Universal Lighting Technologies, Inc.

Mike LeBlanc

Donald Folker

Wei Xiong

John Jay Dernovsek

Mark Bauer

Travis L Berry

Dane Sutherland

Thomas M Poehlman

Brandon Dyer

Christopher Radzinski

James Neal Van Pelt

Candice Ungacta

Theodore E Kluska

Ted Kluska

Deborah Pinkerton

David Blevins

J C Kelley

An edge mount magnetic component includes a bobbin and two E-core halves. The bobbin is configured to receive the two E-core halves when body portions of the two E-core halves are positioned vertically. The bobbin includes a first outer flange, a second outer flange, and a passageway spanning therebetween. The bobbin further includes first, second, third, and fourth pin supports. The first and second pin supports are connected to an outer surface of the first end flange and are spaced apart by at least a width of the passageway. The third and fourth pin supports are connected to an outer surface of the second end flange and are spaced apart by at least the width of the passageway. The bobbin further includes slots for routing a winding to a pin and includes walls to ensure the winding is electrically separated from the E-core halves.

Bobbin for edge-mounted magnetic core

A magnetic connector assembly has two independent magnetic components sharing a common core structure. The magnetic assembly includes first and second bobbins, and includes a magnetic core. The magnetic core includes first and second core halves, each half including a main core body, a first outer leg, a second outer leg, and a middle leg. The first outer leg fits within a passageway of the first bobbin. The second outer leg fits within a passageway of the second bobbin. The middle leg fits between the two bobbins.

Combined U-core magnetic structure

A magnetic assembly structure includes a bobbin, an outer core, an inner core, and a gap spacer. The bobbin has first and second flanges. The bobbin has a passageway extending between the first and second flanges. The passageway has at least one crushable passageway rib and a channel wall parallel to the second flange. The outer core is positioned around the first and second flanges. The outer core includes an opening positioned near the first flange. The inner core is positioned in the opening and in the passageway. The gap spacer is positioned between the inner core and an inner surface of the outer core. The gap spacer and outer core are held in frictional engagement between the inner core and channel wall. The gap spacer defines a gap distance which is adjustable by replacing the gap spacer with one of having a different thickness. Adjusting the gap distance modifies the inductance.

Magnetic core structure

A low profile inductive apparatus is provided via one or more traces in a printed circuit board, the one or more traces defining inductive winding turns about an aperture, and a core comprising an elongate core member configured for positioning through the aperture of the circuit board. The core may be press fit with respect to the printed circuit board, or alternatively the elongate core member and the aperture may be reciprocally threaded. In an embodiment, core flanges may be provided on opposing sides of the printed circuit board, with the elongate core member connected between the core flanges and extending through the aperture. The number of inductive winding turns relates to a required inductance of the inductor when the elongate core member is positioned through the aperture, and a width and thickness of the windings corresponds to a required carrying capacity of the inductor.

Low profile inductor

A magnetic connector assembly has three independent magnetic components sharing a common core structure. The magnetic assembly includes first, second, and third bobbins, and includes a magnetic core. The first bobbin includes at least one latch mechanism of a first type. The second bobbin includes at least one latch mechanism of the first type. The third bobbin includes at least one latch mechanism of a second type configured to engage the latch mechanisms of the first and second bobbins. The magnetic core includes first and second core halves, each including a main core body, a first outer leg, a second outer leg, a middle leg, a first intermediate leg, and a second intermediate leg. The first outer leg fits within a passageway of the first bobbin. The second outer leg fits within a passageway of the second bobbin. The middle leg fits within a passageway of the third bobbin.

Single magnetic assembly combining three independent magnetics using a modified 'E' core with four winding windows

A tunable magnetic assembly includes a bobbin, an outer core, and an inner core. The bobbin has a first and second flanges. The bobbin has a passageway extending between the first and second flange. The passageway has a spiral track defined in a passageway surface. The outer core is positioned around the first and second flanges. The outer core includes an opening positioned near the first flange. The inner core is positioned in the opening and in the cylindrical passageway. The inner core includes at least one protrusion extending from an outer surface and configured to engage the spiral track. A gap distance is defined between the inner core and a portion of the outer core near the second flange. The gap distance is adjustable by moving the protrusion within the spiral track. Adjusting the gap distance modifies the inductance.

Tunable magnetic core structure

A common mode choke assembly includes a main core, a shunt core, and first and second two-piece bobbins. The main core has a generally rectangular main core body, and first and second core riser portions. The first and second core riser portions are connected to opposite ends of the main core body. The first core riser portion includes a first riser notch and the second core riser portion includes a second riser notch aligned with the first riser notch. The shunt core spans between and is positioned within the first and second riser notches. The first and second two-piece bobbins are positioned on opposite sides of the main core body adjacent to the first and second core riser portions. Each two-piece bobbin includes at least first and second end flanges, a passageway, and a mating surface. The assembly further includes a mounting header for receiving the main and shunt core.

Compact common mode choke with differential noise suppression and high self resonant frequency

A magnetic component has a variable inductance over a range of DC bias currents. The component includes a bobbin with a coil positioned around a passageway between first and second end flanges. First and second E-cores have respective middle legs positioned in the passageway with end surfaces of the middle legs juxtaposed within the passageway and spaced apart by a first magnetic gap. An I-bar is positioned in the passageway parallel to and spaced apart from respective first longitudinal surfaces of the middle legs to form a second magnetic gap between the I-bar and the longitudinal surface of the middle leg of the first E-core and to form a third magnetic gap between the I-bar and the longitudinal surface of the middle leg of the second E-core. The magnetic component provides higher inductances for lower bias currents and provides lower inductances for higher bias currents.

Inductor with flux path for high inductance at low load

A magnetic component has a variable inductance over a range of DC bias currents. The component includes a bobbin with a coil positioned around a passageway between first and second end flanges. First and second E-cores (either conventional or EFD E-cores) have respective middle legs positioned in the passageway with end surfaces of the middle legs juxtaposed within the passageway and spaced apart by a first magnetic gap. An I-bar is positioned in the passageway parallel to and spaced apart from respective first longitudinal surfaces of the middle legs to form a second magnetic gap between the I-bar and the longitudinal surface of the middle leg of the first E-core and to form a third magnetic gap between the I-bar and the longitudinal surface of the middle leg of the second E-core. The magnetic component provides higher inductances for lower bias currents and provides lower inductances for higher bias currents.

A magnetic assembly includes a bobbin with two end flanges. A passageway extends longitudinally between the end flanges. An inner core extends through the passageway. The inner core has first and second end surfaces, each end surface proximate to one of the end flanges. A rectangular outer core is positioned around the bobbin with inner surfaces of the outer core close to the outer surfaces of the end flanges of the bobbin. A respective gap is formed between each end surface of the inner core and the adjacent inner surface of the outer core. A protrusion is formed on at least one inner surface of the outer core to control the cavity distance between the inner surfaces of the outer core proximate to the end surfaces of the inner core. The thickness of the protrusion is selectably reduced to increase the cavity distance to control the gaps.

Magnetic core structure and manufacturing method using a grinding post

A combination of a common-mode choke and two integrated RF inductors includes first and second E-core. At least one E-core includes first and second protrusions extending from a body portion. Each protrusion is configured to accommodate a respective winding. In a first embodiment, each protrusion extends from the body portion at an angle perpendicular to legs extending from the body portion. In a second embodiment, each protrusion extends from the body portion in an opposite direction from the legs extending from the body portion, and each protrusion includes a respective channel to receive a respective winding. In a third embodiment, each protrusion extends from the body portion in an opposite direction from the legs extending from the body portion, and each protrusion is sized and shaped to extend into a respective opening in a printed circuit board. Each opening is surrounded by a respective printed circuit winding.

Common-mode choke with integrated RF inductor winding

A magnetic assembly includes a bobbin having at least first and second end flanges. The bobbin includes a channel wall displaced from the first end flange to from a channel therebetween. The channel receives and frictionally engages an I-core to retain the I-core in the channel. The bobbin includes a passageway that receives a middle leg of an E-core. The passageway includes a plurality of longitudinal ribs that extend from the first end flange toward the second end flange. The ribs are tapered with respect to the inner wall of the passageway. The middle leg of the E-core crushes the ribs. The frictional engagement of the crushed ribs with the middle leg retains the middle leg in the passageway. No taping, gluing or other additional step is required to assemble the bobbin and the two cores.

Bobbin and core assembly configuration and method for E-core and I-core combination

A magnetic component for an electronic circuit includes a core having a core body and a core leg extending from the core body. The core body defines a core body height, and the core leg defines a core leg height less than the core body height. A conductive winding is positioned about the core leg. The winding defines a winding height. A winding height offset ratio is defined as the winding height divided by the core body height. In some embodiments the winding height offset ratio is less than about 1.1. The winding can be positioned on a bobbin structure disposed about the core leg. The magnetic component can be positioned in an enclosure to form an electronic device such as a power control or a power supply, and a thermally conductive gap-filler can be positioned between the magnetic component and the enclosure wall to dissipate heat from the magnetic component. The reduced height of the core leg provides a reduced gap distance between the core body and the enclosure wall for improving heat transfer, reducing thermal gap-filler material volume and reducing enclosure size. A method of forming an electronic device is also provided.

Low profile magnetic component apparatus and methods

A magnetic device for an electronic circuit includes a printed circuit board. A first and second magnetic component assembly can be electrically connected to the printed circuit. The second magnetic component assembly can be stacked on the first magnetic component assembly. The first magnetic component assembly can be positioned between the second magnetic component assembly and the printed circuit board. Each magnetic component assembly can include a bobbin, a winding disposed on the bobbin, and a core extending through the bobbin. A second bobbin on the second magnetic component can be positioned on either a first core or a first bobbin of the first magnetic component assembly. The stacked magnetic component configuration can help reduce the board space required to electrically connect both the first and second magnetic component assemblies to the printed circuit board, which can help increase the power density of the magnetic device.

Growing community of inventors

Huntsville, AL, United States of America

Mike LeBlanc