

[0005] Application No. 63 / 735,822 filed on December 18, 2024, entitled “INDUCTIVE COMPONENTS, SYSTEMS, AND METHODS;’’

[0006] Application No. 63 / 735,837 filed on December 18, 2024, entitled “INDUCTIVE COMPONENTS, SYSTEMS, AND METHODS;’’

[0007] Application No. 63 / 735,841 filed on December 18, 2024, entitled “INDUCTIVE COMPONENTS, SYSTEMS, AND METHODS;’’

[0008] Application No. 63 / 735,844 filed on December 18, 2024, entitled “INDUCTIVE COMPONENTS SYSTEMS AND METHODS;”

[0009] Application No. 63 / 735,846 filed on December 18, 2024, entitled “INDUCTIVE COMPONENTS SYSTEMS AND METHODS;” and

[0010] Application No. 63,942,509 filed December 16, 2025, entitled “INDUCTIVE COMPONENTS, SYSTEMS, AND METHODS.”TECHNICAL FIELD

[0011] The present disclosure relates to windings usable in inductive component and other electrical devices, devices including such windings, and methods of making and using the same. The present disclosure further related to inductive components, devices including such inductive components, and methods of making and using the same.PER-584-PCT 61658.160W001 BACKGROUND

[0012] Inductors may be formed of a core and a conductive structure proximate the core (e.g., one or more windings). The shape of the core and configuration of the windings affect a number of performance properties of the inductor.BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Various embodiments of the present disclosure will be understood more fully from the detailed description given below and from the accompanying drawings. In the drawings, like reference numbers may indicate identical or functionally similar elements. Embodiments are described in detail hereinafter with reference to the accompanying figures, in which:

[0014] FIG. 1 is a perspective view of an inductive component according to an embodiment of the present disclosure.

[0015] FIG. 2 is a perspective view of an inductive component according to an embodiment of the present disclosure.

[0016] FIG. 3 A is a perspective view of an inductive component according to an embodiment of the present disclosure.

[0017] FIG. 3B is a partial perspective view of the inductive component of FIG. 3 A.

[0018] FIG. 3C is a partial perspective view of the inductive component of FIG. 3 A.

[0019] FIG. 3D is a partial perspective view of the inductive component of FIG. 3A.

[0020] FIG. 4 is a perspective view of an inductive component according to an embodiment of the present disclosure.

[0021] FIG. 5A is a perspective view of an inductive component according to an embodiment of the present disclosure.

[0022] FIG. 5B is a partial cross-sectional view of an inductive component according to an embodiment of the present disclosure.

[0023] FIG. 5C is a partial cross-sectional view of an inductive component according to an embodiment of the present disclosure.

[0024] FIG. 5D is a partial cross-sectional view of an inductive component according to an embodiment of the present disclosure.

[0025] FIG. 5E is a partial cross-sectional view of an inductive component according to an embodiment of the present disclosure.

[0026] FIG. 5F is a partial cross-sectional view of an inductive component according to an embodiment of the present disclosure.PER-584-PCT 61658.160W001

[0027] FIG. 5G is a partial cross-sectional view of an inductive component according to an embodiment of the present disclosure.

[0028] FIG. 5H is a partial cross-sectional view of an inductive component according to an embodiment of the present disclosure.

[0029] FIG. 6 is a block diagram of a buck converter that may employ an inductive component according to an embodiment of the disclosure.

[0030] FIG. 7 is a flow chart of a method of using an inductive component according to an embodiment of the disclosure.DETAILED DESCRIPTION

[0031] Although the claimed subject matter will be described in terms of certain embodiments and examples, other embodiments and examples, including embodiments and examples that do not provide all of the benefits and features set forth herein, are also within the scope of this disclosure. Various structural, logical, and process step changes may be made without departing from the scope of the disclosure.

[0032] Referring to FIG. 1, an inductive component 100 includes a first coil winding 12 extending from a first terminal 12a to a second terminal 12b and a second coil winding 14 extending from a first terminal 14a to a second terminal 14b. The inductive component 100 may further include a core (not shown) disposed about or encapsulating the first coil winding 12 and the second coil winding 14.

[0033] In some embodiments, the core is an air core. In some embodiments, the core is formed of a magnetic material or a combination of magnetic materials. As used herein, the inductive component may be any component capable of storing energy in a magnetic field, any component capable of creating a magnetic field when electric current is flowed through it, and / or any component configured to add inductance to a circuit. In one or more embodiments, the core material has a higher magnetic permeability than air. In some embodiments, the material is a metal and / or a metal oxide. In some embodiments, the material is a ferromagnetic or ferrimagnetic material. In some embodiments, the material is a soft magnetic material. Magnetic materials can generally be classified into two main groups: soft and hard. Hard magnetic materials have high coercivity and are suitable for permanent magnets, whereas soft magnetic materials have low coercivity’ and are suitable for inductors, transformers, and the like. Generally, soft magnetic materials may be classified based on chemical composition (e.g., variations within the classes of NiFe, soft ferrites, SiFe, CoFe, orPER-584-PCT 61658.160W001 Fe) and / or based on atomic structure (i.e., nanocrystalline. amorphous, poly crystalline, and etc.). Various materials in amorphous and nanocrystalline category generally are suitable for forming the core provided that the manufacturing challenges associated with brittleness can be overcome. Properties of some materials that may be used for the core are summarized in Table 1 below.

[0034] TABLE 1Properties of NiFe an CoFe Alloysρ (μΩ cm) Js (T) Hc (A / m) μmax × 1000Fe64Ni36 75 1.3 40 20 Invar Fe50Ni50 45 1.6 7 15 Isoperm Fe52Ni48 45 1.6 8 180Fe44Ni56 35 1.5 1 300Fe20Ni80 16 1.1 0.4 100 Permalloy Fe16Ni79Mo5 60 0.8 0.4 550 Supermalloy Fe16Ni77Cu5Cr2 56 0.75 0.8 500 Mumetal Fe50Co50 7 2.45 160 5 Permendur Fe49Co49V2 40 2.4 400 17 Hiperco, vac flux

[0035] According to some embodiments, the material is a nanocrystalline and / or amorphous soft magnetic material. In some embodiments, the material is an iron alloy selected from NiFe (e.g., Ni50Fe50 Ni48Fe52, Ni56Fe44, or Ni80Fe20), SiFe, CoFe (e.g., Co50Fe50), or combinations thereof. In some embodiments, the core may be formed from compacted magnetic dust (dust core).

[0036] The first coil winding 12 and the second coil winding 14 are each formed of a flat wire having a rectangular cross-section. The flat wire may be formed of any suitable conductive material, e.g., a metal such as copper. The rectangular cross-sections have a major axis (width) and a minor axis (thickness). The first coil winding 12 and the second coil winding 14 are wound edgewise (edgewise coils). The first coil winding 12 has a thickness 12t and the second coil winding 14 have a thickness 14t. In some embodiments, the thickness 12t is different from the thickness 14t.

[0037] The first coil winding 12 has a first turn number and the second coil winding 14 has a second turn number. In some embodiments, the first turn number is different from the second turn number. In some embodiments, a ratio of the first turn number to the second turn number is 2:1, 3:1, 4:1, 5:1, 3:2, or 5:2. In some embodiments, the first coil winding 12 has a higher turn number than the second coil winding 14 and the thickness 12t is different fromPER-584-PCT 61658.160W001 the thickness 14t. In some embodiments, the first coil winding 12 has a higher turn number than the second coil winding 14 and the thickness 12t is lower than the thickness 14t.

[0038] Although the inductive component 100 is shown with two coil windings, the inductive component 100 may include three or more coil windings. In such embodiments, the three or more coil windings may be electrically insulated and isolated from one another or a terminal of one of the coil windings may be electrically connected to a terminal of another of the coil windings. In some embodiments, the inductive component 100 may include a third coil winding stacked on the first coil winding 12. In some embodiments, the third coil winding may be bifilar with the first coil winding 12 or the second coil winding 14. In some embodiments, the first coil winding 12 may be a bifilar winding and stacked with the second coil winding 14, wherein the second coil winding 14 may be a bifilar winding.

[0039] Turning to FIG. 2, an inductive component 200 includes a first coil winding 22 extending from a first terminal 22a to a second terminal 22b, a second coil winding 24 extending from a first terminal 24a to a second terminal 24b, and third coil winding 26 extending from a first terminal 26a to a second terminal 26b. The inductive component 200 may include a core as described above. As shown, the first coil winding 22, the second coil winding 24, and the third coil winding 26 are trifilar. The flat wire forming the windings may be as described above. A turn number of the windings is equal due to the trifilar configuration. In some embodiments, a thickness 22t of the first coil winding 22 may be different from a thickness 24t of the second coil winding 24 or a thickness 26t of the third coil winding 26.

[0040] Although three coil windings are depicted, the inductive component 200 may include four or more coil windings. In some embodiments, the inductive component 200 may include one or more additional coil windings stacked on the first coil winding 22, the second coil winding 24, and the third coil winding 26. In some embodiments, the inductive component may include a fourth coil winding, and the coil windings may be quadfilar.

[0041] In any embodiments, the coil windings of the inductive component 200 may electrically insulated and isolated from one another. In any embodiments, two of the coil windings of the inductive component 200 may be electrically connected (e.g., by connecting a terminal of one to a terminal of the other). In such embodiments, a turn number of the resultant connected coil windings will be doubled. In some embodiments, the inductive component 200 may include four coil windings with three of said coil windings being electrically connected.PER-584-PCT 61658.160W001

[0042] In some embodiments, the coil windings of the inductive component 100, 200 may be wound in a circular shape as depicted in FIGS 1 and 2. In some embodiments, the shape may be ovoid. In some embodiments, the shape may be square or rectangular with rounded vertices.

[0043] Turning to FIGS. 3A-3D, an inductive component 300 includes a stacked coil winding 32. The inductive component 300 may include a core disposed about the stacked coil winding 32 as described above. The stacked coil winding 32 may be formed of a wire, such as the flat wire described above. In some embodiments, the wire has a square cross-section. As show n in FIG. 3B, the stacked coil winding 32 coils from a first terminal 32a inwardly in a first layer 32b. The first layer 32b is connected via a transverse portion 32c to a second layer 32d. The stacked coil winding 32 coils outwardly in the second layer 32d to a second terminal 32e. It is noted that the descriptions of inw ard and outward coiling are for illustrative purposes and are not intended to dictate modes of manufacturing or using the inductive component 300. In any embodiments, the stacked coil winding 32 may have a generally rectangular or square shape (e g., a rectangle or square with rounded vertices).

[0044] Turning to FIG. 4, an inductive component 400 includes a first stacked coil winding 42 and a second stacked coil winding 44. The inductive component 400 may include a core disposed about the first stacked coil winding 42 and the second stacked coil winding 44 as described above. Each of the first stacked coil winding 42 and the second stacked coil winding 44 may have a structure as described above with respect to the stacked coil winding 32. As shown in FIG. 4, the first stacked coil winding 42 is stacked on the second stacked coil winding 44. In some embodiments, the first stacked coil winding 42 and the second stacked coil winding 44 may have the same structure. In some embodiments, the first stacked coil winding 42 and the second stacked coil winding 44 may differ in one or more of: a number of internal turns (four shown), a number of vertical layers (two shown), a wire thickness, and / or a wire width.

[0045] Although two stacked coil windings are shown, the inductive component 400 may include three or more stacked coil windings. In any embodiments, the stacked coil windings of the inductive component 400 may electrically insulated and isolated from one another. In any embodiments, two of the stacked coil windings of the inductive component 400 may be electrically connected (e.g., by connecting a terminal of one to a terminal of the other).

[0046] Turning to FIG. 5 A, an inductive component 500 includes a first stacked coil winding 52 and a second stacked coil winding 54. The inductive component 500 may include a core disposed about the first stacked coil winding 52 and the second stacked coil winding 54 asPER-584-PCT 61658.160W001 described above. As shown, the first stacked coil winding 52 and the second stacked coil winding 54 are intertwined with one another in a bifilar stacked coil. The configuration shown has the first stacked coil winding 52 on top of the second stacked coil winding 54. FIG. 5B depicts a cross-sectional view the first stacked coil winding 52 and the second stacked coil winding 54 shown in FIG. 5A.

[0047] In some embodiments, the bifilar stacked coil may include the first stacked coil winding 52 positioned side by side with the second stacked coil winding 54, as shown in FIG.5C. In some embodiments, the inductive component 500 may include three or more intertwined stacked coil windings (e.g., trifilar, quadfilar, etc.). For example, as shown in FIGS. 5D-5F, a third stacked coil winding 56 may be incorporated in a vertical stack (FIG.5D), a horizontal stack (FIG. 5E), or a combined vertical-horizontal stack (FIG. 5F).

[0048] In any embodiments, the cross-sectional shape and size of the stacked coil windings may be the same or different from one another. For example, as shown in FIGS. 5G and 5H, in some embodiments, the first stacked coil winding 52 may have a larger cross-sectional area than the second stacked coil winding 54.

[0049] In some embodiments, the inductive component 500 may include an additional stacked coil winding that is not intertwined with the first stacked coil winding 52 and the second stacked coil winding 54. In such embodiments, the additional stacked coil winding may differ from the intertwined stacked coil w indings in one or more of: a number of internal turns, a number of vertical layers, a wire thickness, and / or a wire width.

[0050] The foregoing embodiments are illustrative and any logical combination of number of coil windings, winding thicknesses, turn numbers, etc. described above may be employed. The inductive component described herein may be used in a variety of electrical devices such as a computer, mobile phone, or any other t pe of electronic device. In some embodiments, the inductive component may be included in a transformer, such as a tapped or center tapped transformer. In some embodiments, one or more of the inductive components may be included in a circuit. For example, FIG. 6 depicts a buck converter 610 (e.g., within an electronic device 600) including two inductors LI and L2, each of which may be an inductive component described herein. In some embodiments, the core or inductive component described herein may be incorporated into an inductive-based power converter, such as a boost converter or a buck-boost converter. In some embodiments, the inductive component may be incorporated into a charge pump. In some embodiments, the inductive component is a coupled inductor. In such embodiments, a coupling factor may be different or the same forPER-584-PCT 61658.160W001 each of the coil windings and the number of turns for each coil winding may be the same or different.

[0051] Turning to FIG. 7, a method 700 of using an inductive component, such as any of the inductive components described herein, is shown. The method 700 includes a step 710 of providing an inductive component comprising a conductive winding extending between first and second terminals and a core that is wound about the conductive winding. In the step 720, an electric current is flowed through the winding between the first and second terminals. In the step 730, the inductive component generates a magnetic field in response to the electric current. In some embodiments, generating the magnetic field acts to store energy within the inductive component. In some embodiments, generating the magnetic field acts to create electric current in a secondary winding, as in a transformer. In the method 700, the inductive component may include, e.g., an inductor, a coupled inductor, or a transformer, such as a tapped or center tapped transformed. The inductive component may be part of a circuit including additional electrical components and the circuit may form part of an electronic device, such as a computer or mobile phone. The method 700 may include operating the electronic device.

[0052] An inductive component has been described herein. The inductive component includes: a first edgewise coil formed of a first wire having a first thickness, the first edgewise coil comprising a first number of turns; a second edgewise coil formed of a second wire having a second thickness, the second edgewise coil comprising a second number of turns; and a core material disposed about the first edgewise coil and the second edgewise coil. The first thickness is different from the second thickness or the first number of turns is different from the second number of turns. The inductive component may include any one or more of the following features:

[0053] wherein the first thickness is different from the second thickness;

[0054] wherein the first edgewise coil and the second edgewise coil are bifilar;

[0055] wherein the first edgewise coil and the second edgewise coil are stacked;

[0056] wherein the first number of turns is different from the second number of turns;

[0057] wherein the first thickness is greater than the second thickness and the second number of turns is greater than the first number of turns;

[0058] wherein the first number of turns is different from the second number of turns;

[0059] further comprising a third edgewise coil;

[0060] wherein the inductive component is incorporated into a tapped transformer; and / or

[0061] wherein the inductive component is incorporated into an electronic device.PER-584-PCT 61658.160W001

[0062] An inductive component has been described herein. The inductive component includes: a first edgewise coil formed of a first wire having a first thickness, the first edgewise coil comprising a first number of turns; a second edgewise coil formed of a second wire having a second thickness, the second edgewise coil comprising a second number of turns; a third edgewise coil formed of a third wire having a third thickness, the third edgewise coil comprising a third number of turns; and a core material disposed about the first edgewise coil, the second edgewise coil, and the third edgewise coil. The inductive component may include any one or more of the following features:

[0063] wherein the first edgewise coil, the second edgewise coil, and the third edgewise coil are trifilar;

[0064] wherein the first thickness is different from the second thickness or the third thickness;

[0065] wherein the first edgewise coil, the second edgewise coil, and the third edgewise coil are stacked;

[0066] wherein the first number of turns is different from the second number of turns or the third number of turns;

[0067] wherein the first edgewise coil extends from a first terminal to a second terminal, the second edgewise coil extends from a third terminal to a fourth terminal, and the first terminal or the second terminal is electrically connected to the third terminal or the fourth terminal;

[0068] wherein the first edgewise coil and the second edgewise coil are bifilar and stacked with the third edgewise coil;

[0069] comprising a fourth edgewise coil;

[0070] wherein the inductive component is incorporated into a tapped transformer; and / or

[0071] wherein the inductive component is incorporated into an electronic device.

[0072] An inductive component has been described herein. The inductive component includes: a first winding extending from a first terminal to a second terminal, wherein the first winding spirals inwardly from the first terminal in a first plane for a first number of turns, includes a first transverse portion extending between the first plane and a second plane, and spirals outwardly in the second plane for the first number of turns to the second terminal; a second winding extending from a third terminal to a fourth terminal, wherein the second winding spirals inwardly from the third terminal in a third plane for a second number of turns, includes a second transverse portion extending between the third plane and a fourth plane, and spirals outwardly in the fourth plane for the second number of turns to the fourthPER-584-PCT 61658.160W001 terminal; and a core material disposed about the first winding and the second winding. The inductive component may include any one or more of the following features:

[0073] wherein the first plane is immediately adjacent to the second plane;

[0074] wherein the first number of turns is greater than the second number of turns;

[0075] wherein the first winding is formed a first wire, the second winding is formed of a second wire, and wherein a cross-sectional area of the first wire is larger than a cross-sectional area of the second wire;

[0076] wherein the third plane is between the first plane and the second plane;

[0077] wherein the first winding is formed a first wire, the second winding is formed of a second wire, and wherein a cross-sectional area of the first wire is larger than a cross-sectional area of the second wire;

[0078] wherein the first plane and third plane are coplanar, and the second plane and the fourth plane are coplanar;

[0079] wherein the first winding is formed a first wire, the second winding is formed of a second wire, and wherein a cross-sectional area of the first wire is larger than a cross-sectional area of the second wire;

[0080] further comprising a third winding extending from a fifth terminal to a sixth terminal, wherein the third winding spirals inwardly from the fifth terminal in a fifth plane for a third number of turns, includes a third transverse portion extending between the fifth plane and a sixth plane, and spirals outwardly in the sixth plane for the third number of turns to the sixth terminal;

[0081] wherein the first plane is immediately adjacent to the second plane, the third plane is immediately adjacent to the fourth plane, and the fifth plane is immediately adjacent to sixth plane;

[0082] wherein the third plane is between the first plane and the second plane;

[0083] wherein the fifth plane is immediately adjacent to sixth plane;

[0084] wherein the fifth plane is between the first plane and the second plane;

[0085] wherein a shape of the spirals is rectangular or square with rounded vertices;

[0086] wherein the inductive component is incorporated into a coupled inductor;

[0087] wherein the inductive component is incorporated into a tapped transformer; and / or

[0088] wherein the inductive component is incorporated into an electronic device.

[0089]

[0090] Although various embodiments have been shown and described, the disclosure is not limited to such embodiments and will be understood to include all modifications andPER-584-PCT 61658.160W001 variations as would be apparent to one of ordinary skill in the art. Therefore, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed; rather, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the appended claims.

Claims

PER-584-PCT 61658.160W001CLAIMS WHAT IS CLAIMED IS:

1. An inductive component comprising:a first edgewise coil formed of a first wire having a first thickness, the first edgewise coil comprising a first number of turns;a second edgewise coil formed of a second wire having a second thickness, the second edgewise coil comprising a second number of turns; anda core material disposed about the first edgewise coil and the second edgewise coil; wherein the first thickness is different from the second thickness or the first number of turns is different from the second number of turns.

2. The inductive component of claim 1, wherein the first thickness is different from the second thickness.

3. The inductive component of claim 2, wherein the first edgewise coil and the second edgewise coil are bifilar.

4. The inductive component of claim 2, wherein the first edgewise coil and the second edgewise coil are stacked.

5. The inductive component of claim 4, wherein the first number of turns is different from the second number of turns.

6. The inductive component of claim 4, wherein the first thickness is greater than the second thickness and the second number of turns is greater than the first number of turns.

7. The inductive component of claim 1, wherein the first number of turns is different from the second number of turns.

8. The inductive component of claim 1, further comprising a third edgewise coil.

9. A tapped transformer comprising the inductive component of claim 1.PER-584-PCT 61658.160W00110. An electronic device comprising the inductive component of claim 1.

11. An inductive component comprising:a first edgewise coil formed of a first wire having a first thickness, the first edgewise coil comprising a first number of turns;a second edgewise coil formed of a second wire having a second thickness, the second edgewise coil comprising a second number of turns;a third edgewise coil formed of a third wire having a third thickness, the third edgewise coil comprising a third number of turns; anda core material disposed about the first edgewise coil, the second edgewise coil, and the third edgewise coil.

12. The inductive component of claim 11, wherein the first edgewise coil, the second edgewise coil, and the third edgewise coil are trifilar.

13. The inductive component of claim 12, wherein the first thickness is different from the second thickness or the third thickness.

14. The inductive component of claim 11, wherein the first edgewise coil, the second edgewise coil, and the third edgewise coil are stacked.

15. The inductive component of claim 14, wherein the first number of turns is different from the second number of turns or the third number of turns.

16. The inductive component of claim 11, wherein the first edgewise coil extends from a first terminal to a second terminal, the second edgewise coil extends from a third terminal to a fourth terminal, and the first terminal or the second terminal is electrically connected to the third terminal or the fourth terminal.

17. The inductive component of claim 11, wherein the first edgewise coil and the second edgewise coil are bifilar and stacked with the third edgewise coil.

18. The inductive component of claim 11, comprising a fourth edgewise coil.PER-584-PCT 61658.160W001 19. A tapped transformer comprising the inductive component of claim 11.

20. An electronic device comprising the inductive component of claim 11.

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