High current coupled winding electromagnetic component

Patent metadata

Field	Value
Publication number	US-12260982-B2
Application number	US-202117358387-A
Country	US
Kind code	B2
Filing date	Jun 25, 2021
Priority date	Jun 28, 2020
Publication date	Mar 25, 2025
Grant date	Mar 25, 2025

Abstract

An electromagnetic component includes a magnetic core and a dual-winding arrangement inside the magnetic core structure. The dual-winding arrangement includes a first winding fabricated from an elongated conductor having a first thickness and defining a first inverted U-shaped main winding portion including out of plane axial bends, and a second winding fabricated from a conductor having a second thickness and being formed into a second inverted U-shaped main winding portion with perpendicular sections extending co-planar to one another without any out of plane axial bends.

First claim

What is claimed is:

1. A surface mount electromagnetic component for multi-phase electrical power circuitry implemented on a circuit board, the component comprising:
a magnetic core structure including a top side, a bottom side, opposing lateral sides and opposing longitudinal sides; and
a dual-winding arrangement inside the magnetic core structure and configured to be surface mounted at the bottom side to the multi-phase electrical power circuitry on the circuit board, wherein the dual-winding arrangement comprises:
a first winding fabricated from an elongated conductor having a first thickness, the first winding defining a first inverted U-shaped main winding portion, wherein the first inverted U-shaped main winding portion includes a first top section and first vertical legs perpendicular to the first top section, and wherein the first inverted U-shaped main winding portion further includes out of plane bends transitioning between the first top section and the first vertical legs, wherein the elongated conductor is bent in a geometry of the first inverted U-shaped main winding portion via the out of plane bends;
a second winding fabricated from a planar sheet of a conductor having a second thickness less than the first thickness, the second winding defining a second inverted U-shaped main winding portion, wherein the second inverted U-shaped main winding portion includes a second top section and second vertical legs perpendicular to the second top section, and wherein the second top section and the second vertical legs extend co-planar to one another without any out of plane bends;

wherein the first inverted U-shaped main winding portion and the second inverted U-shaped main winding portion is laterally spaced from one another inside the magnetic core structure while being magnetically coupled inside the magnetic core structure; and
wherein the first winding further includes a first pair of surface mount termination pads at the bottom side of the component, wherein the second winding further include a second pair of surface mount termination pads at the bottom side of the component, wherein the first pair of surface mount termination pads extend in opposite directions to one another toward each opposing lateral side, and wherein the second pair of surface mount termination pads extend in opposite directions to one another toward each opposing lateral side.

2. The electromagnetic component of claim 1 , wherein the magnetic core structure has a length dimension a width dimension, and a height dimension relative to the circuit board; and
wherein the height dimension is substantially greater than the width dimension.

3. The electromagnetic component of claim 2 , wherein the second inverted U-shaped main winding portion of the second winding extends in a plane defined by the height dimension and the length dimension.

4. The electromagnetic component of claim 1 , wherein the surface mount termination pads in the first and second windings extend at 90° orientations relative to one another.

5. The electromagnetic component of claim 1 , wherein a portion of each of the first and second windings is exposed on the top side.

6. The electromagnetic component of claim 1 , wherein the dual-winding arrangement further comprises a separator extending between the first winding and the second winding.

7. The electromagnetic component of claim 6 , wherein the separator is separately provided from the magnetic core structure.

8. The electromagnetic component of claim 7 , wherein the separator has an inverted U-shape that is received in the magnetic core structure.

9. The electromagnetic component of claim 6 , wherein the separator is built-in to the magnetic core structure.

10. The electromagnetic component of claim 9 , wherein the separator comprises first and second columns spaced from a common wall in the magnetic core structure in an amount to receive one of the first and second windings between the separator and the common wall.

11. The electromagnetic component of claim 1 , wherein the magnetic core structure is defined by at least two modular magnetic core pieces.

12. The electromagnetic component of claim 11 , wherein one of the at least two modular magnetic core pieces defines a surface formed with slots to receive corresponding portions of the first winding and the second winding in the dual-winding arrangement.

13. The electromagnetic component of claim 12 , wherein the one of the at least two modular magnetic core pieces defines a first surface and a second surface opposing first surface, each of the first and second surfaces including slots to respectively receive portions of a first dual-winding arrangement on the first surface and portions of a second dual-winding arrangement on the second surface.

14. The electromagnetic component of claim 12 , wherein each of the at least two modular magnetic core pieces defines a surface formed with slots to receive portions of the dual-winding arrangement.

15. The electromagnetic component of claim 11 , wherein one of the at least two modular magnetic core pieces is a flat and planar core piece.

16. The electromagnetic component of claim 1 , wherein the magnetic core structure is defined by a single magnetic core piece.

17. The electromagnetic component of claim 16 , wherein the single magnetic core piece includes a built-in separator feature extending between the first winding and the second winding.

18. The electromagnetic component of claim 16 , wherein the single magnetic core piece is formed with at least one physical gap.

19. The electromagnetic component of claim 1 , wherein a physical air gap extends between a portion of the dual-winding arrangement and the magnetic core structure.

20. The electromagnetic component of claim 1 , wherein the magnetic core structure has a length dimension, a width dimension, and a height dimension relative to the circuit board, wherein the first thickness is multiple times thicker than the second thickness along the width dimension, and wherein the first and second windings are equal along the length and width dimensions.

21. The electromagnetic component of claim 1 , wherein the first thickness is five times of the second thickness.

Assignees

• Eaton Intelligent Power Ltd

Inventors

• Yan Yipeng
• Zhou Dengyan
• Zhou Tingjun

Classifications

• H01F27/24

  Magnetic cores · CPC title

• H01F41/04

  for manufacturing coils {(coils for transformer or inductances H01F27/28)} · CPC title

• H01F27/306

  Fastening or mounting coils or windings on core, casing or other support · CPC title

• H01F27/2852

  Construction of conductive connections, of leads · CPC title

• H01F3/14

  Constrictions; Gaps, e.g. air-gaps (in magnetic shunt paths H01F3/12) · CPC title