Cooper Technologies Company

Eaton Intelligent Power Limited

Yipeng Yan

Robert James Bogert

Dengyan Zhou

Jinliang Xu

Jin Lu

Guo Ouyang

John J Janis

Ahila Krishnamoorthy

Zhigang Cheng

Frank Anthony Doljack

Hundi Panduranga Kamath

Yazhou Wang

Daniel Minas Manoukian

Renford Hanley

Brent Alan Elliott

Baoqi Wang

Brent Elliott

An electromagnetic component assembly includes a first magnetic core piece, a second magnetic core piece, and an inverted U-shaped conductive winding including a base section and first and second legs extending from base section. One of the first and second magnetic core pieces is configured to receive the base section. The first and second magnetic core pieces are gapped from one another to define a first gap, and one of the first and second magnetic core pieces includes a second gap that, in combination with the first gap, allows the component to be operated at more than one stable open circuit inductance (OCL) corresponding to different current loads.

High current swing-type inductor and methods of fabrication

An electromagnetic component such as a power inductor includes first and second magnetic core pieces and a preformed coil winding therebetween. The preformed coil winding includes a top winding section and a pair of coplanar winding legs defining a U-shaped winding section therewith. The pair of winding legs are oriented perpendicular to a circuit board in use. First and second surface mount terminals respectively extend perpendicular to the pair of winding legs in opposing directions to each other, such that each of them extends only on one of the first and second magnetic core pieces but not the other.

Ultra-narrow high current power inductor for circuit board applications

A multi-phase integrated power inductor component assembly includes a plurality of conductive windings on an integrated magnetic core structure accepting each of the plurality of conductive windings in a spaced apart, non-coupled arrangement with respect to one another. The integrated magnetic core structure includes a series of magnetic gaps each being respectively centered on one of the plurality of conductive windings. The windings include surface mount terminations for connection to a circuit board.

Integrated multi-phase non-coupled power inductor and fabrication methods

Magnetic component assemblies for circuit boards include magnetic cores formed with a gap and preformed conductive windings sliding assembled to the cores via the gaps. The gaps in the cores are filled with a magnetic material to enhance the magnetic performance. The magnetic component assemblies may define power inductors.

Magnetic component assembly with filled gap

A surface mount power inductor component for a circuit board including multi-phase power supply circuitry includes a single piece, integrally fabricated magnetic core piece formed with vertically extending interior passageways provided with vertically elongated pre-formed conductive windings that are not magnetically coupled to reduce the footprint of the inductor component while increasing its power capacity. A distributed gap material is also provided in the vertical passageways with the conductive windings that respectively connect to each phase of electrical power.

Integrated multi-phase power inductor with non-coupled windings and methods of manufacture

A surface mount power inductor component for a circuit board includes a magnetic body, at least one conductive coil, and surface mount terminations for completing an electrical connection between the conductive coil and the circuit board. One of the body and the surface mount terminations is configured to accommodate a separately provided component in a vertically stacked relation with the separately provided circuit board component being located between the circuit board and the body.

Surface mount power inductor component with stacked component accommodation

A surface mount swing-type inductor component is configured to establish a non-uniform gap when assembled. The non-uniform gap produces swing-type inductor functionality in a compact package for higher current applications while being manufacturable at relatively low cost.

Magnetic component assemblies for circuit boards include single, shaped magnetic core pieces formed with a physical gap and conductive windings assembled to the cores via the gaps. The physical gaps in the cores are filled with a magnetic material to enhance the magnetic performance. The magnetic component assemblies may define power inductors.

Magnetic component assembly with filled physical gap

Magnetic component assemblies including moldable magnetic materials formed into magnetic bodies, at least one conductive coil, and termination features are disclosed that are advantageously utilized in providing surface mount magnetic components such as inductors and transformers.

Magnetic components and methods of manufacturing the same

A surface mount, power inductor component assembly includes only two different shapes of modular core pieces and a set of windings having the same shape that can be assembled and arranged to have any desired number of non-magnetically coupled windings to accommodate electrical power systems having different numbers of phases of electrical power. The core pieces and windings are vertically elongated to reduce the component footprint on a circuit board yet provide higher power, higher current capability.

Modular integrated multi-phase, non-coupled winding power inductor and methods of manufacture

Magnetic components including pre-formed clips are described that are more amenable to production on a miniaturized scale. Discrete core pieces can be assembled with pre-formed coils and physically gapped from one another with more efficient manufacturing techniques.

High current magnetic component and methods of manufacture

A low profile surface mount electromagnetic component such as a power inductor includes first and second core pieces arranged side by side and having longitudinal side walls facing one another. A preformed coil winding includes vertical legs that are received in vertical slots of the facing longitudinal sidewalls of the component. Inset depressed sections are provided in the top surfaces of the first and second magnetic core pieces and receive a main winding section of the coil winding. Surface mount terminal tabs extend on the bottom surfaces of both the first and second magnetic core pieces.

Low profile, surface mount electromagnetic component assembly and methods of manufacture

Magnetic components such as power inductors for circuit board applications include pressure laminate constructions involving flexible dielectric sheets that may integrally include magnetic powder materials. The dielectric sheets may be pressure laminated around a coil winding in an economical and reliable manner, with performance advantages over known magnetic component constructions.

Miniature power inductor and methods of manufacture

A method for manufacturing a low profile, magnetic component. The method includes stacking a the plurality of substantially planar and flexible magnetic powder sheets, locating a preformed multiple turn conductive winding between at least two of the plurality of substantially planar and flexible magnetic powder sheets in the stack, and pressure laminating the flexible magnetic powder sheets around the preformed multiple turn conductive winding to define a magnetic core containing the winding.

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Shanghai, China

Yipeng Yan