Inductor Assembly with Zero-Length Lead Mounting Bracket
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Solution Overview
Problem
Conventional inductor leads on printed circuit boards create long current paths, leading to increased electromagnetic interference (EMI), reduced efficiency, excessive heat generation, and parasitic effects due to parasitic capacitance, which negatively impact circuit performance.
Innovation Solution
The implementation of an inductor assembly with a zero-length or near-zero-length lead using a mounting bracket with copper or copper alloy material, plated with tin, where at least one leg is connected to a substrate and another leg is connected to an electrical component, minimizing the high-current path length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If inductor leads are soldered directly to the printed circuit board, then the inductor can be mounted and electrically connected, but long current paths are formed that increase electromagnetic interference and reduce circuit performance
Solution Approach 1:
The patent transitions from planar PCB mounting to three-dimensional mounting by placing the inductor directly on top of the PCB surface. The inductor body sits vertically above the board, with terminals extending downward to contact pad surfaces, creating a compact vertical current path that minimizes loop area and EMI while maintaining electrical connectivity.
Solution Approach 2:
The inductor is nested directly onto the PCB surface, with the inductor body positioned over the board and terminals extending down to contact pads. This nesting arrangement eliminates the need for separate lead extensions and creates a compact integrated structure that reduces current path length and parasitic effects.
2Productivity
If inductor leads are soldered to the printed circuit board, then electrical connection is established, but excessive current drop occurs across the current path leading to poor efficiency and heat generation
Solution Approach 1:
The patent employs asymmetric terminal configurations where different terminals extend in different directions and lengths from the inductor body. This asymmetry allows optimization of current path geometry for minimal resistance and inductance, with terminals positioned to create short, direct connections to adjacent contact pads, reducing I²R losses and improving efficiency.
3Ease of operation
If inductor leads are made longer to facilitate mounting, then ease of assembly is improved, but parasitic elements increase and negatively impact circuit performance
Solution Approach 1:
The patent optimizes terminal parameters including length, width, thickness, and curvature to minimize parasitic inductance and capacitance. Terminals are designed with specific dimensional parameters that balance mechanical compliance for assembly with electrical performance, using controlled geometry to reduce parasitic effects while maintaining ease of mounting to contact pads.
Data Source
AI summary
An inductor assembly includes an inductor body including an inductor core and a mounting bracket that includes a first leg, a second leg, and a third leg. A portion of the mounting bracket passes through the inductor body, at least one of the first leg and the second leg of the mounting bracket is arranged to be mounted on a substrate, and the third leg of the mounting bracket is arranged to be mounted on an electrical component mounted on the substrate.