CN104051131A - Integrated inductor assemblies and methods of assembling same - Google Patents

Abstract

The invention provides an integrated sensor assembly (102; 1300; 1400; 1500; 1600; 1700). The integrated inductor assembly includes a magnetic core (138; 1602; 1702; 1800), a first inductor (104) and a second inductor (106). The magnetic core has a first side, an opposing second side, and an opening (166) defined in the magnetic core. An opening extends into the magnetic core from at least one of the first side and the second side. The first inductor includes a first conductive winding (140) inductively coupled to the magnetic core. The first conductive winding includes a first shorting section (194) positioned within the opening. The second inductor includes a second conductive winding (142) inductively coupled to the magnetic core. The second conductive winding includes a second shorting section (200) positioned within the opening. The first and second sensors may be configured to operate independently of each other.

Description

Integrated sensor assembly and method of assembling same

Cross References to Related Applications

This application claims priority to U.S. Provisional Patent Application No. 61/782,961, filed March 14, 2013, which is incorporated herein by reference in its entirety.

technical field

The field of embodiments relates generally to power electronics, and more particularly, to integrated inductor assemblies for use in power electronics.

Background technique

High density power electronic circuits often require the use of multiple magnetoelectric components for various purposes including energy storage, signal isolation, signal filtering, energy transfer, and power splitting. As the demand for higher power density electronic components increases, it becomes more desirable to integrate two or more magnetoelectric components, such as multiple inductors, into the same core or structure.

However, known integrated magnetic assemblies are often insufficiently configured to allow multiple windings to be fabricated on a single structure and operate independently of each other. As a result, when multiple components operate independently in a given electronic circuit, separate cores or structures are used, thereby increasing the number and size of components required for a given operation, and reducing the power density of the given electronic circuit.

Contents of the invention

In one aspect, an integrated sensor assembly is provided. The integrated inductor assembly includes a magnetic core, a first inductor and a second inductor. The magnetic core has a first side, an opposite second side and an opening defined in the magnetic core. An opening extends into the magnetic core from at least one of the first side and the second side. The first inductor includes a first conductive winding that is inductively coupled (or "coupled") to the magnetic core. The first conductive winding includes a first shorting section positioned within the opening. The second inductor includes a second conductive winding inductively coupled to the magnetic core. The second conductive winding includes a second shorting section positioned within the opening. The first and second sensors may be configured to operate independently of each other.

In another aspect, a method of assembling an integrated sensor assembly is provided. The method includes: providing a magnetic core having a first side, an opposite second side and an opening defined in the magnetic core, the opening extending into the magnetic core from at least one of the first side and the second side; providing a magnetic core comprising a first a first conductive winding of a shorted section; providing a second conductive winding including a second shorted section; inductively coupling the first conductive winding to the magnetic core to form a first inductor, the first conductive winding being coupled such that the second a shorting section is positioned within the opening; and a second conductive winding is inductively coupled to the magnetic core to form a second inductor, the second conductive winding being coupled such that the second shorting section is positioned within the opening, and the first and The second conductive winding is inductively coupled to the magnetic core such that the first and second inductors can be configured to operate independently of each other.

In yet another aspect, a magnetic core for use in an integrated inductor assembly is provided. The magnetic core includes a first piece defining a first side of the magnetic core, a second piece defining a second side of the magnetic core opposite the first side, and an opening defined within the magnetic core. The second piece is formed separately from and attached to the first piece. At least one of the first piece and the second piece has a plurality of channels defined therein. Each of the channels is configured to receive a conductive winding to form an inductor. An opening extends into the magnetic core from at least one of the first side and the second side. Each of the channels extends into the opening and is enclosed within the magnetic core between the first piece and the second piece.

Description of drawings

FIG. 1 is a schematic diagram of an exemplary electronic system including an integrated sensor assembly.

Figure 2 is a perspective view of the integrated inductor assembly shown in Figure 1, the assembly including a magnetic core and winding assembly.

FIG. 3 is an exploded view of the integrated sensor assembly shown in FIG. 2 .

FIG. 4 is a top view of the components of the magnetic core shown in FIG. 2 .

FIG. 5 is an end view of a component of the magnetic core shown in FIG. 4. FIG.

FIG. 6 is a top view of another piece of the magnetic core shown in FIG. 2 .

FIG. 7 is an end view of a piece of the magnetic core shown in FIG. 6. FIG.

FIG. 8 is a side view of the winding assembly shown in FIGS. 2 and 3 .

FIG. 9 is a perspective view of the winding assembly shown in FIG. 8 .

FIG. 10 is another perspective view of the winding assembly shown in FIG. 8 .

Figure 11 is a schematic diagram of the integrated inductor assembly shown in Figures 2 and 3, illustrating the magnetic flux produced by the operation of the first and second inductors of the integrated inductor assembly.

FIG. 12 is a schematic diagram of the circuit equivalent of the integrated inductor assembly shown in FIGS. 2 and 3 .

Figure 13 is an end view of a first alternative integrated inductor assembly.

Figure 14 is an end view of a second alternative integrated inductor assembly.

Figure 15 is an end view of a third alternative integrated inductor assembly.

16 is a perspective view of a fourth alternative integrated inductor assembly having a four-piece magnetic core.

17 is a perspective view of a fifth alternative integrated inductor assembly having a three-piece magnetic core.

18 is a top view of a first alternative magnetic core configured to receive four conductive windings to form an inductor assembly integrating four inductors.

19 is a flowchart of an exemplary method for assembling an integrated sensor assembly.

Although specific features of the various embodiments may be shown in some drawings and not in others, this is for convenience only. Any feature of any figure may be referenced and/or claimed in combination with any feature of any other figure.

Reference signs:

100 electronic systems

102 integrated sensor components

104 first sensor

106 Second sensor

108 First Circuit

110 second circuit

112 printed circuit board

114 The first DC voltage source

116 first switching device

118 first diode

120 first capacitor

122 first load

124 first controller

126 second DC voltage source

128 second switching device

130 second diode

132 second capacitor

134 second load

136 second controller

138 core

140 first conductive winding

142 second conductive winding

144 winding components

146 moldings

148 first side of magnetic core

150 second side of core

152 first end of magnetic core

154 second end of magnetic core

156 front side of core

158 Rear side of core

160 core first piece

2nd piece of 162 core

164 core bridge

166 openings

168 channels

170 Internal surface of the first piece

172 The first pair of channels

174 Second pair of channels

176 Central area of inner surface

178 Lateral outer area of inner surface

180 Inner surface of the second piece

182 The first induction section

184 Second induction section

186 First pair of lead segments

188 lead section

190 The first pair of sensing sections

192 induction section

194 The first short-circuit section

196 Second pair of channels

198 The second pair of sensing sections

200 Second short-circuit section

202 Overlap Length

204 Length of integrated sensor assembly

1300 First Alternative Integrated Sensor Assembly

1302 Clearance

1400 Second Alternative Integrated Sensor Assembly

1402 Clearance

1500 Third Alternative Integrated Sensor Assembly

1502 Clearance

1504 Spacers

1600 4th Alternative Integrated Sensor Assembly

1602 four-piece magnetic core

1604 The first piece of magnetic core

2nd piece of 1606 core

The third piece of the 1608 core

The fourth piece of the 1610 core

1700 Fifth Alternative Integrated Sensor Assembly

1702 Three-piece core

1704 The third piece

1800 First Alternative Core

1802 A pair of channels

1804 Isolation opening.

Detailed ways

Exemplary embodiments of integrated sensor assemblies are described herein. An integrated inductor assembly includes a magnetic core, a first inductor and a second inductor. The magnetic core has a first side, an opposite second side and an opening defined in the magnetic core. An opening extends into the magnetic core from at least one of the first side and the second side. The first inductor includes a first conductive winding inductively coupled to the magnetic core. The first conductive winding includes a first shorting section positioned within the opening. The second inductor includes a second conductive winding inductively coupled to the magnetic core. The second conductive winding includes a second shorting section positioned within the opening. The first and second sensors may be configured to operate independently of each other.

Embodiments described herein provide an integrated sensor assembly comprising at least two sensors capable of operating in conjunction with each other and independently. An integrated inductor assembly includes a magnetic core having an opening defined therein and a winding assembly inductively coupled to the magnetic core. The inductive sections of the winding assembly are enclosed within the magnetic assembly, and the shorting sections interconnecting the inductive sections are positioned within the openings of the magnetic core. Such a configuration reduces and/or minimizes mutual inductance between the multiple inductors formed on the magnetic core, thereby enabling the inductors to operate independently of each other. Furthermore, the integration of multiple inductors on a single magnetic core facilitates reducing the number and size of components required to construct a given type of circuit (eg, a power converter).

FIG. 1 is a schematic diagram of an exemplary electronic system 100 including an integrated sensor assembly 102 having a first sensor 104 and a second sensor 106 . The electronic system 100 also includes a first circuit 108 and a second circuit 110 fabricated on a printed circuit board 112 .

In the exemplary embodiment, both the first circuit 108 and the second circuit 110 are buck switching DC-DC voltage converters. Specifically, the first circuit 108 includes a first DC voltage source 114 , a first switching device 116 , a first diode 118 , a first inductor 104 , a first capacitor 120 , a first load 122 and a first controller 124 . The positive terminal of the first DC voltage source 114 is coupled to a first switching device 116 which in turn is coupled to the first inductor 104 and the cathode terminal of a first diode 118 . The anode terminal of the first diode 118 is coupled to the loop input terminal of the first DC voltage source 114 . The first capacitor 120 and the first load 122 are coupled in parallel, and the first inductor 104 is coupled to a first side of the parallel connection between the first capacitor 120 and the first load 122 . The first switching device 116 is operated by a first controller 124 which switches the first switching device 116 between an open position and a closed position to produce an output voltage V _{out of} the first circuit 108 which is measured as The voltage drop across the first load 122 .

In an exemplary embodiment, the second circuit 110 has the same architecture as the first circuit 108 . Specifically, the second circuit 110 includes a second DC voltage source 126 , a second switching device 128 , a second diode 130 , a second inductor 106 , a second capacitor 132 , a second load 134 and a second controller 136 . The positive terminal of the second DC voltage source 126 is coupled to a second switching device 128 which in turn is coupled to the cathode terminal of the second inductor 106 and the second diode 130 . The anode terminal of the second diode 130 is coupled to the loop input terminal of the second DC voltage source 126 . The second capacitor 132 and the second load 134 are coupled in parallel, and the second inductor 106 is coupled to one side of the parallel connection between the second capacitor 132 and the second load 134 . The second switching device 128 is operated by a second controller 136 which switches the second switching device 128 between an open position and a closed position to produce an output voltage V _{out of} the second circuit 110 which is measured as The voltage drop across the second load 134 .

In an exemplary embodiment, the first switching device 116 and the second switching device 128 are transistor switches (specifically, MOSFETs), and the first controller 124 and the second controller 136 are configured to output pulse width modulated The control signal goes to the gate side of the first switching device 116 and the second switching device 128 . In alternative embodiments, first switching device 116 and/or second switching device 128 may be any suitable switching device that enables electronic system 100 to function as described herein. Additionally, first controller 124 and/or second controller 136 may be configured to provide any suitable control signal to first switching device 116 and second switching device 128, respectively, that enables electronic system 100 to kick in.

As described in greater detail herein, the construction of the integrated inductor assembly 102 enables the first inductor 104 and the second inductor 106 to operate independently of each other as well as in conjunction with each other (eg, as part of the same circuit). Thus, although the integrated inductor assembly 102 is described in conjunction with separate buck switching DC-DC voltage converters (ie, the first circuit 108 and the second circuit 110 ), the embodiments described herein may be implemented in any suitable electrical architecture Implemented in , the architecture enables the integrated inductor assembly 102 to function as described herein, including, for example, a multiphase voltage converter in which the first inductor 104 is about 90° or 180° out of phase with the second inductor 106 phase operation.

FIG. 2 is a perspective view of the integrated inductor assembly 102 , and FIG. 3 is an exploded view of the integrated inductor assembly 102 . In the exemplary embodiment, integrated inductor assembly 102 includes magnetic core 138, first conductive winding 140 ( FIG. 3 ) inductively coupled to magnetic core 138 to form first inductor 104 , and 138 to form a second conductive winding 142 of the second inductor 106 . The first conductive winding 140 and the second conductive winding 142 are collectively referred to herein as a winding assembly, indicated generally at 144 . In the exemplary embodiment, the winding assembly 144 also includes a molding 146 ( FIGS. 8-10 ), which was omitted from FIGS. 2 and 3 for clarity.

In the exemplary embodiment, the magnetic core 138 has a generally rectangular shape including: a first side 148; an opposite second side 150; an opposite first end 152 and a second end 154 in a first extending between side 148 and second side 150; and a front side 156 and an opposite rear side 158 between first side 148 and second side 150 and between first end 152 and second end 154 extend. Additionally, in the exemplary embodiment, magnetic core 138 includes a first piece 160 , a second piece 162 , a plurality of core bridges 164 , and an opening 166 defined within magnetic core 138 .

FIG. 4 is a top view of the second piece 162 of the magnetic core 138 , and FIG. 5 is an end view of the second piece 162 of the magnetic core 138 . FIG. 6 is a top view of the first piece 160 of the magnetic core 138 , and FIG. 7 is an end view of the first piece 160 of the magnetic core 138 . In the exemplary embodiment, both the first piece 160 and the second piece 162 are fabricated as a one-piece magnetic block. First piece 160 and second piece 162 are made of any suitable magnetic material, including, for example, ferrite, that enables integrated inductor assembly 102 to function as described herein. Furthermore, the first piece 160 and the second piece 162 are made of the same magnetic material. First piece 160 and second piece 162 are fabricated separately and attached to each other to form magnetic core 138 . In alternative embodiments, the first piece 160 and/or the second piece 162 may not be fabricated as an integral magnetic block (see, eg, FIGS. 16 and 17 ).

In the exemplary embodiment, first piece 160 defines first side 148 of magnetic core 138 , and second piece 162 defines an opposing second side 150 of magnetic core 138 . Furthermore, first piece 160 and second piece 162 collectively define first end 152 , second end 154 , front side 156 , and back side 158 of magnetic core 138 .

Additionally, in the exemplary embodiment, first piece 160 includes a plurality of channels 168 defined therein. Channel 168 is configured to receive a portion of conductive windings 140 and 142 to form one of first inductor 104 and second inductor 106 . Specifically, channels 168 are defined on an inner surface 170 of first piece 160 , and each channel 168 extends from opening 166 toward one of first end 152 and second end 154 . Additionally, in the exemplary embodiment, channel 168 extends to first side 148 of magnetic core 138 about respective first end 152 or second end 154 such that conductive winding 140 And 142 are flush with the respective first end 152 or second end 154 . Furthermore, when the integrated inductor assembly 102 is assembled, the channel 168 is enclosed within the magnetic core 138 between the first side 148 and the second side 150, more specifically between the first piece 160 and the second piece 162. .

As shown in FIG. 3 , the plurality of channels 168 includes a first pair 172 of channels 168 and a second pair 174 of channels 168 . A first pair 172 of channels 168 extends from opening 166 toward first end 152 of magnetic core 138 , and a second pair 174 of channels 168 extends from opening 166 toward second end 154 of magnetic core 138 . The channels 168 of the first pair 172 of channels 168 are substantially parallel to each other, and the channels 168 of the second pair 174 of channels 168 are substantially parallel to each other. As shown in FIG. 6 , each pair 172 and 174 of channels 168 divides inner surface 170 into a central region 176 and lateral outer regions 178 .

The second piece 162 includes an inner surface 180 that faces the inner surface 170 of the first piece 160 when the integrated inductor assembly 102 is assembled. In the exemplary embodiment, inner surface 180 of second piece 162 is substantially planar and does not include any channels therein. In an alternative embodiment, the inner surface 180 of the second piece 162 may include channels corresponding to the channels 168 of the first piece 160 . In a further alternative embodiment, the inner surface 170 of the first piece may be substantially planar (ie, the first piece 160 does not include the channel 168 ), and the channel 168 is defined within the inner surface 180 of the second piece 162 .

Referring to FIG. 2 , the opening 166 divides the magnetic core 138 into a first inductive section 182 and a second inductive section 184 . The first inductive section 182 extends from the opening 166 to the first end 152 of the magnetic core 138 and includes a first pair 172 of channels 168 . Second inductive section 184 extends from opening 166 to second end 154 of magnetic core 138 and includes second pair 174 of channels 168 . The opening 166 is configured to limit magnetic flux from one of the first inductor 104 and the second inductor 106 from interfering with or affecting the operation of the other of the first inductor 104 or the second inductor 106 .

In the exemplary embodiment, opening 166 has a generally rectangular shape and extends through magnetic core 138 from first side 148 to second side 150 . That is, the opening 166 extends through both the first piece 160 and the second piece 162 . In alternative embodiments, opening 166 may have any suitable shape that enables integrated sensor assembly 102 to function as described herein. Furthermore, in alternative embodiments, the opening 166 may extend into the magnetic core 138 from only one of the first side 148 or the second side 150 . That is, the opening 166 may not extend completely through the magnetic core 138 . In some suitable embodiments, the opening 166 in the magnetic core 138 is filled with one or more non-magnetic materials to prevent foreign objects from entering the opening and interfering with the operation of the integrated inductor assembly 102 .

The core bridge 164 extends between and interconnects the first inductive section 182 and the second inductive section 184 . Additionally, the plurality of core bridges 164 at least partially define openings 166 . In the exemplary embodiment, first piece 160 includes two core bridges 164 disposed on opposite sides of opening 166 , and second piece 162 includes two core bridges 164 disposed on opposite sides of opening 166 .

In the exemplary embodiment, core bridge 164 is configured to provide a low reluctance flux path between first inductive section 182 and second inductive section 184 such that when first inductive section 182 and second inductive section The first inductor 104 and the second inductor 106 can "share" the magnetic core 138 when one of the segments 184 is not saturated by the operation of the corresponding first inductor 104 or second inductor 106 . In an exemplary embodiment, each core bridge 164 is made of a suitable magnetic material, such as ferrite. Furthermore, in the exemplary embodiment, core bridge 164 is integrally formed with one of first piece 160 or second piece 162 of magnetic core 138, but in alternative embodiments one or more core bridges 164 may be formed with The first piece 160 and/or the second piece 162 are formed separately. The "sharing" of the magnetic core 138 between the first inductor 104 and the second inductor 106 increases the first inductance when one of the first inductor 104 and the second inductor 106 is operating at a low load or low current. The saturation current of inductor 104 and second inductor 106 (ie, the current when core 138 saturates), because core bridge 164 enables inductors 104 and 106 to utilize A portion of core 138 that saturates for operation at low load or low current.

As described above, the first inductor 104 includes a first conductive winding 140 inductively coupled to the magnetic core 138 and the second inductor 106 includes a second conductive winding 142 inductively coupled to the magnetic core 138 . FIG. 8 is a side view of winding assembly 144 including first conductive winding 140 , second conductive winding 142 and molding 146 . 9 and 10 are perspective views of the winding assembly 144 .

Referring to FIGS. 3 and 8-10, the first conductive winding 140 is made of a suitable conductive material (eg, stamped copper) and includes a first pair 186 of lead segments 188, a first pair 190 of sensing segments 192, and The first pair 190 senses a first shorting segment 194 interconnected by segments 192 .

The sensing segments 192 of the first pair 190 of sensing segments 192 are positioned within the channels 168 of the first pair 172 . Each inductive segment 192 of the first pair 190 of inductive segments 192 extends from the opening 166 toward the first end 152 of the magnetic core 138 to a corresponding lead segment 188 of the first pair 186 of the lead segments 188 . The inductive segment 192 of the first pair 190 of inductive segments 192 is enclosed within the magnetic core 138 between the first side 148 and the second side 150 , more specifically between the first piece 160 and the second piece 162 . The sensing segments 192 of the first pair 190 of sensing segments 192 are arranged in a first plane.

A first shorting segment 194 is positioned within the opening 166 and extends between and interconnects sensing segments 192 of the first pair 190 of sensing segments 192 . In the exemplary embodiment, first shorting section 194 is oriented substantially perpendicular to each sensing section 192 of first pair 190 of sensing sections 192 . Furthermore, in the exemplary embodiment, first shorting section 194 has a substantially planar configuration and is obliquely angled relative to a first plane in which first pair 190 of sensing sections 192 are disposed. Specifically, the first shorting section 194 is angled obliquely toward the first side 148 of the magnetic core 138 . Additionally, in the exemplary embodiment, first shorting segment 194 has a larger cross-sectional area than each sensing segment 192 of first pair 190 of sensing segments 192 .

Each lead segment 188 of the first pair 186 of lead segments 188 is connected to a corresponding inductive segment 192 of the first pair 190 of the inductive segments 192 at the first end 152 of the magnetic core 138 . In the exemplary embodiment, each lead segment 188 of the first pair 186 of the lead segments 188 extends from a corresponding one of the first pair 190 of the sensing segments 192 toward the first side 148 of the magnetic core 138 . Angular extension of about 90°. Furthermore, in the exemplary embodiment, each lead segment 188 of the first pair 186 of lead segments 188 extends beyond the first side 148 of the magnetic core 138 such that the first pair 186 of the lead segments 188 connects the magnetic core 138 to the The surface (eg, a printed circuit board) to which the integrated sensor assembly 102 is soldered or mounted is spaced apart.

In the exemplary embodiment, second conductive winding 142 has a substantially similar configuration as first conductive winding 140 . Specifically, the second conductive winding 142 is made of a suitable conductive material (eg, stamped copper) and includes a second pair 196 of lead segments 188 , a second pair of 198 sensing segments 192 , and a second pair of 198 sensing segments 192 . Segments 192 are interconnected by a second shorting segment 200 .

The sensing segments 192 of the second pair 198 of sensing segments 192 are positioned within the channels 168 of the second pair 174 . Each inductive segment 192 of the second pair 198 of inductive segments 192 extends from the opening 166 toward the second end 154 of the magnetic core 138 to a corresponding lead segment 188 of the second pair 196 of the lead segments 188 . The inductive segment 192 of the second pair 198 of inductive segments 192 is enclosed within the magnetic core 138 between the first side 148 and the second side 150 , more specifically between the first piece 160 and the second piece 162 . The sensing segments 192 of the second pair 198 of sensing segments 192 are disposed in a second plane, which in the exemplary embodiment is parallel to the first plane in which the first pair 190 of sensing segments 192 are disposed. Also, in the exemplary embodiment, the second plane is the same plane as the first plane in which the first pair 190 of sensing segments 192 are disposed. As such, first pair 190 of sensing segments 192 and second pair 198 of sensing segments 192 are disposed in substantially the same plane in the exemplary embodiment.

The second shorting segment 200 is positioned within the opening 166 and extends between and interconnects the sensing segments 192 of the second pair 198 of sensing segments 192 . In the exemplary embodiment, second shorting section 200 is oriented substantially perpendicular to each sensing section 192 of second pair 198 of sensing sections 192 . Furthermore, in the exemplary embodiment, second shorting section 200 has a substantially planar configuration and is obliquely angled relative to a second plane in which second pair 198 of sensing sections 192 are disposed. Specifically, the second shorting section 200 is angled obliquely toward the second side 150 of the magnetic core 138 . Additionally, in the exemplary embodiment, second shorting section 200 has a larger cross-sectional area than each sensing section 192 of second pair 198 of sensing sections 192 . As shown in FIG. 8 , the first shorting section 194 and the second shorting section 200 are angled away from each other at approximately the same angle. More specifically, the first shorting section 194 is angled toward the first side 148 of the magnetic core 138 at an angle α relative to the first plane, and the second shorting section 200 is angled at an angle β relative to the second plane. (substantially equal to angle α) is angled toward the second side 150 of the magnetic core 138 . Angles α and β may be any suitable angles in the range of about 90° to about 180°. In the illustrated embodiment, angles α and β are each about 120°. In addition, as shown in FIG. 8, when viewed through the opening 166 (specifically, along a viewing direction perpendicular to the first plane and/or the second plane), the first shorting section 194 and the second shorting section 194 200 overlap each other by length 202 within opening 166 .

Each lead segment 188 of the second pair 196 of lead segments 188 is connected to a corresponding inductive segment 192 of the second pair 198 of the inductive segments 192 at the second end 154 of the magnetic core 138 . Accordingly, first pair 186 of lead segments 188 and second pair 196 of lead segments 188 are disposed on opposite ends of magnetic core 138 . In the exemplary embodiment, a first pair 186 of lead segments 188 is disposed on first end 152 of magnetic core 138 , and a second pair of lead segments 188 is disposed on second end 154 of magnetic core 138 . Furthermore, in the exemplary embodiment, each lead segment 188 of the second pair 196 of the lead segments 188 extends from a corresponding inductive segment 192 of the second pair 198 of the inductive segments 192 toward the second side of the magnetic core 138 150 extends at an angle of about 90°. Furthermore, in the exemplary embodiment, each lead segment 188 of the second pair 196 of lead segments 188 extends beyond the second side 150 of the magnetic core 138 such that the second pair 196 of the lead segments 188 connects the magnetic core 138 to the The surface (eg, a printed circuit board) to which the integrated sensor assembly 102 is soldered or mounted is spaced apart.

Referring to FIGS. 8-10 , the first shorting section 194 and the second shorting section 200 are enclosed within the molding 146 . Molding 146 is configured to be received within opening 166 . Molding 146 may be formed from any suitable molding including, for example, phenolic resin molding. The magnetic permeability of the molding 146 may be greater or less than that of air, depending on the desired magnetic permeability within the opening 166 . The molding 146 facilitates assembly of the integrated inductor assembly 102 by reducing the number of separate parts that need to be assembled and also by maintaining the relative position of the first shorting section 194 and the second shorting section 200 . In alternative embodiments, molding 146 may be omitted from winding assembly 144 .

Due to the configuration of the first conductive winding 140 and the second conductive winding 142, the first inductor 104 and the second inductor 106 are substantially single-turn inductors. In other words, the first conductive winding 140 and the second conductive winding 142 are wound no more than a single turn around the magnetic core 138 . As a result, the DC resistance of the first inductor 104 and the second inductor 106 is reduced compared to a multi-turn inductor. Additionally, due to the encapsulation of the sensing section 192 within the magnetic core 138, the inductance of the first inductor 104 and the second inductor 106 may be comparable to known multi-turn inductors.

11 is a schematic diagram of the integrated inductor assembly 102 showing the magnetic flux generated by the operation of the first inductor 104 and the second inductor 106, and FIG. 12 is a schematic diagram of the circuit equivalent of the integrated inductor assembly 102 . The configuration of the integrated inductor assembly 102 facilitates minimizing mutual inductance between the first inductor 104 and the second inductor 106 (i.e., magnetic flux produced by different inductors induces an electromotive force in one inductor), thereby The first inductor 104 and the second inductor 106 are enabled to operate independently of each other. Specifically, since the sensing section 192 is enclosed within the magnetic core 138 having a relatively high magnetic permeability, and the magnetic core 138 is divided into the first sensing portion by the opening 166 having a relatively low magnetic permeability compared to the magnetic core 138 The segment 182 and the second induction segment 184 , and thus the magnetic flux generated by the first inductor 104 and the second inductor 106 , are substantially confined within the first induction segment 182 and the second induction segment 184 , respectively. As a result, the magnetic flux within opening 166 is substantially less than the magnetic flux within magnetic core 138 and mutual inductance between first inductor 104 and second inductor 106 is minimized. As shown in FIG. 12, the configuration of each of the first inductor 104 and the second inductor 106 is equivalent to two inductors connected in series by the corresponding shorting section 194 or 200 (corresponding to the sensing section 192) , the shorting section 194 or 200 generates little or no magnetic flux within the magnetic core 138 .

Furthermore, because the first shorting section 194 and the second shorting section 200 are angled away from each other, the first shorting section 194 and the second shorting section 200 can overlap each other within the opening 166 while still remaining one another. Sufficient distance is maintained to minimize the mutual inductance between the first inductor 104 and the second inductor 106 . Such overlap reduces the overall length 204 ( FIG. 2 ) of the integrated inductor assembly 102 compared to integrated inductor assemblies where the shorting sections are not angled, and thus requires significantly greater spacing along the length of the assembly to limit mutual inductance. . Furthermore, given that the flux from one inductor 104 or 106 extends into the sensing section 182 or 184 of the other inductor 104 or 106, the core bridge 164 provides a relatively low reluctance path for such flux, which enables Interference between the fluxes of the first inductor 104 and the second inductor 106 is minimized.

Various modifications may be made to the integrated inductor assembly 102 to further minimize or control the mutual inductance between the first inductor 104 and the second inductor 106 and/or to adjust the performance of the integrated inductor assembly 102 .

For example, FIG. 13 is an end view of a first alternative embodiment 1300 of an integrated inductor assembly having a gap 1302 disposed between the first side 148 and the second side 150 of the magnetic core 138 to increase the the saturation current. Unless otherwise noted, integrated inductor assembly 1300 is substantially identical to integrated inductor assembly 102 (shown in FIGS. 2 and 3 ). In the embodiment shown in FIG. 13 , gap 1302 is positioned between central region 176 of inner surface 170 of first piece 160 and inner surface 180 of second piece 162 and extends the entire length of integrated inductor assembly 1300 .

14 is an end view of a second alternative embodiment of the integrated inductor assembly 102 having a gap 1402 disposed between the first side 148 and the second side 150 of the magnetic core 138 to increase saturation of the magnetic core 138 current. Unless otherwise noted, integrated inductor assembly 1400 is substantially the same as integrated inductor assembly 102 (shown in FIGS. 2 and 3 ). In the embodiment shown in FIG. 14 , gap 1402 is positioned between laterally outer region 178 of inner surface 170 of first piece 160 and inner surface 180 of second piece 162 and extends the entirety of integrated inductor assembly 102 . length.

15 is an end view of a third alternative embodiment 1500 of an integrated inductor assembly having a gap 1502 and a plurality of spacers 1504 disposed between the first side 148 and the second side 150 of the magnetic core 138 to provide The saturation current of the core 138 is increased. Unless otherwise noted, integrated inductor assembly 1500 is substantially the same as integrated inductor assembly 102 (shown in FIGS. 2 and 3 ). In the embodiment shown in FIG. 15, the gap 1502 extends across the entire interface between the first piece 160 and the second piece 162, and the spacer 1504 is provided at the desired position between the first piece 160 and the second piece 162. position to provide a mechanical connection between the first piece 160 and the second piece 162 . In the embodiment shown in FIG. 15, spacers 1504 are formed of a non-magnetic material.

In the embodiment shown in Figures 13-15, gaps 1302, 1402, and 1502 do not contain any filler material and are therefore air gaps. In alternative embodiments, gaps 1302 , 1402 and/or 1502 may be filled with one or more non-magnetic materials, including, for example, Mylar™, to adjust the characteristics of integrated inductor assembly 1300 , 1400 and/or 1500 .

FIG. 16 is a perspective view of a fourth alternative embodiment 1600 of an integrated inductor assembly having a four-piece magnetic core 1602 . Unless otherwise noted, integrated inductor assembly 1600 is substantially identical to integrated inductor assembly 102 (shown in FIGS. 2 and 3 ). Magnetic core 1602 of integrated inductor assembly 1600 includes a first piece 1604 , a second piece 1606 , a third piece 1608 , a fourth piece 1610 , a plurality of core bridges 164 , and an opening 166 defined within magnetic core 1602 .

The first piece 1604 and the second piece 1606 are interconnected to each other by the core bridge 164 , and the third piece 1608 and the fourth piece 1610 are interconnected to each other by the core bridge 164 . Furthermore, first piece 1604 and second piece 1606 together define first side 148 of magnetic core 1602 , and third piece 1608 and fourth piece 1610 together define second side 150 of magnetic core 1602 . Additionally, first piece 1604 and third piece 1608 collectively define first end 152 of magnetic core 1602 , and second piece 1606 and fourth piece 1610 collectively define second end 154 of magnetic core 1602 . First piece 1604 , second piece 1606 , third piece 1608 , and fourth piece 1610 collectively define front side 156 and back side 158 of magnetic core 1602 .

A first pair 172 of channels 168 (shown in FIG. 3 ) is defined on the inner surface of the first piece 1604 and a second pair 174 of channels 168 (shown in FIG. 3 ) is defined on the inner surface of the second piece 1606 . The first pair 190 of inductive segments 192 (shown in FIG. 3 ) are positioned within the first pair 172 of channels 168 on the first piece 1604 and between the first side 148 and the second side 150 of the magnetic core 1602, specifically The ground is enclosed within the magnetic core 1602 between the first piece 1604 and the third piece 1608 . A second pair 174 of channels 168 (shown in FIG. 3 ) is defined on an inner surface of the second piece 1606 . Second pair 198 of inductive segments 192 (shown in FIG. 3 ) are positioned within second pair 174 of channels 168 and between first side 148 and second side 150 of magnetic core 1602 , specifically second piece 1606 and the fourth piece 1610 are enclosed in the magnetic core 1602 .

In the embodiment shown in FIG. 16 , core bridge 164 is manufactured separately from each of first piece 1604 , second piece 1606 , third piece 1608 , and fourth piece 1610 . Additionally, core bridges 164 are made from a single piece of magnetic material and are connected to each other to provide improved mechanical stability to integrated inductor assembly 1600 .

FIG. 17 is a perspective view of a fifth alternative embodiment 1700 of an integrated inductor assembly having a three-piece magnetic core 1702 . Unless otherwise noted, integrated inductor assembly 1700 is substantially the same as integrated inductor assembly 1600 (shown in FIG. 16 ). In particular, integrated inductor assembly 1700 is substantially identical to integrated inductor assembly 1600, except that third piece 1608, fourth piece 1610, and core bridge 164 interconnecting third piece 1608 with fourth piece 1610 are replaced by The third piece, 1704, is solid. Furthermore, the opening 166 in the magnetic core 1702 only extends from the first side 148 to the third piece 1704 . That is, opening 166 does not extend through the entirety of magnetic core 138 .

Although integrated inductor assemblies 102, 1300, 1400, 1500, 1600, and 1700 are described as each including two inductors, integrated inductor assemblies 102, 1300, 1400, 1500, 1600, and 1700 may be modified to include two The above sensors, for example three, four, six or more sensors.

For example, FIG. 18 is a top view of a first alternative embodiment of a magnetic core 1800 configured to receive four conductive windings to form an inductor assembly integrating four inductors. As shown in FIG. 18, the magnetic core 1800 includes four pairs 1802 of channels 168, each pair configured to receive conductive windings to form an inductor. Magnetic core 1800 also includes two openings 166 each having two pairs 1802 of channels 168 extending from openings 166 toward one of first end 152 and second end 154 of magnetic core 138 . Additionally, magnetic core 1800 includes isolation openings 1804 positioned between openings 166 . Isolation openings 1804 extend in the longitudinal direction of magnetic core 1800 and provide separation between inductor pairs formed on magnetic core 1800 . In the illustrated embodiment, the isolation opening 1804 extends through the magnetic core 1800 .

19 is a flowchart of an exemplary method 1900 of assembling an integrated sensor assembly, such as the integrated sensor assembly 102 shown in FIGS. 2 and 3 . A magnetic core such as magnetic core 138 is provided 1902 . The magnetic core includes a first side, an opposing second side, and an opening defined in the magnetic core. An opening extends into the magnetic core from at least one of the first side and the second side. A first conductive winding such as first conductive winding 140 is provided 1904 . The first conductive winding includes a first shorting section, such as first shorting section 194 . A second conductive winding such as second conductive winding 142 is provided 1906 . The second conductive winding includes a second shorting section, for example the second shorting section 200 . A first conductive winding is inductively coupled 1908 to the magnetic core to form a first inductor, such as first inductor 104 . The first conductive winding is coupled to the core such that the first shorting section is positioned within the opening. A second conductive winding is inductively coupled 1910 to the magnetic core to form a second inductor, such as second inductor 106 . The second conductive winding is inductively coupled to the magnetic core such that the second shorting section is positioned within the opening. Furthermore, the first and second conductive windings are inductively coupled to the magnetic core such that the first and second inductors can be configured to operate independently of each other.

Exemplary embodiments of integrated sensor assemblies are described herein. An integrated inductor assembly includes a magnetic core, a first inductor and a second inductor. The magnetic core has a first side, an opposite second side and an opening defined in the magnetic core. An opening extends into the magnetic core from at least one of the first side and the second side. The first inductor includes a first conductive winding inductively coupled to the magnetic core. The first conductive winding includes a first shorting section positioned within the opening. The second inductor includes a second conductive winding inductively coupled to the magnetic core. The second conductive winding includes a second shorting section positioned within the opening. The first and second sensors may be configured to operate independently of each other.

In contrast to at least some integrated magnetic assemblies, in the integrated inductor assemblies described herein, at least two inductors are formed on a single magnetic core, and the inductors are capable of operating in conjunction with each other and independently. The inductive sections of the winding assembly are enclosed within the magnetic assembly, and the shorting sections interconnecting the inductive sections are positioned within the openings of the magnetic core. This configuration provides a compact integrated inductor assembly, yet sufficiently minimizes the mutual inductance between the multiple inductors formed on the magnetic core to allow independent operation of the inductors. The compact configuration of the integrated inductor assembly also reduces the number of components and board space required to form a given circuit compared to the same circuit board formed using discrete components. Furthermore, by using a shorter winding to form the inductor, and also by using a shorting section with a larger cross-sectional area than the inductive section of the winding, the integrated inductor The configuration of the components reduces the DC resistance of the inductor formed therein.

Additionally, the integrated sensor assemblies described herein provide improved performance over discrete inductors when the sensors of the integrated sensor assembly operate in conjunction with one another. In particular, when the inductors operate in conjunction with each other (for example, by operating inductors that are approximately 180° out of phase with each other), the energy loss of the integrated inductor assembly compared to a discrete inductor used to perform an equivalent function is due to the magnetic core The magnetic flux inside is offset and reduced.

Additionally, the integrated inductor assembly described herein uses a core bridge to provide a low reluctance flux path between the different inductive sections of the magnetic core. Core bridges allow different sensing sections of the core to be "shared" when one sensing section is not fully saturated. As a result, the saturation current of the inductor formed on the magnetic core can be increased compared to a discrete inductor.

The order of execution or performance of the operations in the embodiments of the invention shown and described herein is not critical unless otherwise indicated. That is, unless otherwise indicated, the operations may be performed in any order, and embodiments of the invention may include additional or fewer operations than disclosed herein. For example, it is contemplated that performing or performing a particular operation before, simultaneously with, or after another operation is within the scope of aspects of the invention.

Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the invention, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims (10)

1. An integrated sensor assembly (102; 1300; 1400; 1500; 1600; 1700) comprising: A magnetic core (138; 1602; 1702; 1800) having a first side, an opposite second side, and an opening (166) defined in said core, said opening extending from said first side and said second at least one of the two sides extends into the magnetic core; a first inductor (104) including a first conductive winding (140) inductively coupled to the magnetic core, the first conductive winding including a first shorting section (194) positioned within the opening ;as well as a second inductor (106) including a second conductive winding (142) inductively coupled to the magnetic core, the second inductive winding including a second shorting section (200) positioned within the opening , wherein the first and second sensors are configurable to operate independently of each other. 2. The integrated sensor assembly (102; 1300; 1400; 1500; 1600; 1700) according to claim 1, characterized in that said first and second shorting sections (194, 200) are in said The openings (166) overlap each other. 3. The integrated sensor assembly (102; 1300; 1400; 1500; 1600; 1700) of claim 1, wherein said opening (166) extends from said first side to said second side Extends through said magnetic core (138; 1602; 1702; 1800). 4. The integrated inductor assembly (102; 1300; 1400; 1500; 1600; 1700) of claim 1, wherein said first conductive winding (140) further comprises a first pair (190) of inductors a segment (192), the first shorting segment (194) interconnecting the first pair of sensing segments; and The second induction winding (142) also includes a second pair (198) of induction segments (192), the second shorting segment (200) interconnecting the second pair of induction segments. 5. The integrated sensor assembly (102; 1300; 1400; 1500; 1600; 1700) according to claim 4, characterized in that said first pair (190) of sensing segments (192) and said first Two pairs (198) of induction segments (192) are enclosed within said magnetic core (138; 1602; 1702; 1800) between said first and second sides. 6. The integrated sensor assembly (102; 1300; 1400; 1500; 1600; 1700) according to claim 4, characterized in that, the first pair of (190) induction sections (192) are arranged on the first In a plane, the first shorting section (194) is angled obliquely relative to the first plane. 7. The integrated inductor assembly (102; 1300; 1400; 1500; 1600; 1700) of claim 1, wherein said magnetic core (138; 1602; 1702; 1800) has first and second opposing ends extending between one side and said second side, said first conductive winding (140) extending from said opening (166) toward said first end, and said A second induction winding (142) extends from the opening toward the second end. 8. The integrated inductor assembly (102; 1300; 1400; 1500; 1600; 1700) of claim 1, further comprising a molding (146) disposed within the opening (166) , said first and second shorting sections (194, 200) are enclosed within said moulding. 9. The integrated inductor assembly (102; 1300; 1400; 1500) of claim 1, wherein the magnetic core (138; 1800) comprises a first piece (160) and a second piece (162 ), said second piece (162) is formed separately from said first piece and is attached to said first piece, wherein said opening (166) extends through said first piece and said second piece . 10. The integrated inductor assembly (102; 1300; 1400; 1500; 1600; 1700) of claim 1, wherein the magnetic core (138; 1602; 1702; 1800) comprises a first section (182) and a second section (184) to which the first conductive winding (140) is inductively coupled and to which the second inductive winding (142) is inductively coupled segment, the magnetic core further comprising a plurality of core bridges (164) interconnecting the first segment and the second segment, the plurality of core bridges at least partially defining the opening (166).