Edge-Mounted Filter Inductor With Segmented Winding
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Solution Overview
Problem
Conventional high-current filter inductors are large, fixed format components that do not align with the industry's need for compact, low-profile, and high-efficiency solutions in electronic packaging, particularly in power supply modules.
Innovation Solution
A compact winding-magnetic core configuration for filter inductors that allows them to be mounted along the edge of a printed circuit board (PCB), with a shaped winding section and integrated connector pins, reducing the overall size and improving thermal resistance and power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional high-current filter inductors are designed with traditional winding configurations, then they provide sufficient inductance for high-current applications, but they result in large size and high profile that do not meet compact electronic packaging requirements
Solution Approach 1:
The winding is divided into multiple discrete sections (first winding section, second winding section, third winding section) that are positioned at different locations around the magnetic core. This segmentation allows the inductor to achieve the required inductance through distributed winding sections while reducing the overall footprint and profile compared to a single large winding structure.
Solution Approach 2:
The patent transitions from planar winding layouts to a three-dimensional configuration where winding sections are positioned at different heights and angular positions around the magnetic core. The first winding section is at a first height, the second at a second height, and the third at a third height, creating a multi-layer spatial arrangement that packs more inductance into a smaller volume.
2Length of stationary object
If the profile of filter inductor is reduced to meet low-profile requirements, then compactness is improved, but thermal management and current carrying capacity may be compromised
Solution Approach 1:
The winding is divided into multiple discrete sections (first winding section, second winding section, third winding section) that are positioned at different locations around the magnetic core. This segmentation allows the inductor to achieve the required inductance through distributed winding sections while reducing the overall footprint and profile compared to a single large winding structure.
Solution Approach 2:
The patent transitions from planar winding layouts to a three-dimensional configuration where winding sections are positioned at different heights and angular positions around the magnetic core. The first winding section is at a first height, the second at a second height, and the third at a third height, creating a multi-layer spatial arrangement that packs more inductance into a smaller volume.
3Ease of manufacture
If traditional separate winding and connector configurations are used, then manufacturing is simplified, but overall size is increased and current paths are lengthened resulting in higher power consumption
Solution Approach 1:
The patent integrates the winding structure and connector pins into a single unified component. The first end of the first winding section is directly connected to a first connector pin, and the second end of the third winding section is directly connected to a second connector pin, eliminating the need for separate connection elements and reducing the overall current path length.
Solution Approach 2:
The winding sections serve dual functions: they provide the inductive function for current filtering while simultaneously serving as the structural basis for electrical connection through their integrated end connections to connector pins. This multi-functionality reduces the number of separate components needed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration lowers the profile of the filter inductor by up to a quarter, decreases size, shortens current paths, reduces power consumption, and enhances thermal resistance in PCB assemblies.
Implementation Method 1
A conventional filter inductor typically includes a magnetic core, and a coil of conductive wire wrapped around the magnetic core. Employing a magnetic core with a high permeability, as well as increasing the number of turns of the coil of conductive wire around the magnetic core, can increase an inductance of the filter inductor.
Data Source
AI summary
A filter inductor for high-current applications. The filter inductor includes a magnetic core and a winding. The winding includes a shaped section having opposing ends, a pair of arm sections laterally extending from the opposing ends of the shaped section, respectively, and a pair of inductor pins, each extending perpendicular from an end of a respective arm section. The magnetic core includes a first core portion and a second core portion. The first core portion includes a recessed channel configured to receive the shaped section of the winding. The second core portion includes a pair of recessed regions configured to receive the pair of arm sections of the winding, respectively. The first core portion and the second core portion are coupled in contact to one another to secure the shaped section of the winding within the magnetic core. The filter inductor can be edge-mounted to a printed circuit board.