Other

Lucent Technologies Inc.

At&t Bell Laboratories

Tyco Electronics Logistics Ag

Tyco Electronics Power Systems, Inc.

Matthew Anthony Wilkowski

Robert Joseph Roessler

William Lonzo Woods, Jr

Galliano Ricardo Busletta

Robert James Catalano

Paul Joseph Offer, Jr

Lennart Daniel Pitzele

Randy T Heinrich

Ashraf W Lotfi

Wayne C Bowman

David Leonard Stevens

Thang Danh Truong

Arthur Martin

Karim Nashaat Wassef

William L Woods

Ronald B Praught

Peter Mignano

Galliano Riccardo Busletta

A magnetic device is provided that may be employed with surface mount technology. In an advantageous embodiment, the magnetic device includes a magnetic core having a magnetic core half and a springable winding positioned about at least a portion of the magnetic core half. The springable winding includes a terminus biased against the magnetic core half.

Magnetic device having a springable winding

An apparatus for establishing inductive coupling in an electrical circuit arranged on a plurality of dielectric substrates, the substrates being in a substantially abutting relationship and presenting a plurality of substantially parallel planar expanses, includes: (a) at least one first core segment situated in at least one first depression provided in a first planar expanse; (b) at least one second core segment situated in at least one second depression provided in a second planar expanse; (c) a selected second core segment is arranged for establishing magnetic flux coupling with a selected first core segment to establish a magnetic core structure; (d) a plurality of electrically conductive through-hole structures traverse at least one substrate; (e) a plurality of electrically conductive circuit traces are arrayed upon at least two of the planar expanses. The conductive traces and the through-hole structures cooperate to establish inductive coupling.

Apparatus for establishing inductive coupling in an electrical circuit and method of manufacture therefor

An electromagnetic apparatus having an adjusting effective core gap includes: (a) an electrical winding; and (b) a ferrous core situated proximal with the electrical winding. The core has a first terminus and a second terminus arranged in spaced relation to establish a gap distance between the termini in a region in substantial register with the termini. The winding and the core cooperate to establish an inductance related with an electrical current applied to the winding. At least one terminus of the termini has a configuration responsive to varying the current by effecting selective local saturation of successive portions of the at least one terminus for successive values of the current. The selective local saturation establishes successive new effective gap distances. Each respective new effective gap distance is appropriate for establishing a successive new optimum inductance for the current value then extant.

Electromagnetic apparatus having adjusting effective core gap

A magnetic device and a method of manufacture therefor. In one embodiment, the magnetic device includes: (1) a bobbin having a winding guide and molded-in margins proximate opposing inside flanges of the bobbin, each of the opposing inside flanges having at least one notch formed in an inside face of each of said opposing inside flanges; (2) an inner winding wound about the winding guide and between the molded-in margins; (3) an outer winding wound about the inner winding and the winding guide and between the flanges; and (4) an insulating plate, provided in the at least one notch and interposed between the inner and outer windings, a thickness of the insulating plate providing a predetermined creepage distance between at least one lead of the inner winding and the outer winding.

Magnetic device and method of manufacture therefor

An apparatus is disclosed for facilitating heat dissipation in an electrical device hat includes a core structure traversing a substrate when the core structure is in an installed orientation. The apparatus comprises: (a) at least one aperture through the substrate for accommodating traversing by the core structure; each respective aperture has periphery defined by a respective circumjacent face extending a height substantially equal with the substrate thickness; (b) a layer of thermally conductive material situated discontinuously on the circumjacent face of at least one respective aperture. The respective aperture is configured to establish a thermally conductive engagement with at least one facing portion of the core structure traversing the respective aperture in the installed orientation. The method comprises the steps of: (a) providing at least one aperture through the substrate for accommodating the traversing by the core structure; each respective aperture having a circumjacent face extending a height substantially equal with the substrate thickness; (b) providing a layer of thermally conductive material situated discontinuously on the circumjacent face of at least one respective aperture; and (c) assembling the electrical device in the installed orientation. The respective aperture is configured to establish a thermally conductive engagement with at least one facing portion of the core structure traversing the aperture in the installed orientation.

Apparatus and method for facilitating heat dissipation in an electrical device

A magnetic device and a method of manufacturing the same. In one embodiment, the device includes: (1) a magnetic core and (2) a winding structure located proximate the magnetic core. The winding structure includes:(2 ) a multilayer main circuit board containing an interconnected first plurality of winding layers, (2 ) a multilayer overlay board located proximate the main circuit board and containing an interconnected second plurality of winding layers and (2 ) conductors coupling the first and second pluralities of winding layers together to cause the first and second pluralities of winding layers to function cooperatively as windings for the magnetic device.

Magnetic device employing a winding structure spanning multiple boards and method of manufacture thereof

A low-profile, surface mount magnetic component is described along with magnetic devices and power supplies using the magnetic components. The magnetic component is formed from a magnetic core which is surrounded by a plurality of conductive elements. The conductive elements fit into channels in the sides of the magnetic core, the channels having angled sides that increase in width from the top to the bottom. The conductive elements have their ends bent inwards against the bottom of the magnetic core to form surface mountable contact surfaces. A recess in the top of the magnetic core allows the conductive elements to be loaded before the ends are bent inward so that when the conductive elements are unloaded they fit tightly against the magnetic core and the conductive surfaces are coplanar.

Low profile, surface mount magnetic devices

A surface mount core assembly comprises a header with breakaway support rails. The breakaway support rails are used in the manufacturing process to maximize the core window of the assembly, and may be removed to minimize the footprint of the assembly. In the present embodiment, the assembly comprises, for example, a transformer wherein prefabricated conductor rings are used to further maximize the fill of the core window with conductor material.

Surface mount circuit assembly

An inter-substrate conductive mount for a surface mountable circuit board, a method of manufacturing the circuit board and a surface mountable power magnetic device. In one embodiment, the circuit board includes: (1) a substrate, (2) an inter-substrate conductive mount composed of a material having a melting point above a solder reflow temperature and including a compliant solder joint at an interface of the substrate and (3) a solder located proximate the conductive mount, the conductive mount of a sufficiently low weight such that a surface tension of a liquid state of the solder is sufficient to maintain the conductive mount in contact with the substrate as the solder is brought to the reflow temperature, the conductive mount being capable of mounting the substrate to an adjacent substrate and providing a conductive path therebetween.

Inter-substrate conductive mount for a circuit board, circuit board and power magnetic device employing the same

A magnetic device, a method of manufacturing the magnetic device and a DC/DC converter employing the magnetic device. The magnetic device comprises: (1) a first core-portion composed of a magnetic material and having first and second legs associated therewith, the first leg having a first end face and a predetermined first cross-sectional area, the second leg having a second end face and a predetermined second cross-sectional area different from the first cross-sectional area, (2) a winding assembly having first and second windings associated therewith and disposed about first and second winding apertures, respectively, the first and second legs passing through the first and second winding apertures, respectively, to couple the first and second windings magnetically to the first and second legs, respectively, (3) a second core-portion composed of the magnetic material and adapted to mate with the first and second legs of the first core-portion and (4) an interstitial non-magnetic material of a predetermined uniform thickness disposed on the first and second end faces and joining the first and second core-portions to form a core for the magnetic device, the non-magnetic material forming a uniform air gap in the first and second legs.

Magnetic core structures and construction techniques therefor

A magnetic device (10), suitable for attachment to a substrate, includes at least one sheet winding (24) having a pair of spaced-apart terminations (26), each receiving an upwardly rising portion (28) of a lead (12). The sheet winding terminations and upwardly-rising lead portions, together with at least a portion of the sheet windings, are then encapsulated with masses of insulative material (18, 19 and 34). A ferromagnetic core (20,22) surrounds at least a portion of the sheet windings to impart a desired magnetic property to the device.

Method of making a surface-mount power magnetic device

A spiral, self-terminating coil (12) is formed of an elongated metallic member (10) having at least a first and second tabs (22,23) extending out from a separate one of the ends (18,20) of the member such that each tab is perpendicular to the axis of the member. At least one notch (26) is provided in the member (10) intermediate the tabs and parallel thereto. Each notch (26) is located so that when the member is wound in the spiral, the notches are aligned with the tab inside of the spiral. The inside tab can thus be oriented perpendicular to the spiral turns so as to extend through the notches beyond the spiral.

Spiral, self-terminating coil and method of making the same

A transformer includes a preformed winding with each turn having a channel cross section. The individual units are joined to form the desired multiturn winding. Another winding is inserted within the channel cross section of the multiturn winding. In one embodiment, the channels of the two turns are joined to form a closed passageway. In another embodiment, they are nested one within each other to form a concurrent passageway.

Growing community of inventors

Mesquite, TX, United States of America

Matthew Anthony Wilkowski