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The present invention relates generally to magnetic component structures that include wire windings around magnetic cores. Windings around a magnetic core produce a magnetic flux in core that can have an effect on current flow in other windings on the magnetic core. Such structures may be used in circuits as transformers or as inductors.
More particularly, this invention pertains to magnetic component structures having a magnetic core with multiple legs, with one or more windings on multiple legs. Typically, such magnetic components have magnetic cores that include one or more bobbins fixed to the cores. The location of the bobbins can be altered as necessary to facilitate different uses and different circuits. Typically these magnetic cores and bobbins are combined as one structure. It can be difficult to wind wire around such structures, as the bobbins can get in the way of each other during the winding process. This difficulty also increases when the magnetic core has multiple legs, as one leg will interfere with winding wire around a bobbin on another leg.
Additionally, when the bobbins and magnetic cores are one structure, each bobbin configuration on the core is a different structure, and accordingly, each structure must be manufactured separately. If the magnetic components are manufactured by injection molding for example, a different mold form must be made for each bobbin configuration. This can increase the cost of production for manufacturers that produce several types of magnetic components with different bobbin configurations on the magnetic cores.
What is needed, then, is a magnetic component apparatus that includes a magnetic core with multiple legs, multiple bobbins, and multiple windings, where wire can be easily wound around the bobbins on the magnetic core.
The present invention includes an interconnectable bobbin apparatus that can be placed on one leg of a magnetic core, and which can be selectively connectable to a second bobbin located on another leg of the magnetic core. The present invention also includes a magnetic component apparatus which utilizes interconnectable bobbins.
One embodiment of an interconnectable bobbin includes a bobbin body that can be located on one leg of a multiple leg magnetic core. The bobbin body has a first end flange and a second end flange, the first and second end flanges being opposite one another. A fastener is configured on the first end flange. The fastener is positioned to engage a second bobbin which can be located on an adjacent leg of the magnetic core. In one embodiment, the fastener includes a protrusion extending from the first end flange of the interconnectable bobbin which engages a corresponding recess in the second bobbin.
A benefit of such an embodiment of an interconnectable bobbin apparatus is that each bobbin can be wound separately and independently. The bobbins and windings can then be assembled by connecting the bobbins together by their respective fasteners to form the general magnetic component shape or structure. The magnetic core can then be inserted through the bobbins to form the assembled magnetic component.
Another benefit of some embodiments of an interconnectable bobbin structure is related to manufacturing. In contrast to conventional structures that are made with the magnetic core and bobbins as one structure, the interconnectable bobbin and the magnetic cores can be manufactured separately. Conventionally, each bobbin for different bobbin locations on the magnetic core must be manufactured as a unique unit. However, in some embodiments of the present invention, manufacturers can make a large number of identical interconnectable bobbin structures, assemble them into a variety of different bobbin configurations, and then insert the magnetic core through the connected bobbins to complete the assembly. This may alleviate the need to make unique molds for different bobbin configurations on a magnetic core.
Another aspect of the invention is a magnetic component apparatus that utilizes the interconnectable bobbin apparatus. The magnetic component structure generally includes a magnetic core with a first leg and a second leg. The first leg of the magnetic core extends into a first bobbin having a first axial passage. A first winding can be placed on the first bobbin. The second leg of the magnetic core extends into a second bobbin having a second axial passage. A second winding can be placed on the second bobbin. The first and second bobbins can be connected as described for the interconnectable bobbin apparatus.
Another aspect of the present invention is a method of constructing a magnetic component with interconnectable bobbins for winding wire around a magnetic core. The method generally includes providing a magnetic core with a first leg and a second leg. A first bobbin and a second bobbin are also provided. The first and second bobbins are connected. A magnetic core is then inserted through the bobbins, the first leg of the magnetic core being inserted through the first bobbin, and the second leg of the magnetic core being inserted through the second bobbin.
A further embodiment of the present invention provides an electronic device such as a power supply, power converter, power inverter, or transformer that utilizes a magnetic component having multiple core legs. Multiple interconnectable bobbins can be located on adjacent legs of the magnetic core and can be connected together. Windings can be located on the interconnectable bobbins.
One object of the present invention is to provide an interconnectable bobbin that can be connected with one or more other bobbins on adjacent legs of a magnetic core.
Another object of the invention is to provide an interconnectable bobbin that can be connected to one or more other bobbins to form the shape of a multiple leg magnetic core.
A further object of the invention is to provide an interconnectable bobbin that is capable of being connected with one or more other bobbins to form a variety of magnetic component bobbin configurations.
Yet another object of the invention is to provide an interconnectable bobbin that can be wound separately from the magnetic component and then connected with one or more other bobbins to form the magnetic structure.
Another object of the invention is to provide a method to easily position windings on a multiple leg magnetic core.
Still another object of the invention is to provide a magnetic component apparatus that utilizes interconnectable bobbins.
A further object of the invention is to provide a method for constructing a multiple leg magnetic component with interconnectable bobbins.
Numerous other objects, advantages and features of the present invention will be readily apparent to those of skill in the art upon a review of the following drawings and description of a preferred embodiment.
The present invention provides an interconnectable bobbin apparatus that can be connected to one or more bobbins on adjacent legs of a multiple leg magnetic core. The present invention also provides a magnetic component apparatus which utilizes one or more of the interconnectable bobbins.
A first embodiment of an interconnectable bobbin apparatus 10 is shown in
Additionally, second bobbin 26 may also include a fastener 30 (
A second end perspective view of interconnectable bobbin 10 in
Fastener 18 in the embodiment of
Referring to
A benefit of such an interconnectable bobbin 10 is that it allows each bobbin to be wound independently and separate from an overall magnetic component assembly. Winding the bobbins independently can be easier and less complicated than attempting to wind a bobbin already fixed to a magnetic core. After the desired number of bobbins have been wound, the bobbins can be connected together in a variety of arrangements which can be suitable for a variety of applications. A magnetic core can then be inserted into the bobbins to complete the assembly of a magnetic component. An interconnectable bobbin can save substantial time during the manufacturing process in some embodiments because the bobbins can be wound and then can be quickly assembled together with a magnetic core.
A second manufacturing advantage to an interconnectable bobbin 10 is that it eliminates the need to manufacture, through molding or otherwise, a specific magnetic component for each bobbin configuration. Because the interconnectable bobbins can be connected together to form a large number of different bobbin configurations, a manufacturer can produce or mold multiple interconnectable bobbins with a common design. The bobbins can then be connected together to form a variety of magnetic components as previously described, thereby reducing the number and variety of unique molds needed, which may reduce overall manufacturing costs.
A second aspect of the present invention includes a magnetic component apparatus that includes multiple interconnectable bobbins similar to the embodiment of
In the embodiment of
A second embodiment of a magnetic component apparatus 34 is seen in
Magnetic core 36 in
A third embodiment of a magnetic component 34 is seen in
A fourth embodiment of a magnetic component 34 is seen in
A perspective exploded view of an embodiment of a magnetic component apparatus is shown in
A perspective exploded view of another embodiment of the magnetic component apparatus 34 is shown in
It will be apparent to one skilled in the art that there can be a large number of different configurations for the interconnectable bobbins on magnetic cores which are useful for a variety of applications. Certain bobbin configurations have been herein described, but such descriptions are not intended to be a limitation of the scope of this invention. There are many configurations not specifically mentioned that are within the scope and spirit of the present invention.
A view of an embodiment of a modified E-core is shown in
Another aspect of the present invention is a method for constructing a magnetic component with interconnectable bobbins for winding wire around a magnetic core. The method generally includes providing a magnetic core having a first leg and a second leg. A first bobbin and a second bobbin are provided. The first bobbin and the second bobbin are then connected. The magnetic core is inserted through the first bobbin and the second bobbin, with the first leg of the magnetic core being inserted into the first bobbin, and the second leg of the magnetic core being inserted through the second bobbin, thereby forming the assembled magnetic component. The method may also include winding a first wire around the first bobbin and winding a second wire around the second bobbin before connecting the two bobbins together. The first bobbin may further include a protrusion extending from the first bobbin and the second bobbin may further include a recess. The connecting step in the method may then further include inserting the protrusion into the recess.
This method can further include providing more than two bobbins and providing a magnetic core with more than two legs. For example, the magnetic core may include a third leg, and the method may further include providing a third bobbin, connecting the third bobbin to the second bobbin, and inserting the third leg of the magnetic core through the third bobbin. The method can be similarly extrapolated to produce a number of different magnetic components with different bobbin configurations, including the configurations previously described herein.
Thus, although there have been described particular embodiments of the present invention of a new and useful Magnetic Component Apparatus with Interconnectable Bobbins it is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims.
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