Surface-Mount Toroid Inductor for High-Current PCB Space Savings
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Solution Overview
Problem
Conventional inductors in IC packages are limited in supporting high current due to space constraints, and existing mounting methods restrict design flexibility and occupy valuable real estate on both sides of the PCB.
Innovation Solution
An inductor design that can expand and contract at the same magnitude and rate as a printed circuit board, allowing it to be mounted on one side of the PCB without penetrating the substrate, thereby reducing size and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional inductors are mounted using through hole technology, then the inductors can be securely coupled to the PCB, but the inductors occupy areas on the backside of the PCB thereby reducing the amount of real estate available on the backside to populate components
Solution Approach 1:
The inductor is designed with a flat profile that allows it to be mounted on the front side of the PCB without protruding through to the backside. The leads extend only partially through the PCB thickness, creating a dimensionally constrained component that occupies space primarily in the Z-dimension rather than extending into the backside plane, thereby freeing up PCB backside real estate for additional components.
Solution Approach 2:
The inductor structure is segmented into distinct functional zones: the magnetic core and coil assembly is confined to the front side of the PCB, while the leads provide a transition zone that connects to the backside without occupying significant backside surface area. This segmentation allows the active inductor components to be isolated on the front side while maintaining electrical connection through the PCB.
2Area of stationary object
If inductors are mounted or integrated into the header or connector, then the inductors can be positioned in limited spaces, but the position of the inductors is fixated thereby restricting the amount of designs available when populating components onto the PCB
Solution Approach 1:
The inductor is designed as a standalone surface-mountable component with standardized lead configurations that can be adapted to various PCB layouts and circuit designs. The flat profile and lead arrangement allow the same inductor type to be used in multiple design configurations, providing universality across different applications while maintaining space efficiency.
3Power
If the inductor is designed to handle high current, then the inductor can support power electronics applications, but the inductor size increases thereby occupying more space on the PCB
Solution Approach 1:
The inductor utilizes a thin-profile magnetic core structure with flattened geometry that allows high current handling capability while minimizing the vertical and horizontal space occupation. The core is designed with optimized magnetic path geometry that concentrates the magnetic flux efficiently, allowing high power density in a compact, thin package that can be mounted on standard PCBs without requiring excessive space.
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 solution enables a reduced-size circuit card assembly with lower manufacturing costs, increased design flexibility, and efficient use of PCB space, as it allows for additional components on the opposite side of the inductor.
Implementation Method 1
Inductors are passive electronic components that store energy in the form of a magnetic field. Every conductor has a certain amount of inductance associated therewith.
Data Source
AI summary
An inductor comprises a base having a top surface, a bottom surface, and at least one side surface. The top surface is spaced from the bottom surface. The at least one side surface connects the top surface to the bottom surface. A core is located on the top surface and coupled to the base. At least one coil extends helically about the core. The at least one coil has at least one end extending outwardly from said core. At least one lead is coupled to the at least one coil and extending outwardly from the base in a coplanar relationship with the bottom surface. A circuit card assembly including the inductor and a method of manufacturing the circuit card assembly are also disclosed herein.