Edge-Mounted Magnetic Bobbin for PCB Space Reduction
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Solution Overview
Problem
Existing bobbin configurations for magnetic components with E-core halves occupy a large surface area on printed circuit boards due to the orientation of the E-core halves, which limits space efficiency and requires significant board space.
Innovation Solution
A bobbin configuration with a passageway and pin supports that allows the E-core halves to be mounted with their width oriented vertically, reducing the overall surface area required by positioning the middle legs between the outer legs and using pin supports and flange slots to secure the winding, thereby minimizing the horizontal space needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If E-core halves are mounted in conventional horizontal or vertical configurations, then the magnetic component can be assembled with standard bobbin designs, but the surface area occupied on the printed circuit board is large
Solution Approach 1:
The patent applies dimensionality change by transitioning from conventional horizontal/vertical mounting orientations to an edge-mounted configuration where the E-core halves are positioned with their width dimension oriented vertically. This reorientation in a different dimensional arrangement reduces the horizontal footprint on the PCB while maintaining all necessary magnetic and electrical functions.
Solution Approach 2:
The patent inverts the conventional mounting approach by positioning the E-core halves on the edge of the bobbin rather than on the top or bottom surfaces. This inversion of the mounting orientation allows the magnetic component to occupy less surface area on the PCB while maintaining functional integrity through the use of flange slots and pin supports for securing the windings.
2Area of stationary object
If the E-core halves are reoriented with width vertical to reduce PCB space, then surface area is reduced by approximately 20%, but new mounting structures (flange slots and pin supports) are required
Solution Approach 1:
The patent merges multiple functions into integrated structures: the flange slots serve both as mechanical support for the E-core halves and as pathways for securing the windings, while the pin supports simultaneously provide structural anchoring and electrical connection points. This merging reduces the need for separate components and simplifies the overall mounting structure despite the reoriented configuration.
Solution Approach 2:
The flange slots and pin supports are designed as multi-functional elements that perform multiple roles: mechanical support, structural alignment, winding securing, and electrical connection. This universality allows the mounting structure to handle the reoriented E-core configuration without requiring additional specialized components, thereby limiting the increase in device complexity.
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 reduces the surface area occupied by the magnetic component on the printed circuit board by approximately 20% compared to conventional horizontal and vertical configurations, enhancing space efficiency without compromising electrical characteristics.
Implementation Method 1
A coil is wound around the outside of at least a portion of the central passageway between at least a first outer flange and a second outer flange
Data Source
AI summary
An edge mount magnetic component includes a bobbin and two E-core halves. The bobbin is configured to receive the two E-core halves when body portions of the two E-core halves are positioned vertically. The bobbin includes a first outer flange, a second outer flange, and a passageway spanning therebetween. The bobbin further includes first, second, third, and fourth pin supports. The first and second pin supports are connected to an outer surface of the first end flange and are spaced apart by at least a width of the passageway. The third and fourth pin supports are connected to an outer surface of the second end flange and are spaced apart by at least the width of the passageway. The bobbin further includes slots for routing a winding to a pin and includes walls to ensure the winding is electrically separated from the E-core halves.