Abstract: 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.

Abstract: A magnetic assembly includes a bobbin and first and second cores. Each core has a main body. At least one of the cores has first and second outer legs and a center leg extending from the main body. The bobbin includes a first channel on a first end flange and a second channel on a second end flange. Each channel includes a plurality of crushable ribs that extend into the channel. The first and second cores are inserted into the respective first and second channels to engage and crush the crushable ribs. The crushed ribs frictionally engage the main bodies of the two cores to retain the two cores in a fixed relationship with the bobbin without requiring tape or glue. In one embodiment, both cores are E-cores. In another embodiment, one core is an extended E-core and the other core is an I-core.

Abstract: A magnetic assembly includes a single bobbin structure that supports a first coil and a second coil. A first E-core has a center leg positioned within the first coil. A second E-core has a center leg positioned within the second coil. An I-core is positioned between the first E-core and the second E-core. The I-core completes a first set of magnetic paths between the center leg and outer legs of the first E-core and also completes a second set of magnetic paths between the center leg and outer legs of the second E-core. The two E-cores and the I-core are stacked in a vertical E-I-E configuration with respect to a common set of pin rails. In one embodiment, the first coil and the first E-core are configured as a transformer; and the second coil and the second E-core are configured as an inductor.

Abstract: A magnetic device for an electronic circuit includes a bobbin having a bobbin body with an axial passage, a first pin rail, and a second pin rail. A winding can be disposed around the bobbin body. A core can have a core leg extending into the axial passage. The bobbin can be disposed on a printed circuit board. The core and the winding can be elevated off of the printed circuit board. The bobbin can include a first spacing member positioned between the bobbin body and the first pin rail, and a second spacing member positioned between the bobbin body and the second pin rail. The core can be positioned on the first and second spacing members such that the core is at an offset position from the first and second bobbin pin rails. The winding can additionally be offset from the first and second pin rails.

Abstract: A magnetic assembly includes a bobbin with two end flanges. A passageway extends longitudinally between the end flanges. An inner core extends through, and is centered in, the passageway. The inner core has first and second end surfaces, each 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 of the inner core and the adjacent inner surface of the outer core. The passageway includes crushable ribs that secure the inner core within the passageway. The outer surfaces of the end flanges include crushable ribs that secure the core with respect to the bobbin. The passageway and inner core may have an oval-shaped profile. The passageway and inner core may have a circular profile.

Abstract: 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.

Abstract: A magnetic component includes a first core half having a core body with first and second core legs protruding from the core body and a middle core leg protruding from the core body between the first and second core legs. A first U-shaped channel is defined between the first core leg and the middle core leg, and a second U-shaped channel is defined between the second core leg and the middle core leg. A first rounded outer core surface is disposed on the core body oriented substantially parallel to the first U-shaped channel, and a second rounded outer core surface is disposed on the core body oriented substantially parallel to the second U-shaped channel. In some embodiments, a second core half having a similar shape is positioned oppositely adjacent the first core, and a bobbin structure is positioned on the middle core legs such that the first and second U-shaped channels form transverse clearance openings in the magnetic component.

Abstract: A header apparatus for providing electrical connection between a daughter card and a printed circuit board. The header apparatus may include a body having a base and a backing portion extending outwardly from the base portion. The header apparatus may include at least one pin extending through the base in a direction substantially parallel to the backing portion, and a gap formed between opposing surfaces of the backing portion and the at least one pin. The header apparatus may be configured to receive at least a portion of the daughter card at the gap to connect the header apparatus and the daughter card. The header apparatus may be connected to a daughter card and/or main printed circuit board, and may communicatively couple the daughter card and main printed circuit board.

Abstract: A common mode inductor includes a bobbin with two windings. A first winding is positioned between a first end flange and a first offset flange. A second winding is positioned between a second end flange and a second offset flange. The windings are spaced apart by a center section without windings. A pair of E-cores, each having a pair of outer legs and a center leg, are positioned in a passageway of the bobbin such that the center leg of each E-core is surrounded by a respective one of the two windings. An I-bar is positioned in the center section of the bobbin between the two offset flanges with the I-bar perpendicular to the outer legs and the center legs of the two E-cores. The I-bar core increases leakage inductance between the two windings to improve the suppression of electromagnetic interference caused by common mode noise in the two windings.

Abstract: An isolated buck converter protects inverter switches during non-zero voltage switching and reduces output ripple current by maintaining operation of an output inductor of the isolated buck converter in a continuous current mode. Continuous current mode operation is maintained by various combinations of: shifting the frequency of operation of the inverter switches of the isolated buck converter as a function of output current of the isolated buck converter; employing pulse density modulation to decrease the off time of the isolated buck converter which will decrease the magnitude of the current ripple; and use a step gap core (i.e., a swinging choke) for the output inductor that saturates to a lower value of inductance for high load current and a higher value of inductance at low load current.

Abstract: A horizontal printed circuit board (PCB) holder for connection to a first PCB and a second PCB may include a frame having one or more legs extending outwardly from the frame, each of the one or more legs having a passageway therein, and at least one conductive pin fixedly secured within the passageway of at least one of the one or more legs. The at least one conductive pin may convey electrical signals between the first PCB and the second PCB. A PCB holder assembly may include first and second PCBs connected to a PCB holder. A method of providing a PCB holder may include determining at least one characteristic of a first PCB and second PCB, configuring the PCB holder according to the determined characteristic(s), and connecting the first and second PCBs to the PCB holder.

Abstract: A magnetic component for an electronic circuit includes a core having one or more core surface grooves defined on a side wall, an end wall or both, along the outer core perimeter. Each core surface groove can improve heat flux away from the magnetic component. In some embodiments, a thermally conductive gap filler material is disposed adjacent one or more of the core surface grooves. An electronic device includes a magnetic component with one or more core surface grooves positioned on a circuit board inside an enclosure. The gap filler material spans a gap between the magnetic component and an enclosure wall interior surface, thereby providing a thermal bridge between the component and the enclosure facilitating heat flux away from the core to the enclosure wall.

Abstract: A bobbin apparatus for a magnetic component includes a core passage having one or more core passage steps located therein. The core passage steps provide one or more gaps between a core disposed in the core passage and the bobbin body. A potting material may be disposed in the gap or gaps in some applications to enhance heat transfer and/or to improve magnetic component performance by reducing effects of fringing flux on inner windings. A method of assembling a magnetic component to include one or more gaps between the core and bobbin core passage is also provided.

Abstract: An auxiliary winding circuit board includes one or more auxiliary conductive windings. The auxiliary winding circuit board is positioned at an axial end of a bobbin, and a core leg extends through an opening in the auxiliary winding circuit board. A main conductive winding is positioned on the bobbin. The auxiliary winding disposed on the auxiliary printed circuit board has enhanced voltage-isolation from the main winding positioned on the bobbin, allowing both a high-voltage main winding and a low-voltage auxiliary winding to be located on one magnetic component. The magnetic component is configured for mounting on a printed circuit board for an electronic device such as a power supply. A modular magnetic component apparatus includes a bobbin with main winding assembly and multiple auxiliary winding circuit boards that may be interchangeably mounted between the bobbin and core for desired applications.

Abstract: A magnetic component apparatus includes a bobbin having a bobbin body, a first pin rail, a second pin rail, and a longitudinal axis. First and second pin rows are located on the first pin rail. The second pin row is located at an exterior position from the first pin row. A third pin row is located on the second pin rail. The first, second, and third pin rows can be oriented in a direction transverse to the longitudinal axis. A plurality of windings can be located on the bobbin body. Some embodiments can include a fourth pin row located on the second pin rail, the fourth pin row located at an exterior position from the third pin row. In some embodiments one or more wire guide channels can be defined in the first or second pin rails to help keep breakout wires from the plurality of windings separate.

Abstract: A component printed circuit board is provided between a magnetic component and a main printed circuit board. The magnetic component includes a device such as an inductor or transformer and includes a bobbin for winding one or more coils and a magnetically permeable core. Terminal pins protrude from the bobbin toward the main printed circuit board and provide electrical connection between the magnetic component and the main printed circuit board. The component printed circuit board includes component vias positioned to accept one or more of the terminal pins allowing the terminal pins to be used for electrical connection to both the component printed circuit board and the main printed circuit board. One or more component traces or shielding layers are disposed on the component printed circuit board. Each component trace provides an electrical connection between two or more terminal pins passing through the component printed circuit board.

Abstract: A magnetic device includes first and second magnetic cores defining first, second, and middle legs extending between first and second back walls, an air gap defined in the middle leg. First, second, and middle legs, and first and second back walls have a substantially equal width. A first winding is located on the first leg, a second winding located on the second leg, and a third winding located on the middle leg. The magnetic device can be part of an electronic ballast circuit including an AC power source, a positive AC rail, a negative AC rail, a resonant capacitor coupled between the positive and negative AC rails, multiple positive and negative lamp terminals configured to couple to respective gas discharge lamps, and windings on a magnetic device coupled between the positive AC rail and respective positive lamp terminals. The third winding is coupled between AC power source and positive AC rail to define a resonant inductor.

Abstract: An interconnectable bobbin has first and second end flanges and a fastener on the first end flange positioned to engage a second bobbin on an adjacent leg of a multiple leg magnetic core. A magnetic component apparatus includes one or more of the interconnectable bobbins, the magnetic component apparatus including a magnetic core with first and second legs, the first leg extending into a first bobbin, and the second leg extending into a second bobbin, wherein the first and second bobbins are fastened together.

Abstract: A bobbin apparatus and associated magnetic component is configured to reduce gap losses associated with a core air gap in a bobbin-wound magnetic component such as an inductor or transformer. The bobbin includes a step structure protruding from the winding surface between bobbin ends. The step is operable to provide spacing between the conductive windings disposed on the bobbin and the core air gap inside the bobbin axial passage. The spacing reduces stray flux interactions with the conductive winding, thereby reducing gap losses and preventing undesirable heating of the winding and core. Additional winding configurations and methods for use with the bobbin apparatus are also provided.

Abstract: A transformer apparatus provides a primary winding and a secondary winding. The primary winding is divided into multiple primary winding layers. Each primary winding layer includes a number of primary layer turns. The secondary winding includes several secondary winding layers. In some embodiments, the transformer includes alternating primary and secondary winding layers wound around a bobbin structure. At least one secondary winding layer is positioned adjacent a primary winding layer. In some embodiments, the number of primary layer turns in each primary winding layer is equal to the total number of primary winding turns divided by the number of primary winding layers. A method of winding a transformer is also provided.