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Method for a horseshoe toroid inductor

IP.com Disclosure Number: IPCOM000006857D
Publication Date: 2002-Feb-06
Document File: 6 page(s) / 578K

Publishing Venue

The IP.com Prior Art Database

Abstract

Disclosed is a method for horseshoe shaped electrodes on a toroid inductor. Benefits include improved functionality, improved product versatility, and improved simplicity of manufacturing.

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Method for a horseshoe toroid inductor

Disclosed is a method for horseshoe shaped electrodes on a toroid inductor. Benefits include improved functionality, improved product versatility, and improved simplicity of manufacturing.

Background

              Conventional inductors are not configurable for being either an inductor or transformer or for having differing values. The characteristics are fixed.

              Conventional surface mount inductors require plastic bodies or other external (and relatively expensive) parts to convert the leaded device into a surface mounted device (SMD).

              Anytime a conductor (wire) completes a turn around the body of a toroid core it becomes a working inductor. Conventional toroid inductors are typically manufactured by manually winding an enamel coated copper wire around the body of a doughnut-shaped toroid core (see Figure 1). The two wire ends are stripped, tinned, and configured into leads for manual insertion into holes in an electronic circuit board (see Figure 1).

              To convert a through-hole toroid to a surface-mount part, conventional technology employs a special plastic holder that adds significant cost and consumes more circuit-board surface space (see Figure 2).

General description

              The disclosed method includes a construction technique for creating a surface-mount toroid inductor. The key elements are:

•             Placing horseshoe shaped pieces of wire onto a toroid core.

•             The customer completes the necessary 360-degree winding(s) around the toroid when soldering it onto the board by means of circuit-board trace routings that connect the ends of each 270-degree horseshoe to the next.

•             Inductance value and current handling capability are somewhat controllable by the customer through the selection of the number of incomplete windings (horseshoes) connected in series, parallel, or no connection.

•             A lid or cover is affixed to the horizontally mounted toroid (for SMD applications).

Advantages

              The disclosed method enables the consumer to configure a single part into many different inductance values and current handling capabilities. One part may satisfy a variety of inductor applications, enabling the consumer to use fewer part numbers with greater versatility of product design. Also, even after the end product is completed and functioning in the field, the inductor characteristics can be changed (within discrete limits) at anytime if required.

              The disclosed method enables the automatic application of conductors onto the toroid core, increasing part-to-part consistency of electrical parameters and reducing cost.

              The disclosed method eliminates the plastic body and greatly reduces the cost of offering a surface-mount version of a toroid inductor.

Detailed Description

              The disclosed method includes a versatile toroid inductor that is configurable by the consumer. When the inductor is shipped from the inductor manufacturer, it is not yet a working inductor. The consumer provides the connection (via circuit board traces) to complete the 360-degr...