Closed-Core Inductor Array Layout for Dense PCB Mounting
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Solution Overview
Problem
High-Q inductors face challenges in mounting due to limited space on printed circuit boards, especially in VPX cards, leading to inefficient use of board area and reduced inductor density.
Innovation Solution
An inductor assembly with a toroidally-shaped core and winding, coupled to a circuit board via castellated vias, featuring a conductive elongate member and spacers to enhance compact mounting and reduce coupling, allowing for a high-Q inductor array with increased density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If surface-mounted closed-core inductors are placed on a printed circuit board, then inductors can be mounted with improved packaging, but they require a relatively large printed circuit board area reducing inductor density
Solution Approach 1:
The inductor assembly uses a nested configuration where multiple closed-core inductors are positioned within a shared mounting structure on the circuit board. The inductors are arranged in a compact pattern with their leads interleaved and connected through a common terminal structure, effectively nesting multiple components within a reduced footprint area.
Solution Approach 2:
The invention transitions from traditional planar surface-mount placement to a three-dimensional mounting arrangement. Inductors are positioned with vertical spacing and interleaved lead connections that utilize the Z-dimension, allowing multiple inductors to occupy overlapping projected areas on the circuit board, thereby increasing density without compromising manufacturing ease.
2Reliability
If a large array of inductors is placed on a printed circuit board, then circuit performance is improved, but unused space between inductors increases leading to inefficient board area utilization
Solution Approach 1:
Multiple inductors share common mounting structures, terminal connections, and support elements. The assembly combines multiple individual inductor units into a single integrated package that is mounted as one unit on the circuit board, eliminating redundant mounting features and reducing the total area required for a large array of inductors.
Solution Approach 2:
The mounting assembly incorporates universal, multi-functional elements that serve multiple inductors simultaneously. A single support structure provides mechanical mounting for several inductors, while common terminal structures provide electrical connections for multiple components, reducing the overall footprint required for large inductor arrays.
3Adaptability or versatility
If high-Q inductors are mounted on a VPX card with limited height and width, then the card can be populated with required components, but the limited board space restricts inductor placement options
Solution Approach 1:
The inductor assembly is segmented into modular units that can be independently configured and mounted. Each module contains a specific number of inductors arranged in a compact pattern, allowing the VPX card to be populated with multiple such modules to achieve the required component density while working within the limited height and width constraints.
Solution Approach 2:
The assembly utilizes vertical spacing and three-dimensional lead routing to accommodate multiple inductors within the limited planar area of the VPX card. By arranging inductors with vertical offsets and using interleaved connection paths, the design maximizes the use of available Z-space, effectively increasing placement capacity without increasing the card's footprint.
Data Source
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AI summary
An electronic circuit device 10 may include a main circuit board 14 having an inductor assembly mounting area 16 thereon, and an inductor assembly 20 coupled to the main circuit board adjacent the inductor assembly mounting area. The inductor assembly 20 may include an inductor assembly circuit board 28 with an inductor assembly circuit board though-opening 30 therein, and closed-core inductors 34 coupled to the inductor assembly circuit board in side-by-side relation and having lower portions 36 extending into the inductor assembly circuit board though-opening.