Stacked Inductive Device Using Bonded Windings and Modular Cores
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Solution Overview
Problem
Existing ferrite-cored inductive devices, such as EP-core devices, face challenges in manufacturing complexity, high cost, and inflexibility due to the use of bobbins and pre-formed core pieces, which limits their miniaturization and configurational flexibility.
Innovation Solution
The solution involves a stacked inductive device design using multiple identical magnetically permeable core elements and bonded windings without a bobbin, allowing for cost-effective and flexible configuration with reduced size, where windings are assembled within cavities formed by the core elements, enabling direct assembly onto a PCB without a termination header.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-formed core pieces and bobbins are used in traditional ferrite-cored inductive devices, then the structural integrity and magnetic performance are maintained, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The device is divided into discrete modular components including separate core elements, winding elements, and termination elements that can be independently manufactured and then assembled. This segmentation allows each component to be optimized for its specific function while simplifying the overall manufacturing process and reducing complexity.
Solution Approach 2:
The patent employs universal core elements and winding elements that can be used across multiple device configurations and applications. These standardized components serve multiple functions and can be adapted to different specifications, thereby reducing the need for custom-manufactured parts and simplifying production.
2Reliability
If traditional EP-core devices with bobbins are used, then the magnetic shielding and flux density are achieved, but the device size and cost increase
Solution Approach 1:
The traditional bobbin structure is extracted and removed from the design. Instead of using a bulky bobbin to hold the windings, the patent employs a direct assembly approach where winding elements are positioned and secured between core elements, eliminating the need for the bobbin and thereby reducing device volume.
Solution Approach 2:
The winding elements are nested within the magnetic circuit formed by the core elements, with terminations nested through the core structure. This nested arrangement allows compact integration of all components within a minimal volume while maintaining magnetic shielding effectiveness.
3Reliability
If pre-formed core pieces are used, then the magnetic flux path is established, but the configurational flexibility and adaptability are reduced
Solution Approach 1:
The magnetic circuit is segmented into discrete core elements that can be independently positioned and configured. This segmentation enables flexible arrangement of core elements to create different magnetic flux paths and device configurations depending on application requirements, while maintaining reliable magnetic coupling between elements.
Solution Approach 2:
The patent employs a modular assembly approach where core elements, winding elements, and terminations can be dynamically configured during assembly to meet different specifications. This dynamic configurability allows the same basic components to be adapted for various applications without requiring pre-formed custom pieces.
4Strength
If bobbins and termination headers are used in traditional devices, then the structural support and electrical connections are provided, but the manufacturing cost and assembly complexity increase
Solution Approach 1:
The separate bobbin and termination header components are extracted and eliminated from the design. Their functions are integrated into the core elements and winding elements themselves, which provide both structural support and electrical connection capabilities, thereby reducing part count, manufacturing cost, and assembly complexity.
Solution Approach 2:
The structural support function previously provided by the bobbin and the electrical connection function provided by termination headers are merged into an integrated assembly where core elements and winding elements work together as unified components, eliminating the need for separate supporting structures.
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 approach results in a compact, high-performance inductive module with reduced manufacturing costs and increased flexibility, enabling smaller size and multiple configurations while maintaining electrical performance, and allowing for the use of existing technologies like bonded wire.
Implementation Method 1
the wound windings and the magnetically permeable core elements cooperate to provide a magnetic path for magnetic flux
Implementation Method 2
two or more windings which may or may not be wrapped around a magnetically permeable core
Data Source
AI summary
Improved inductive electronic apparatus and methods for manufacturing the same. In one exemplary embodiment, the apparatus comprises an inductive device module comprising N inductors and N+1 core elements. The core elements comprise ferrite core pieces that are optionally identical to one another. These core elements are stacked (e.g., in a longitudinal coaxial arrangement) such that the back of one core element associated with a first inductor provides a magnetic flux path for a second inductor. Form-less (bonded) windings are also optionally used to simplify the manufacture of the device, reduce its cost, and allow it to be made more compact (or alternatively additional functionality to be disposed therein). One variant utilizes a termination header for mating to a PCB or other assembly, while another totally avoids the use of the header by directly mating to the PCB.