TWI278877B - Controlled inductance device and method - Google Patents

Abstract

Improved inductive apparatus having controlled core saturation which provides a desired inductance characteristic with low cost of manufacturing. In one embodiment, a pot core having a variable geometry gap is provided. The variable geometry gap allows for a ""stepped"" inductance profile with high inductance at low dc currents, and a lower inductance at higher dc currents, corresponding for example to the on-hook and off-hook states of a Caller ID function in a typical telecommunications line. In other embodiments, single- and multi-spool drum core devices are disclosed which use a controlled saturation element to allow for selectively controlled saturation of the core. Exemplary signal conditioning circuits (e.g., dynamically controlled low-capacitance DSL filters) using the aforementioned inductive are disclosed, as well as cost-efficient methods of manufacturing the inductive devices. Various embodiments of improved gapped toroid devices and an associated methods of manufacturing are also disclosed.

Description

1278877 发明, DESCRIPTION OF THE INVENTION: FIELD OF THE INVENTION The present invention relates generally to components used in electronic applications, and more particularly to use in a filter sinker for digital subscriber line (DSL) or similar telecommunications systems, and other devices. Improved inductive components. [Prior Art] Nowadays, the installation of digital subscriber line (DSL) is usually familiar with the installation, or especially when the user installs a micro device or embedded telephone filter on each phone to carry the phone (including fax, Telephone replies, etc.) are isolated from the line and DSL signal paths. Figure 1 shows a typical installation of a built-in filter. The self-installable microfilter is a challenging design because it must have enough blocking bands in the DSL band to protect and DSL performance, but it should also have a slight impact on voice band performance. Only then. Figure la shows a typical conventional inline architecture for use in DSL applications. However, this conventional filter design often fails to meet the requirements of a subscriber for return loss and DSL blocking. An important issue The overall capacitance required to meet the requirements of the DSL blocking band also creates additional side tones in the telephone band, which is a very common result. In addition, the return loss problem becomes more severe when multiple microfilters are added for each user's phone. Involved in the sub-i filter, this is mainly to maintain the power of the wave. 1278877 In some countries, the filter circuit requirements are urgent. For example, the main challenge is to provide "foot" The blocking band must also provide high speech band return loss. Conventional inductive components are mostly based on their inductive properties and are generally not suitable for use in the aforementioned applications. As described herein, the term "inductance" The characteristic '' usually refers to the inductance curve or the change in inductance as a function of the dc current through the inductor. Figures 2a and 2b show the inductive characteristics associated with typical prior art inductors with fixed inductance or variable inductance, respectively. It is worth noting that in a typical "fixed" inductor, the inductance characteristic 1 〇 2 is a fairly flat or constant as a function of current until a fairly high current is reached. In comparison, the inductance curve and current of the variable inductor The function changes as it is, either in the basic linear mode 1 〇6, or in a slightly "slow ladder", in mode 108, as shown in Figure 2b. Figure 2b generally represents conventional device models manufactured by the United States, Coilcraft Corporation of Cary, Illinois, and others, such as the DT1608 series of SMT power inductors. Figure 3 shows the architecture of the aforementioned Coilcraft device. As shown in FIG. 3, apparatus 300 includes a two-piece core 302 having a base 304 with an off-center post 306. The upper center block 308 has an aperture 3 1 0 that is much larger than the diameter of the column 306. This arrangement creates a continuously variable gap that is actually on the outer surface of the post 306 and the inner surface of the aperture 310, which varies from a minimum gap near the closest point to the opposite point to a maximum diameter at the closest point. value. This continuously varying gap has at least two disadvantages, including: (i) a continuously varying or "mitigating ladder", inductive characteristics, which are undesirable or not optimal in some applications in 4 1278877, and (ii) The manufacturing cost is high because two center blocks with accurate relative tolerances (including accurate adjustment of the upper center block 308 and the pedestal 304) must be provided. Furthermore, regardless of the off-center column 306 and another center The block's own tolerances still have the additional cost associated with manufacturing the off-center column. Such off-center arrangements are generally not beneficial to the use of well-known calibration aids, such as the split pin devices described later herein. 'Including, for example, some DSL filter circuits that require higher blocking band loss (for example, for caller ID function), it is required to have an inductance element different from the inductance of Figure 2a or 2b. The caller ID described above In the case, a higher blocking band loss is required in the standby (on-h〇〇k) state to protect the caller ID device from overload current through the DS1 signal. The pCT application number pCT/Tjs 〇1/45568 in the application (which was filed on November 14, 2001, entitled "High Perf〇rmance MicwFilter and Splitter Apparatus", which has been accepted by the applicant) The exemplary filter circuit is described in its entirety for reference. In this circuit, the removal of most of the capacitance during the standby state reduces the filter and wave blocking band losses and thus forces it as previously described. An additional or replacement device is used to increase the loss of the blocking band. Similarly 'for the issue issued on April 3, 2001 (which has also been assigned to the assignee of the case), the title is "Impedance Blocking Filter Circuit" An exemplary filter circuit as described in U.S. Patent No. 6,2,229, 259 discloses an improved inductive component that is required for a plurality of filters, the 5 1278877 having sufficient inductance to allow the circuit to pass through the standby resistor. Broken band loss, while also allowing for larger capacitors. In addition, in order to control the inductance performance, gap type ring coils have been used. Application on September 13, 2000 (application number is 〇9/ 661628) and issued on November 4, 2003, entitled "Advance (j Electronic Microminiature Coil And Meth〇d 〇f Manufacturing, US Patent No. 6,642,847, discloses a combination of a toroidal core and a plurality of A microelectronic coil device of a coil, wherein the coil is separated by one or more layers of insulating material. The insulating material is vacuum deposited on top of the first set of coils and cured before the next set of coils are wrapped around the core. The toroidal core can also be selectively provided to a controlled thickness gap to control the saturation of the core. U.S. Patent No. 6,642,847, issued to A.S. Pat. Ten this gap is partially expanded through the annulus to reduce EMI. Within each gap, an insulating shim having a magnetic metal strip superposed over the shim is inserted. When a current is applied to the coil on the core, the resulting magnetic flux is introduced into the magnetic strip and surrounds the gaps. The loss of the sigma-frequency excitation eddy current in the magnetic band is quite high, and the coil has a low Q value but has a high inductance. At high coil currents, the tape is saturated, the inductance is reduced and the Q of the coil is increased. In a switching voltage regulator, this inductor tends to produce only a small amount of acoustic and electromagnetic radiation noise. In addition to the desired inductive performance characteristics, the manufacture of inductive components is as low as 6 1278877. The inductive component market (and the dsl filter circuit market) is uniquely price-competitive, and thus, even in the case of cost efficiency or a reduction in the price of these components, the viability of the manufacturer's products can be achieved. It has a huge impact. The method of controlling the inductance of a prior art is often complicated and requires relatively high manufacturing costs due to the increased labor and/or components associated with producing the desired inductive characteristics. Board and internal space losses are also a problem with many electronic devices (including DSU wave circuits); therefore, in addition to the desired performance characteristics and low cost, the minimum physical size and footprint is highly desirable. An electronically executed device that is inexpensive and inexpensive to manufacture, but occupies a considerable board or interior space' is generally not commercially viable. ETSI Technical Standard 952, Part 1, Volume 5 (ETSITS 952-1-5) entitled "Access network xDSL transmission filters"; Part 1: ADSL filters for European deployment; Volume 5: Specification of ADSL/POTS distributed Filters" specifies the requirements and test methods for distributed filters for DSL distribution filters and local exchanges installed at the local loop and near the network termination point (NTP). This standard specifies The local loop's client distributes the requirements and test methods for the correct ADSL/POTS distributed chopper. For each standard, the standby voice band electrical requirements contain two conditions: (i) a 50 V DC feedback voltage, and use Impedance mode ZON (10kQ), or (ii) DC loop current flowing through the distributed filter between 〇.4mA to 2.5mA; and using the impedance mode of 600 Ω to terminate distributed filtering by speech frequency 1278877 LINE and POTS ports. The standard standby ADSL band electrical requirements can be met with a DC feedback voltage of 50 V, and the impedance mode z0N (i 〇k Ω ) is used. It is satisfied with a DC current of 13 mA to 80 mA. These requirements are urgent, especially simple low-cost inductor components. > Based on the foregoing, an improved inductor component with low manufacturing cost and desired inductance characteristics is required. Digital subscriber line (DSL) signals and other signals. Such an improved device ideally (i) has the desired inductive characteristics in standby and use states to support, for example, the caller ID function φ. Loss (ii) is manufactured with high economic cost efficiency, (iii) has reliability, and (iv) has a substantial impact on volume and footprint. SUMMARY OF THE INVENTION The present invention provides a suitable application for, for example, DSL filter circuits. In the improved inductor element and its method of manufacture, the foregoing needs are met. In a first aspect of the invention, an improved inductor element for use in a power amplifier is disclosed. A magnetically permeable core that controls the saturation of the bull, the core and the component cooperate to produce the desired inductance characteristics (eg, substantially opposite the dc current curve) ",, stepped or discontinuous inductor). In an exemplary embodiment, the apparatus includes a substantially cylindrical potentiometer (can-shaped) core having a first core element and a second core element, the second having a portion formed between at least a portion of the core element The gap of the variable body includes, for example, a first portion having a first gap width of 8 1278877 and a second abutting portion having a second gap width. The saturation of the devices at different current values is controlled to provide substantially stepped inductance characteristics over the frequency band of interest. A bulk or separate terminal matrix is also provided for electrically connecting the device to an external component such as a printed circuit board (PCB). In a second exemplary embodiment, the improved apparatus of the present invention comprises a single or multi-part wound ''double," magnetic drum core having first and second terminal elements, wherein the controlled core saturation element is placed The periphery of all or part of the drum-like terminal element ^ ^: Control-saturation element includes 'in an exemplary architecture, a nickel-iron (Ni-Fe) strip. With its iron-containing portion, this material contains a magnetic nozzle that interacts with the magnetic drum to provide the aforementioned stepped inductance characteristics. In a third exemplary embodiment, the improved inductive component comprises a "triple" drum core having first and second terminal elements, and a central component disposed between the terminals to bridge between the two terminal elements . The Ni-Fe type is usually between at least a portion of the periphery and the center member. In the second aspect of the present invention, it is intended to provide a modified DSL filter device. The filter arrangement typically includes a D S L filter circuit incorporating a cross-over, one or more of the aforementioned inductive elements' and is thus adapted to enhance the 9-strong blocking band performance. In an exemplary embodiment, the filter circuit includes a dynamic switching filter circuit adapted to reduce sigma capacitance, and thus allows for multi-signal circuits without generating undesirable and/or dual drum devices being used to provide distributed The filter is used for a given electrical low return loss. The aforementioned input of the can core increased during the standby state 1278877. In a third aspect of the invention, the circuit board assembly includes a substrate having a plurality of conductive tracks and one or more of the aforementioned inductive elements mounted thereon ( For example PCB). In an exemplary embodiment, the aforementioned DSL filter circuit is distributed on the substrate, thus providing a DSL filter "card" that is combined with the edge plug. In a fourth aspect of the invention, an improved method of providing controlled inductance through the use of inductive components is disclosed. The method generally includes: providing an inductor having a core and a controlled saturation component; selecting a parameter of the controlled saturation component to provide (i) a relatively high inductance during a no current state; (ii) being non-zero and The inductor is relatively low during the current state above a given current threshold; and the device is operated within a circuit capable of generating a current free and non-zero current state through the device. In an exemplary embodiment, the behavior of selecting a parameter includes selecting a material, a thickness, and a shape of the controlled saturation element for controlling its magnetic saturation. In the fifth bear of the present invention, a method of manufacturing an inductance element is disclosed. In an exemplary embodiment, the method generally includes providing a first core element and a second anger element adapted to match; configuring a first portion of the gap formed between the first and second elements to a first width; The second portion of the slit is configured to a second width; the core is wrapped with a wire; and the first and second members are assembled. In a second exemplary embodiment, the method generally includes providing a drum core having first and second terminal elements and a coil region; winding at least one wire over the coil region; bridging the bridge using a controlled saturation component One and second terminal elements. In a third exemplary embodiment, the method 10 1278877 includes: providing a drum core having first and second terminal elements, and at least one coil region; winding a wire over the at least one coil region; and using at least one controlled The saturation element bridges the first piece and the center element. In a sixth aspect of the invention, an improved article (related to the method of manufacture) is disclosed. The apparatus generally includes: an element; at least one coil disposed on the core element; a cap element substantially surrounding at least one of the coils; and an inductive control element, a core element, and the at least one coil embodiment In the device, the device comprises a drum core in a vertical direction, in a double-stranded coil. The drum includes a basic portion that is mounted on a plurality of conductive terminals (e.g., PCB) on a parent device, each of which is electrically connected. The controlled inductive component encloses an alloy strip that is placed substantially within the cap and captured between the caps to provide an additional electrical inductance provided by the example device within the device (ie, multiple The elimination criteria (frequencies) can meet or exceed the relevant performance criteria TS 1 01 95 2-1-5 distributed filter specifications. In the seventh aspect of the invention, an improvement (related to the manufacturing method) is revealed. The device typically includes: a magnetically permeable core member; at least one coil disposed on the core member; and a bridged configuration non-a toroidal magnetically permeable member. In an exemplary embodiment, the transmissive element comprises a permalloy and is partially insulated with a central element. At least one of the second element is controlled by a second inductive element. A magnetically permeable core is placed on top of the cap. In one example, there is at least a sensing path for the parent device and a nickel-containing (Ni) base portion. Through the r frequency (notch, such as ETSI's slit toroidal slotted toroidal core element gap, the magnetic permeability is placed in the gap 11 1278877. During operation, the gap is current "rotation," toroidal inductance; The alloy element is saturated to effectively remove the inductance of the device. In another embodiment, the core gap is traversed by a permalloy strip, wherein the core and strip are substantially enclosed within an outer cover (eg, a heat shrinkable tube) In another embodiment, the toroidal slot device is mated with a saturation control element that substantially comprises a toroidal metal plate or "washer." To provide the desired degree of magnetic coupling through the core slot, the gasket and the top surface of the device / or the bottom surface is matched. The thickness of the gasket and the extent of the core can be controlled to provide the desired electrical and inductive characteristics of the device, and to provide a very low cost solution. [Embodiment] Referring now to the drawings, all the same numerals The same parts are used. As used herein, the term 'signal processing,' or ''processing', shall be understood to include, but is not limited to, signals Pressure transformation, filtering and noise cancellation, signal separation, impedance control and correction, current limiting, capacitance control, and time delay. As used herein, the term "digital subscriber line (or "DSL") should be understood as a DSL architecture or service. Any form, whether symmetrical or otherwise, includes unrestricted so-called "G.lite, ADSL (eg conforming to ITUG.992.2) J RADSL: (rate-adaptive DSL), VDSL (very high bit rate DSL) ), SDSL (Symmetric DSL), SHDSL or Super High Bit Rate DSL, also known as G.shdsl (eg compliant with ιτυ recommendation G.991.2, certified by 12 1278877 ITU-T in February 2001) 'HDSL: (High) Data rate DSL), HDSL2: (second generation HDSL) 'and 1DSL (integrated service digital network DSL), and in_preinises telephone line network (eg hpn). It will be further recognized although the terms "family," and "user Here, it may be used in connection with one or more aspects of the exemplary embodiments of the present invention, but the present invention in no way limits these applications. The present invention can also be successfully applied to 'small or large commercial, industrial' and If needed, 'even in the military, etc.. # It should be noted that although the following description is arranged according to the relevant standard plugs of the RJ_type connectors and models well known in the telecommunications field, the present invention can Used in conjunction with any number of different model connectors. Therefore, the following discussion is merely an example of a broader concept. In addition, the terms "website," and "user site," as used herein, shall include having to provide there. Any location (or location group) of the telecommunications line business is not limited to residential buildings, apartments, offices, and businesses. Finally, as used herein, the term "expansion device" means that the package β includes any type of telecommunication device compatible with conventional telecommunication lines, and is not limited to conventional telephones, answering machines, facsimile machines, and wireless devices. Or a satellite receiver, and a multi-line telephone. SUMMARY The present invention effectively solves the problem of correcting the inductive component's inductive characteristics in a low cost manner to provide inductance values for two or more substantially discontinuous 13 1278877 as a function of dc current, In an exemplary environment of a home or user DSL chopper circuit, 'this substantially discontinuous characteristic allows a higher input impedance for the ferrator in the standby state. When combined with a dynamic switching data circuit, the low shunt capacitance And the desired high blocking band loss is advantageously provided in a single circuit. The improved inductive component of the present invention is cost effective to manufacture and is spatially compact and compact. It should be understood that the improved inductive component of the present invention is used for Described in the DU circuit, but the application of such an inductive component can go beyond the # DSL circuit, including any need in the literal sense. The circuit of the characteristic inductive component described herein. Therefore, the scope of the present invention should be determined by the patent application, and is not through the exemplary embodiments set forth herein. The improved inductive component will now be described with reference to Figure 4-4f, in detail. Various exemplary embodiments of the improved inductive component of the present invention are described. Those skilled in the art will recognize that the embodiments described herein are merely examples of the broad concept of providing a controlled saturation inductive component that is It is low-cost and produces the desired inductive characteristics. Many different physical architecture variations (described here to apply in accordance with the present invention. For example, shown in Figures 4 and 4a, the inductor is shown In a remote embodiment of the first embodiment of the component 400, the device 400 typically includes a potentiometer or a "pot" having a design of two elements 402a, 402b that are designed to match the A. When engaged, the two elements 402a, 402b have the shape 402 ° ^ ^ 14 1278877 in this embodiment

They are substantially cylindrical and each include a centrally placed post 406a, 406b that forms a channel or slot 408a, 408b therearound. It should be understood, however, that other core types (including, for example, the well-known "E" core type, which are effective double "E" plastic in a mirrored deployment, or "U" core design) can also be used with the present invention. Use. The slot 408 has an inner volume in which the coil of the device 410 is located. Each element 402 is formed from a magnetically permeable material, such as Mn-Zn, which is well known in the electronics arts. An aperture 409 is formed in the side of the core member (at the junction of the two elements 402a, 402b) to allow entry/exit of the wires. Obviously, other mechanisms for wire entry/exit can be used, including through the top or bottom of the core surface, and the like. In addition, certain core types (e.g., the aforementioned "E" cores) are designed to be opened to provide an outlet for the wires.

Inductive component 400 also includes one or more conductive coils 41 3 formed by winding a desired shape of wire through a central post 406 of core 402. In the exemplary embodiment, 'the so-called "magnetic wire", which is well known in the field of electronics, is used because it has both relatively low cost and good electrical and mechanical properties. Magnetic wires are usually wound around transformers and inductive components. Also included are wires of copper or other inductive material that are covered with a thin polymeric insulating layer or polymer layer compound such as polyurethane, polyester, polyamidamine (aka "Kapt") or the like. The thickness of the overlay and the compound determine the dielectric strength of the wire. Magnetic wires ranging from 31 to 42 AWG are mostly used in microelectronic transformer or inductor applications, although other sizes may be used in certain applications. The inductive component 400 of the figure may also optionally include a termination matrix 425 'which is used to connect the aforementioned coil to an external device such as a pcB pad or trace 15 1278877

trace. The inductive components of the type disclosed herein are typically placed on a surface such as a pCB substrate and placed on the surface to conveniently provide low profile and low installation cost. The termination matrix 425 includes a non-inductive matrix architecture 427 and a plurality of large to flat section terminals 429 that are isolated from each other by a matrix architecture 427. For each or each terminal, the free end of the inductive element coil 413 terminates, for example, by soldering and/or wire winding on a slot formed in the end of terminal 429 (not shown). The bottom end portion 431 of each terminal 429 is adapted for surface mounting (e.g., soldering) to a corresponding PCB contact pad (not shown) or other similar inductive analog. The core 402 of the inductive component 400 is located atop the frame 427 and can be mounted thereon by the use of an adhesive or other number of conventional devices on the bottom surface of the second core member 402b.

As a further alternative, the terminal 429 can be mounted directly into or on the core 4〇2 (not shown) such that they are frictionally and/or adhesively embedded in the apertures in the core elements 402a, 402b. And then terminate the free end of the coil 413 there. Numerous other architectures for the terminal and mounting it (either directly or indirectly) to the 4 4 2 2 exist, for example, in the ball grid array method well known in the industry, or multi-pin (eg, In the pin idle array, the aforementioned alternative architecture can be readily understood by those skilled in the art. The region 414 between the opposing surfaces of the respective core element posts 406a, 406b includes a "variable" shape designed to provide the desired inductance characteristics (described below with respect to Figure 4c). In the illustrated embodiment illustrated in the figure, the variable body includes two regions 416, 418 disposed between the posts 16 1278877 406, each having a different slit width (double layer). The first region 416 has a first slit width W1 of about 0.010 inches (〇·254 mm), and the second region 418 has a slit width W2 of about 0·〇〇1 inch (〇〇254 mm), and W2 is smaller than W1. When viewed in plan view (Fig. 4b), the two regions 416, 418 comprise two adjacent elements that are generally formed in the cross-sectional area of the entire column 4〇6. In this embodiment, the first region 4 i 6 includes The entire surface area of the post 406 is about 9%, which is separated from the second region by the chord 41.9. The second region 418 contains approximately 1% of the remaining cross-sectional area. In this exemplary embodiment The gap (multiple gaps) is filled with air However, it should be understood that one or more other materials having the desired characteristics can also be used. For example, the gap can be filled with a highly magnetic magnetoresistive compound to further control the inductance curve of the core. Typically in DSL filter applications, The core is prevented from being saturated by the dc loop current in the telephone line, and the series inductor core (multiple cores) must have a gap. However, there is no "loop current in the standby state. By implementing the multi-region gap shape described above, the fourth The inductive component of the figure provides the desired "stepped" inductance characteristics. More specifically, the inductor's standby inductance value is 2-1 times larger than the value used (depending on the selected parameters, as discussed below). When an individual telephone or other expansion device associated with the filter circuit is used, the width W2 of the second region 41 8 described above is sufficiently small to allow saturation of the core having the primary use of the dc loop current. This results in the inductance of the device. Falling into the desired usage value. As will be understood, the values of w 1 and W 2 'and the cross-sectional areas of the first and second regions 416, 418 The relative distribution of 17 1278877 helps determine the specific inductor value used, as well as the "stepped," shape of the inductor. In this case, a two-stage characteristic is provided to produce two desired inductor values (ie, standby and use states). Figure 4c illustrates the inductive characteristic 450 associated with the example skirting of Figure 4. As shown in the "Figure, this characteristic has - a relatively high and substantially fixed inductance value (at low dc current) The first portion 452' through the device) has a substantially vertical second portion 454' that reduces inductance as the dc current increases, and a third portion 456 that has a relatively low inductance at higher dc currents (also substantially fixed). , and a fourth part 458, in which the device is completely saturated. The first portion 452 represents a dc current value that produces little or no core saturation, and a higher inductance in the exemplary DSL filter circuit corresponding to the standby state. During the second portion 454 of the curve 450, the core begins to saturate and there is a sharp (steep) drop in inductance as the dc current increases. This sharp drop is particularly related to the magnetic flux density that increases through small gaps (which increase with increasing current in saturation), which effectively removes the turns from the circuit. Even as the dc current is further increased, the core saturation' and the device progress into the third portion 456 of the curve 450. Here, as the current increases, the inductance remains substantially constant, reaching the saturation region 458. Comparing with the inductance achieved in the first 'second, second and third areas 452, 454, 456' Once the core is fully saturated, the inductance will quickly fall again to a small value. It should be noted that although the embodiment of Fig. 4 uses a two-region arrangement of center pillars, other arrangements of 18 1278877 may be used in order to produce the desired electronic properties. For example, in an alternative embodiment (Fig. 4d), the mating faces of the third region 470 to the stem 4 〇 6 are added, thereby adding a third order ("three layers") in the inductance characteristics. In a further alternative embodiment (Fig. 4e), the two layers or regions 416, 418 of the slot area are concentric with each other such that the second region 4 1 8 having a smaller gap W 2 surrounds the portion having a larger gap W 1 The first area 416 is surrounded. The thickness D1 of the wall or torus 474 associated with the second region 418 is controlled to provide the desired inductance characteristics. Moreover, the wall or annulus 474 can be gradually reduced as a function of vertical height such that, for example, its width D 1 closer to the slit W2 is smaller than the width of the point above the slit. Alternatively (or alternatively) the discontinuous annulus 474 can be made, for example, interrupted from time to time by one or more regions along its circumference, the gap being increased on its circumference, such as in Figure 4f. This is achieved by the removal of material in these areas. The aforementioned concentric arrangement also facilitates the use of a central adjustment device, such as U.S. Patent No. 5,952, entitled "Blind hole pot core transformer device", issued on September 14, 1999, to Pulse Engineering Co., Ltd. A split-pin through-hole arrangement as described in detail in No. 907 is incorporated herein by reference in its entirety. The arrangement uses a set of central apertures formed in the center post of each of the first and second core members, and an open friction pin received in one of the apertures prior to the transfer of the core. When the core elements are combined, the free ends of the split pins are received within the unblocked apertures of the other core members, thereby adjusting the two core members of the quasi-disc. 19 1278877 Many other different architectures are possible for the center post 406, many of which produce different inductive performance characteristics. Furthermore, as discussed previously, the differently shaped slot arrangements of the illustrated embodiment can be readily applied to other In the core structure, for example, "E" type and "U", core.

It will be appreciated that the embodiments of Figures 4a-4f can be manufactured at low cost because (as described in more detail below) they can easily be used off-the-shelf or, off-the-shelf, low cost cans. The core, which can be simply modified as described herein to provide the desired inductance characteristics. Since the slits of different shapes are completely contained within the volume of the device, it is advantageous for these devices to eliminate the need for more space than conventional can cores.

Referring now to Figure 5, a second exemplary embodiment of the improved inductive component of the present invention is described. In this embodiment, a typical drum (or spool) known in the art is used in conjunction with the controlled saturation component 508. Core 5〇2. The blowout 502 includes a center spool region 504 and two terminal members (e.g., flanges) 5〇6a, 5〇6b at the end of the distribution spool region 504. The spool region 504 includes a coil 5 1 0 that is wound concentrically around the spool. As in the embodiment of Fig. 4, the core 502 is constructed of a magnetically permeable material. However, it will be appreciated that it may be replaced with multiple pieces of core, but to reduce cost (or other reasons), the core 502 of the illustrated embodiment is structurally single piece. The controlled saturation element 508 of the illustrated device comprises a thin (approximately 〇〇〇1 inch' or 0.0254 mm, thick) elongated strip of nickel-iron (Ni_Fe) alloy that is longitudinally aligned along the core 5〇2 so that it It is possible to bridge two terminal elements 5〇6a, 5〇6b. In this embodiment, element 508 is glued or bonded to the two terminal elements 5〇6 20 1278877 via an adhesive. Since (i) is magnetically permeable (and electrically conductive) because of the iron content, and (11) the nickel content is substantially strong and hard enough, Ni-Fe is selected as the controlled saturation element 5 〇8. Although it is possible to replace other alloys based on the desired characteristics, the figure 5〇8 has iron of 8〇% and 2〇c/❶. For example, different percentages of nickel and iron can be used. Alternatively, different types of alloys such as Ni-Fe-Cr (generally considered to be Inconel) or so-called "stainless steel" (mainly Fe-C_Cr, or Martensitic or others) ) may be used alone or in combination. One advantage of containing chromium is the passivation of the element 508, which greatly eliminates the effects of iron degradation mechanisms including iron oxide morphology ("rust") and corrosion conditions. The controlled saturation element 508 may advantageously be configured as a belt in a larger sheet, including previous applications where cementing is as described in more detail below, as their existing usefulness facilitates easy and cost effective manufacture. It will be appreciated that the cross-sectional view and thickness of the controlled saturation element 508 can affect the point at which the device is saturated, as well as the relative inductance values for different currents. Thus, while a flat belt of about 〇 1 inch (0.0254 mm) thick is used in the illustrated embodiment, other thicknesses and/or cross-sectional views may be used. For example, it may be desirable to utilize one or more substantially circular cross-section alloy wires (not shown) as controlled saturation elements. It will also be appreciated that a combination of materials may be used in one or more controlled saturation elements 508 used on a given device. For example, the device can be mounted with two or more smaller diameter strips 5〇8 placed around the device to bridge the two terminal elements 506 at multiple locations (see Figure 5a). As another alternative, the strip 508 shown in Fig. 5 can be replaced with one or more continuous sheets of alloy "tape" 561 that "extend, partially extend or completely surround each terminal element 506. Peripheral (Fig. 5b). A well-known model in the art (eg by the Raychem Corporation of Menlo)

The heat shrink tubing 563 of Park, CA can optionally be used in place of or in addition to the aforementioned adhesives to save cost and to permanently weld the saturating element 508 to the drum end 506. Other coupling options are available, including copper/position welding, soldering, clamping, and more. As another alternative, a synthetic saturation element 508 can be used in which two or more different alloys can be used in combination with each other, for example, to form a substantially discontinuous, parallel or up and down folded strip. Without the proper controlled saturation element 508, the inductance of the core 052 (and the entire device) is primarily determined by the gap between the terminal elements 506. However, by using a suitable saturation element 508, the gap between terminals 506 is bridged to substantially boost the inductance of device 5 在 in a low or no current state (e.g., standby). However, when the expansion device connected to the inductive component 500 is used, the dc current rises, thereby increasing the flux density at the thinner component 50 8 . This results in a rapid saturation of the component 508, thereby substantially reducing the inductance of the device (''stepped'). The inductive component 500 of Figure 5 can also optionally include, for example, the above described with respect to Figure 4 The aforementioned coil is connected to an array of terminals of an external device such as a pcB塾 or trace, and optionally, the terminal 529 can be mounted directly to the inside or outside of the core (as shown) so as to pass through friction and/or cementation. They are embedded in the aperture 535 of the core element 502 and terminate the free end of the coil 413 there. Referring again to the alternative embodiment of Figure 5c, wherein 妓~匕a is adapted to receive the notch of the L-type terminal 586 588. The free end 580 of the terminal coil 513 is placed within the recess 588 to permit electrical termination at the terminal 586. Many of the other architectures for the terminal and their mounting (or directly or indirectly) to the core 5〇2 are present. For example, known ball grid array methods, or pins (for example, used in a pin grid array). Those skilled in the art should readily appreciate the alternative architecture β as in the embodiment of Figure 4, due to the large section The simplification of the means for controlling the inductance curve of the device is very efficient in manufacturing the inductance components of Figures 5-5c. This is distinguished from the more complex (and costly) conventional devices used to provide custom inductance characteristics. Another embodiment of the improved inductive component of the present invention is now described with reference to Figure 6. In this embodiment, apparatus 600 includes a dual drum core 602 having first and second members 602a, 602b and placed in two A central element (e.g., a flange) 6 〇 5 ^ between the terminal elements 602 is provided to each of the two spool regions 6 0 4 including one or more sets of concentric winding coils 61. 0 along the axis 611 of the device. A single controlled saturation element 608 is placed longitudinally and connected to each of the three elements 602a, 602b, 605, thereby bridging the two gaps formed therebetween. However, it should be understood that two discontinuous saturations A degree element 608 (not shown) can be used to bridge the two gaps of the double bobbin anger 602. In addition, 23 1278877 the single spool drum core described above with respect to Fig. 5 can have various alternative architectures, such as Use not Alloys, continuous belts, multi-saturation elements, etc., can be equally applied to the two-wire core of Figure 6. Filter Circuit Insertion Referring now to Figures 7-9, an improved filter circuit utilizing the above-described inductive components is disclosed. As previously discussed, the inductive component of the present invention solves the problem of being able to modify the inductive characteristics of the inductive component at low cost to provide two or more substantially discontinuous inductance values as a function of dc current. In a home or user DSL filter circuit In an exemplary environment, the substantially discontinuous characteristic takes into account the significantly higher input inductance of the filter for use in the standby state. When coupled with the dynamic switching filter circuit (eg, as depicted in Figure 7), low The shunt capacitance and the desired high blocking band loss are advantageously provided in a single circuit. In other words, the improved inductor of the present invention, when combined with the dynamic filter of FIG. 7, provides a single filter circuit that provides a low impedance filter in use and a high impedance filter in standby. It is also advantageous to maintain the same (or similar) frequency cutoff performance. Therefore, the combination of these two 70 pieces (that is, the "stepped" inductance element and the dynamic switching filter circuit) creates synergy. When the inductive component of the present invention is combined with the filter circuits of FIGS. 8 and 9, the excellent blocking bandability is provided at a very low cost by the use of the combination of the other FIG. 6 or the use of the two-wire inductor. Referring now to Figure 7, a dynamic micro 24 ί 278 877 with a modified inductive component is described. According to the wave example package, such as the English and the heel in this sub-element, etc.) (Example of the wheel of the component wheeled each. Circuit L4) Input socket A first embodiment of a telephone messenger architecture. It should be understood that although the implementation of Figure 7 contains an exemplary design suitable for meeting the requirements of use in multiple countries with certain performance requirements, the dynamic filter of the present invention is selected by the correct components. It can also be adapted to be used accurately in applications. Based on the well-known disclosure, it is easy for the person familiar with the technology to determine such an alternative application and cooperation. Therefore, Xiao Li does not further describe. It should also be appreciated that while depending on the plurality of discrete electrical components used to form the circuit (that is, resistors, inductors, capacitors, switches, etc.), the following discussion may be made, but portions of the circuit may be integrated components such as The integrated circuit) or other form of the form having the desired function and electrical characteristics is implemented. As shown in Figure 7, filter circuit 700 typically includes a plurality of terminals (line side jacks) 704 and two input inductors 706, 708 in portions 702. In the present embodiment, the two input inductors 706, 708 each include a previously described model of controlled saturation inductance which provides the desired input inductance characteristics previously discussed. An output portion 720 includes two additional inductors 724, 726 (L3, three capacitors 727, 228, 730 (C4, C9, C6). The filter's "stepped" inductors (LI, L2) 706, 708 are Connected to line side 74, and the capacitive input portion 720 of the filter is connected to the side jack 740 of the filter. Line and telephone side jacks 704, 740, although common type modular jacks used in electrical applications, But you should also know

25 1278877 can be replaced by other types of modular plugs and connectors. Filter 700 further includes a DSL jack 750, which in the illustrated embodiment includes an RJ-1 Type 1 DSL jack, although other alternatives are also possible. The DSL jack 750 is routed directly from the electronic path 752 to the line side jack 704 (plug) to provide a convenient DSL or Home Phone Network (HPN) jack. The basic filter shown in the circuit of Figure 7 is composed of two input inductors 7〇6, 708 (L1, L2), two output partial inductors 724, 726 (L3, L4), and three bridge capacitors 727, 728. A four-stage elliptical low-pass filter consisting of 730 (C4, C9, C6, respectively). Input inductors 706, 708 provide the desired input inductance characteristics and prevent loading on the DSL circuit, although two capacitors 734, 736 (C1, C7) in input portion 720 are added to output inductors 724, 726. (L3, L4) to produce a sway at 30 kHz • level, but it should also be understood that other reactance and capacitance values can be selected for other resonant frequencies. Accordingly, the embodiment of Figure 7 is a four-stage elliptical filter that produces a significant 30 KHz interrupt. This elliptical blocker feature allows for such a design to minimize overall capacitance to the usual <4〇nF usage and 5nF standby (that is, <4〇]E-〇9 Farad in use, and 5E-09 Farad standby State), which minimizes the capacitive effects on the phone's voice band performance. In order to make the filter 700 dynamic and to take care of the self-installation of the multi-filter for each phone by the user, add two reed switches 762, 764 (ΚΙ ' K2 ) to remove the call for standby (idle) Most of the filter capacitors. In the embodiment of Figure 7, the reed switches 762, 764 are magnetically coupled 26 1278877 to the dual inductor 770 (L5A), as evidenced at January 30, 2001 and April 3, 2001 respectively. U.S. Patent Nos. 6,181,777 and 6,212,259, entitled "Impedance Blocking Filter Circuit", are assigned to the assignee of the present application. More specifically, the reed switches 762, 764 are coupled to the inductor 770 by virtue of their physical proximity to the inductor and thus create a magnetic field. The inductor/reed switch 766 in this embodiment is comprised of a cylindrical frame and includes a dual inductor and two reed switches 7 6 2, 7 6 4 . It will be apparent to those skilled in the art that the dual inductor/reed switch device 766 can be replaced with two single inductor/switch units (not shown) to perform the same function. In the illustrated embodiment, the reed switches 762, 764 are disposed along a longitudinal level that is substantially parallel to the longitudinal axis of the spool of the device. This architecture provides the aforementioned magnetic coupling between the coil of the inductor 770 and the switch to operate the latter. Device 766 is selected to be activated at a predetermined loop current threshold (e.g., approximately 6-16 mA). If the loop current threshold is too low, the reed switch can vibrate during circuit operation and can therefore shorten the use of the switch. On the other hand, if the loop current threshold is too high, the loop current will not be sufficient to activate the switch under worst-case conditions. When no loop current flows (because the phone is in standby), there is no magnetic field from the dual inductor 770 and the reed switches 762, 764 are open, which disconnects the capacitors 727, 73 从 from the circuit (to C6). In this embodiment, this reduces the total capacitance from approximately 37.7 nF to 4.7 nF for each standby filter. This 4.7nF value is intended to drive either standby 27 1278877

The minimum value required for a capacitor with a resonance below 3 OKHz. In addition, in order to protect the reed switch 262, 264 from ringing voltage, power crossover voltage and extremely fast transient voltage damage, as shown in Figure 7, including crossing the reed switch 762, 764 - or two Regulated diodes 776, 778 (D1, D2) to limit the peak voltage to less than 12 V. Since the capacitor is in series with the diode, the single diode 776, 778 of the illustrated embodiment is ideal for operation and will bias the single diode when the AC signal is present. However, either the aforementioned diode arrangement can be replaced by a dual back-to-back 6-12V. regulated diode, a single regulated diode, or even a low capacitance varistor. The construction and selection of such components is consistent with the current objective of providing a minimum capacitance in the device, and is also well known in the electronics arts and, therefore, is not described further herein. When the reed switch is turned off, in order to prevent the spike signal of the reed switch 762, 764 switching current from passing through the C9 capacitor 728 and the C4 capacitor 727 (and 〇1'7 7 capacitor 734.736), two resistors 780, 782 are added ( 115,

R6) is in series with the C4 and C6 capacitors 726, 730 to limit the minimum current rating of the switch current below the switch. In order not to affect the filter's blocking band performance, choose a sufficiently low R5, R6 resistor value. The dynamic component pairs of the filter 700 described above provide sufficient return loss. The urgent requirements for improving the previous discussions (such as those of the European/UK specifications) are still insufficient. To solve this problem, the resonant impedance consisting of a dual inductor 77〇(L5A, L5B) 'parallel network capacitors 790,792 (C2,C3), and parallel network resistors 794,796 (R4 and R1) The correction circuit boosts the voice band back by adding a positive phase impedance in the 2-3 KHz band. 28 1278877 Wave loss is as 770 (R3 is used for the most advanced country); Inductance (L1 in the pass impedance: Zhongdu Resistant, and the increased sub-size is 1 db. The dual inductor 770 (L5A, L5B) is dual-purpose; previously described in addition to the reed switch during drive, dual inductor and network capacitor C2, C3 The 790,792 combination) also constitutes the differential resonant impedance in series with the line-in. Parallel network resistors 794, 796 ' R4 ) limit this impedance to approximately 7 ohms, which also limits the insertion loss to large Acceptable level (that is, the circuit 7 〇 0 in Figure 2 of Figure 7 further mentions 1 micro farad ringing capacitor 791 (C10) on pins 4 and 5 of the telephone jack. In some (eg English applications) Need to use such a filter to ring some three lines It should be understood, however, that this capacitance may alternatively be dependent upon the particular application of the wave circuit of the present invention. It is further noted that the circuit 700 of the embodiment of Figure 7 is advantageously formed using separate coils. Inductors of various circuits 7 〇 6, 708, 724, 726 ' L2 ' L3 ' L4 ) instead of, for example, dual EP 13 inductors commonly used in many conventional designs. The device provides longitudinal modularization And differential impedance 'This is required for certain applications (including eg European telecommunications standards). Traditional EP-based designs do not have an effective longitudinal resistance and therefore require additional coils. Additional coils add extra dc resistance to compensate for the increased impedance Larger coils are often required, thus providing the cost and space requirements associated with each filter. Conversely, with the difficult coil design of the present invention, there is no need to increase the longitudinal coil or boost filter inductance. In the illustrated embodiment, Use controlled saturation inductors and /

29 1278877 II, and double shielded inductors such as * can provide a description of the longitudinal impedance and provide a magnetic field to drive the reed switch (as applicable). The dynamic filter circuit 7〇〇 disclosed herein means that the state of the filter structure can be changed on the telecommunication line by providing U) capable of changing the state depending on the operating conditions of the associated expansion device; and (Π) providing enhanced return loss performance. Etc. impedance correction circuit to solve the problem of insufficient blocking band and voice band b is more clear, in the telecommunication line fault with voice and DSL signal components, when one of the phones on the S line is used (usually only It is used by one of the phones during any time), and the dynamic circuit using the filter boosts the capacitance of the ,, while all other standby phones on the same line maintain a low capacitance relative to the used circuit. Because of the enhanced DSL blocking band The main need is to use the telephone, and the presence of the polarity-protected diode bridge of the phone. Therefore, this dynamic capacitance characteristic is acceptable and compatible with conventional applications. The DSL high-level energy can be overdriven. Use this diode bridge in the phone to create unwanted inter-modulation distortion. Therefore, an enhanced DSL blocking band is needed to block such Drive state. When the phone or other expansion device is in standby, the diode bridge is removed from the circuit and requires a smaller filter DSL blocking band attenuation. Therefore, it can be applied very small in the filter circuit associated with the standby phone. Capacitance ^ This allows the use of the phone to have a relatively large capacitance, and therefore the dynamic filter can have close splitter performance. However, it should be recognized that removing most of the electricity during standby mode 30 1278877 It also reduces the blocking band loss, which can cause problems for certain operating states that require increased standby blocking consumption (such as caller ID.) The inventive controlled saturation inductive component 400, 500 is in circuit 7 The problem is solved by the person who only reduces the input inductance value in the standby state (that is, by providing a "stepped" inductance relative to the heart current). Therefore, the combination of a dynamic switching filter circuit and a controlled saturation on-inductor provides near-performance at a very low cost over a wide range of applications, including multi-spread applications with caller ID or similar functions. Referring now to Figures 8 and 9, other embodiments with improved inductive element filtering circuits are described. The circuit of Figure 8 includes a line having inputs 866, 868 connected to respective input inductors 840' 842 or an exemplary circuit 800 of Figure 8 utilizing a two-line sensing element such as that shown in Figure 6 to provide both Inductors 840, 842, however, may also be substituted for no architecture (e.g., two single spool drum assemblies 500). The two inductors provided by the dual spool inductor 600 advantageously generate enough inductance for more than one filter to allow the waveguide 800 to block the band loss through the standby and improve with the larger use capacitor. The blocking band (for example, it requires the function of such a higher blocking band for the caller ID), but still meets the return loss. The use of the dual spool device 6〇0, which replaces the inductor 840'842, provides significant cost benefits' because the manufacturing cost of the twin spool device is typically extremely low compared to manufacturing two single wire spindles. In addition, the 8th circuit is also extremely simple to manufacture, requiring only two inductors 84〇, 842 with losses on both sides of the ideal part of the waveguide. The same component of the shaft is the same as the phase diagram of the required sample (also 31 1278877, that is, a double spool inductor), thus taking into account the high performance of the interrupted band and the filter. Effective cost circuit. The circuit 900' of Fig. 9 is similar to the above-described Fig. 8 and includes a line or wheel-in side having inputs 966, 968 connected to two respective input inductors 940' 942, and also includes distributed and external side jacks 96. 0 ' 9 7 2 Selectable three-phase filter circuit for communication. Such a three-phase filter component is desirable in some environments. Manufacturing Method Referring now to Figures 1 and b, the method for fabricating the previously described inductive component is discussed in detail herein and illustrated in the form of a logic flow diagram. It should be recognized that in accordance with the previously described embodiments (ie, The can core and drum core device are described herein below, but the method of the present invention can generally be applied to various other architectures and embodiments disclosed herein by suitable modifications, such as in electronic devices. The system is within the knowledge of those skilled in the art. Referring first to the 10&Fig., a method 1000 of making the improved can core device of Fig. 4 is described. In a first step 102 of method 1000, a second element 402b of a can core is obtained or fabricated. ^ The core 402 of the exemplary device of FIG. 4 is preferably fabricated using a number of known processes (eg, material preparation, extrusion, and Sintered) formed of a magnetically permeable material. The core 402 is fabricated to have specific properties including magnetic flux properties, cross-sectional shape and area, height, 32 1278877 and column diameter, as is well known in the art and thus is not described herein. The first anger element 402a may here be constructed directly from the previously described variable body slot structure (step 1 004), for example by fabricating a tungsten piece for assembling a first core element 4 0 2 a including the desired slot characteristics. Or appearance. Alternatively, the first core element 402a can be effectively constructed as a mirror image of the second element 402b via step 1006 (step 1007) and processed (step 1〇〇8) to produce the desired various shape slits. The process of step 10 〇 8 includes an implementation of machining at least a portion of the center post 406 of at least the first core component 402 & to a desired architecture (eg, a structure having a gap width W1 and W2 of Μ%/1%). In the example. Such machining involves, for example, the exact portion of the polished stem 4 60. Alternatively, the processes may include micro-cutting or grinding, or even cutting or ablation by laser energy. Next, through step 1010, core elements 402a, 402b may optionally be coated with a layer of polymeric insulating material (e.g., parylene) or other material on some or all of the surfaces to protect the coil from damage or insulation. This cover layer is particularly useful when using a coil of a slim size or a coil covered with a very thin coating that is easily worn during winding. Next, after step 1 〇 1 2, the core is wound in the shape of the desired wire. Such wire shapes may include, for example, winding a thin gauge magnetic wire concentrically around the center post 406 of the core in a substantially annular "annular" pattern, although other types of wires (insulation or other) and winding modes may be used. The two core members 402 can then be assembled and adjusted as desired (e.g., using a viscous 33 1278877 bonding compound (step 1014). The coils are captured in recesses formed in the core 402 and routed through their free ends. An aperture 409 in the core element 402 (or other similarly penetrating) side. Next, via step 1016, a terminal array 425 and/or terminal 429 is provided or fabricated. Although the terminal array architecture 427 is desirably used from a suitable poly-sigma The medium/primary or transfer mold process is formed, however, other materials and methods may be substituted. The terminal 429 may include desired characteristics such as notches for piercing and substrate contact attenuators on their bottom ends, and It is stamped or subsequently embedded in the frame 427. Thus the fabrication of the terminal array is well known in the electronics arts 'so it is not further described herein. Next, the harness core is placed or mounted into the terminal array 425 of the type previously described via step 1 。 18., for example, in an exemplary embodiment, a magnetic bead or drop, such as a ring, of a suitable binder is used. Oxygenate, the core 402 is adhered to the frame 427 of the terminal array. The coil is then terminated to the terminal 429, for example using a soldering process that is wound into a recess formed in the end of the terminal (step 1〇2〇). The assembled inductive component 400 is then optionally inspected through step 1022 to complete the manufacturing process. Referring now to Figure lb, a method for fabricating the improved drum apparatus of Figures 5 and 6 is described, for simplicity. See, in particular, the single-wire axis anger of Figure 5. In the first step 1 052 of the method 10000, the drum core is obtained or fabricated. The core 502 of the exemplary apparatus of Figure 5 is preferably familiar from many uses. The process 'is formed, for example, in material preparation, pressing, and sintered magnetically permeable materials. The production has a core 5 02 including magnetic flux characteristics, cross-sectional shape and specific properties of area, height and column diameter, since it is already in the art. And therefore not further described here. & T to 'after step 丨〇 5 4, in order to protect the coil from damage or wear' may optionally use a layer of alloy insulation (such as parylene) on some or all surfaces The base or other material covers the core 502. Next 'wrap the core with the desired wire shape through step 1 056. Such a wire shape may comprise, for example, a wire wound concentrically around the core in a substantially helical twist pattern. The shaft area, however, other types of wires (insulation or other) and winding modes can be used. Next, terminal 529 is provided or constructed via step 1058. As previously indicated, terminal 42 9 can include desired characteristics, such as in their The recess and substrate contact attenuator on the bottom end for winding. The construction of such terminals is well known in the electronics arts and is therefore not further described herein. Next, the terminal 529 is embedded or soldered to the harness core 502 via step 1060. For example, in an exemplary embodiment, terminal 529 is adhered to a groove 535 of g 502 with a drop or a suitable binder such as epoxy resin. During the step 1060, the coils are terminated in the slot 535 and under the terminal 529 by routing their free ends, thereby forming an electrical connection therewith. In addition or as an alternative, other methods such as routing and soldering (consistent with the selected terminal architecture) may be used. Next, through step 1062, one or more controlled saturation elements 508 are constructed. In the exemplary embodiment of Figure 5, element 508 comprises a Ni-Fe strip. 35 1278877 This tape is manufactured by first forming a Ni_Fe alloy sheet of the desired thickness (step 1 064). After step 1 to 66, one side of the sheet is subsequently impregnated with a suitable labile binder (or alternatively an epoxy resin based binder) and the sheet is passed through step 1 068 using a cutter. Cut into strips of the appropriate size. Next, in step 1070, one or more strips 5 0 8 obtained from step 1062 above are secured to the core 5 〇 2 along the longitudinal direction of its axis for bridging between the two terminal elements 502a, 502b. Void. Such connections may be made by automated means (e.g., suitable for placing component 508 accurately onto the core 502 machine), or by hand. The assembled inductive component 500 is then optionally tested via step 1072 to complete the manufacturing process. Alternatively, in an embodiment of a core device using a Ni-Fe continuous belt or similar alloy, the foregoing process may be practiced so that a suitably sized belt can be cut and applied to the core 502. Then apply a heat shrink sleeve or pipe (if used) at least to the peripheral region of the end flange of the core 'covering the controlled saturation band 5 0 8 ' and then exposing it to heat enough to shrink the sleeve tight band 5 08 Bonded to the drum core flange. Referring now to Figures 11 and 11a, another embodiment of a controlled inductive element in accordance with the present invention is disclosed. In the embodiment of Figures 11 and 11a, the device 1 100 basically comprises a "drum, a magnetic core element 11 02 and a double-stranded coil 1 1 〇 4 of the type known in the field of electronic components, with the coil placed ( Wound to the central part of the latter 1 1 06 around the core element 1 1 02. From the upper core flange 1 1 1 0 diameter difference 36 1278877 (here means less than) the base part flange 1 η 2 diameter position It is seen that the core element of the illustrated embodiment is substantially asymmetrical. In this embodiment, the upper flange 1110 has a diameter of approximately 0.256 inches (6.52 mm). However, the lower flange 1112, inside the lip 1124, has a diameter. Approximately 0.346 inches (8·79 mm), however, other values may be selected. The core element 1 1 02 in this embodiment is composed of a ferrite material, however, it should be recognized that other materials (ΜΝ-Ζη, etc.) may be used. A plurality of apertures 1 1 10 or holes are also formed in the substrate flange to allow routing of the double-stranded inductor outside the inner volume of the device 11 00 for final bonding (eg, soldering) to the core element 1 1 02 substrate Inductor terminal 1119. Inductor terminal 1119 is soldered into Formed in a recess below the substrate flange 1112 (not shown), such as with a binder (e.g., an oxidized magnet binder) or a perfusion mixture. As will be appreciated and implemented by those skilled in the art, it can also be used for Other architectures of these terminals. Routing the leads outside the inner volume makes the device easier to manufacture, however it should also be recognized that other architectures (including terminations within the inner volume of device 1100) may be used if desired in accordance with the present invention. A cylindrical cap (screen) element 1120 is placed substantially adjacent the majority of the coil 1104 and the core member 11A2, the size of the custom cap ι12〇 being the same as the lip or edge formed on the upper surface of the substrate portion flange 1112. 1124 is matched. Therefore, the cap 2丨丨 actually depends on the lip of the flange 丨丨j 2 when the two elements are combined. In the illustrated embodiment the beveled cap matches the inner edge 1 of the face 丨丨27 1 23 so as to form a tapered slit near the periphery of the substrate flange ' 2 ' However, such chamfering is not necessary in the practice of the invention. 37 1278877 In terms of the protective layer, the cap 1120 Further great benefits are provided, such as 'protecting the external electronic components closest to device 1 00 from EMI generated within device 11 00 during operation. The effect of this protective layer effect is mostly from being guided or forced by cap 1120 A void within the inner volume of the cap. In the illustrated embodiment, the cap is approximately 0.067 inches (1.7 mm) thick, although other thickness values may be used. Cap 1 1 2 0 is ultimately attached to the substrate flange 1 1 1 2 Above, for example, using a bonding agent or even soldering. However, before the cap 1 1 2 〇 is bonded to the core element 1 102, the conscious inductive element 1130 is placed between the cap 1120 and the substrate of the core element 1102 so that The two elements at at least two different positions on the periphery of the base flange i 丨丨 2 "clamp" the controlled inductance element 丨丨 3 〇; that is, within the aforementioned tapered gap. In the illustrated embodiment, the controlled inductive component 1130 comprises a ruthenium (Ni) alloy ribbon having a predetermined thickness (e.g., within 5 inches of the range of 〇 〇〇 〇 然而), although other values may be used. However, it should also be recognized that JN||IW ____ can be combined with bandwidth and strip thickness to provide the desired electrical and inductive characteristics for the device. The width of the band i 丨 30 is also controlled to a desired value (here, about 5 · 〇 8 nm (0.2 〇〇 inches)). As will be appreciated, the increased width and/or thickness of the saturation increases the current carrying capacitance with 丨丨3 。. Moreover, the band 1130 may have a width X or thickness that is not uniform or varied as a function of the length of the 匕 as shown in the lib diagram. Such a type can provide the desired advantages in the motor/saturation characteristics of the belt because, for example, a thirst current or surface effect generated within the material. It may also contain a plurality of smaller 38 1278877 with 1 1 3 Oa, 1 1 3 Ob, for example as shown in Figure 1 1 c. It can be used in conjunction with the present invention to provide a number of different architecture controlled inductors (whether "banded" or otherwise). However, the assignee of the present application has found that the single uniform strip shown in the embodiment of Figure 11 provides the best combination of desired characteristics, that is, low cost, good electrical performance, and ease of manufacture ( Both the belt and the device as a whole), especially due to the belt.

During manufacture, the belt 1 1 30 is placed symmetrically on top of the upper flange 1 1 1 0 of the core element (and as required) so that it hangs down along one side of the central portion of the core element to at least the flange 1 of the substrate 1 1 2 level. Alternatively, a drop of eucalyptus or a binder may be used to secure the position of the belt 1 1 3 0 relative to the core member 1 102. Thus, when the cap member 1 120 is placed over the top of the core 1 102, the sagging portions of the strap 1130 are partially captured at their ends between the inner edge of the cap 1120 and the base flange 1 1 12, whereby the cap 1 120 Tension can be applied to the belt 1 130 as it slides into its final stop position. In order to facilitate the easy matching of the flange 1 1 1 2 and the cap 1 1 2 0 at the time of assembly, it may optionally be at the end portion of the belt 1130

Place two sets of bends 11 80. In another alternative embodiment, the inductive element 1 130 can be preformed and glued or otherwise placed within the cover or cap 1120 so that it can be properly placed when the cap 11 20 is placed on the core element 1 102 Place. It will be appreciated that the inductive component 1100 of Figure 11 can have a variety of different uses including, for example, providing a boosted inductance and reduced cancellation frequency in the tuned portion of the elliptical filter previously described. Such performance allows the improved device 1100 to comply with more stringent or demanding regulations that are not compliant with the prior art (at least in the same level of performance, simplicity, and low cost provided by the present invention), such as the foregoing. ET SI TS 9 5 2 -1 - 5 standard. Referring now to Fig. 12, an exemplary embodiment of a method of manufacturing the device 11 of Fig. 11 is described. As shown in Fig. 2, the method 200 includes a core element 1 1〇2 and a cap 1 120 (step 1202) which are first provided, both of which are composed of the same (or similar) magnetically permeable material such as an oxidized magnet. The construction of these types of elements is well known and will not be further described. As part of the construction process, as previously discussed, two or more apertures 1 1 1 7 are formed in the substrate flange 1112 and four recesses are used for the terminal 1 1 1 9 . Next, at step 1204, a conductive termination 1119 is provided and placed within the aforementioned recess. They can be joined by friction, bonded with epoxy resin or colloid, or bonded to the core member if mechanical rigidity is desired. Next, in step 1206, the (double strand) coil is wound in a layered pattern near the central portion of the core element 1 102 to a desired depth/length. As part of this step, any insulating material outside the free ends of the coils is stripped to facilitate subsequent termination of the coils to their respective terminals 1119. The free ends of the coils (stripped) are then routed through the apertures and down to the terminal 1 1 19 where they are electrically terminated (step 1208). Such terminations may include soldering, epoxy resin bonding, routing, soldering or the like, or any combination thereof. Next, via step 1210, an inductive component (band) 1130 40 1278877 is provided and formed on the upper flange 1110 of the core component 1102 so that the tip is tilted along the longitudinal direction of the core. As with the selective use of a binder or a sulphate, the next cap 1120 is assembled to the device I1 00 to engage the substrate flange 1112, as previously described, which is actually "stayed" in the formation of these components. The length of the gap is at the end of the two elements 1120 '1112. If it is desired to assist the position of the fixing element such as the use of the so-called "oxidized magnet binder" glue '1 1 0 2, however, other techniques may be used instead of the 'example to design the element so that the frictional engagement is sufficient to bring the element to the end, After step 12, the end of the side wall 1130 of the cap is used. If you need 'the device can also be 3 steps 1216). With a gap torus, reference is now made to Figures 1 3 - 1 4b to reveal the changes. Figure 1 3 shows the first picture with a gap torus. In this embodiment, the device 1 300 is typically oscillated 1 302. The gap 1 304 extends from the outer radius up to the inner radius'. However, it should be recognized that for the duration of the supply, it is possible to use the position of the band 1130 as discussed above, either in whole or in part, as shown in Figure 11 for some applications. On the page portion, and the remaining portion of the strip on the slit of the slide (step 1212) ^ captures the strip 1130, and the cap can also be exemplified or bonded to the core member as if it were sufficiently tightly held 1 120, 1102 In the effective rinsing to trim the belt β for the detection (the top of the embodiment of the torus with gaps is applied to the top portion of the through-core 1 302 having a torus shape [magnetic and/or electrical gap. The inductance of the toroidal element 41 1278877 is varied as a function of the load current. One or more of the circumference of the core 1 3 02 from the first side of the gap is approximately 30 degrees and the second side of the gap is approximately 30 degrees. Conductive coils 1313, however, it is also appreciated that other angular relationships (whether symmetrical or asymmetrical to the gap) may be used. The coils are evenly distributed around the circumference of the core with a roughly 300 degree circumference, however, in order to provide varying characteristics in the device It is also possible to utilize a non-uniform coil space (density). In an exemplary embodiment, the coil consists of a so-called "magnetic wire" of the type well known in the electronics field; both because of its relatively low cost This type of wire is used for excellent electrical and mechanical properties. To allow termination of the external device coil lead 1 306 to extend out of the core. Referring now to Figure 4, a first embodiment of a gapped toroidal device 13 is shown. A cross-sectional view (where the gap region is slightly enlarged to show the details more clearly). Placed within the gap 1 3 04 is a magnetically permeable element 1 308 that extends at least partially into the intervening β 1 3 04. The elements 13 〇 8 can be controlled. The depth is to provide the desired magnetic and electrical properties; in the illustrated embodiment, the depth at which the top of the element 1 308 is rapidly extended by approximately 8 inches on the torus core edge is used.

The permeable member 1308 is composed of a permalloy J or a belt which is generally selected to be slightly larger than the core (see Fig. 14a), and is also larger (maximum) in the embodiment of the present invention. Roughly, it is 0.06 inches wide. Virtual ##, see that you can also choose other materials that have the appropriate electrical and magnetic properties of the model known in the field (or in combination with the permalloy described here).

As shown in the bimetallic or layered composite I, not shown). Such seals may include, for example, nickel, copper-nickel-nickel-iron alloy, or any other metal or conductive material that is magnetically permeable. It should also be appreciated that while Figure 4 shows a "U-shaped, cross-section of magnetically permeable elements 13 〇 8 , element 1 308 may also be composed of other cross-sectional shapes, such as "V-type" (see Figure 14b) or even It is a V-shaped cut-off tip (Fig. l4c). This architecture provides a magnetic "bridge" through the core gap, in one embodiment, an epoxy resin 13 12 that is simultaneously dispensed on the outer radius surface of the core element and the side of the element attached to the outer radius surface. The element 1 308 is attached to the core element. Other methods may be used to attach the element 1 3 0 8 to the core element 1 3 02, and are not limited to other adhesives, raised surface features, or frictional contacts. The insulating spacer 1310 separates the inner side of the magnetically permeable element 1 308. In one embodiment, the spacer 13 10 includes a MylarTM component, however it will be appreciated that other insulating materials (polymer or other) may be envisioned. And not limited to polymethylamine (KaptonTM), fluoropolymer (eg, TefzelTM), ceramic and even powder-impregnated tape or kraft paper and combinations thereof. Gasket 1310 avoids shortening of magnetically permeable element 1308 This will additionally greatly reduce the ability of the unstable gap annulus to maintain high inductance at low currents and low inductance at high currents. In addition to separating the inside of the magnetically permeable elements 13〇8, the spacer 13 10 ensures In The physical contact between the element 1308 and the adjacent spacers. In one embodiment, friction is used, however other spacers such as adhesive bonding may be used to attach the spacer 13 1 to the element 1 3 0 8 . Referring now to Figure 15, a method of making the gaps of Figures 13 and 14 is described. As shown in Figure 15, the generalized method 1500 includes first providing a seamless annulus of the type described herein ( Step 1 5 02 ). It should be noted that 43 1278877 · 疋 can be pre-benched around the core, or alternatively, after the method described herein is wound. Next, the water 'passes through step 1 504, according to the desired size To construct a torus with a gap (the soil, 4 optionally, the conventional gap within the torus is configured to the desired size). This can be done by using any number of well-known mechanical techniques^ To g $ . Optionally, it should be understood that during the manufacturing process it is possible to use the desired % of the gap to form the annulus, thereby removing the separation, subsequent machining or gap composition steps. In selecting the appropriate material (for example, slope Mo alloy Permalloy)) may be used in the core after iS i 13 10, in order to meet (when assembled) 15〇4 gap formed in step, after the step 1506 of these objects and the insulating member 1308 configurations few

Cause the desired shape and size. At least a portion of the permalloy element 1308 is in direct physical contact with each of the inner (side) surfaces of the gap, thereby permitting the formation of a permeable material from one side of the gap to the other side of the gap.

Conduction path. The correct selection of the thickness of the elements 13 〇 8 (e.g., always 0.0005 inches in the illustrated embodiment) and the thickness/shape of the insulating member 13 10 facilitate the implementation of this requirement, although such connections can be achieved by other methods as well. Next, the permeable element 1 308 and the insulating member 13 10 are embedded into the gap (step 1 508) to a desired depth, and the epoxy resin 1 3 1 2 is bonded at the appropriate position. It should be understood that although the 14th figure only shows that the enamel tree S is placed around the periphery of the gap 1 3 〇4, it is possible to use the ring in order to tightly fix different components at the relative positions of each other. Oxygenate or sealant covers the entire gap/machining element/insulation element or any part thereof. 44 1278877 Referring now to Figures 16 and 16a, another embodiment of the gap annulus device of the present invention is described. In this embodiment, the permalloy strip 16 〇 2 placed closest to the gap 1 604 opposite the insert element of Figure 13 is used to traverse the core gap of the device 1 600. In the illustrated embodiment, to produce an overall inductance of 8 4 mI1, approximately 6 thousand points are selected (and other values (and gap architecture) can be used without doubt, just exemplified below.

In its most basic architecture, the device 16A includes a permalloy ribbon 丨6〇2 that directly matches the core material on the opposite side of the gap, thereby maintaining the conduction path between the two sides by the band 1 602. . In a variant (i<Fig.), the strip is only bonded or lapped to the peripheral region of the core closest to the gap. The assembled core and tape can be covered if desired (using, for example, eucalyptus vinegar or parylene sealant and wound. Alternatively, the core can be pre-bonded and the strip 1602 can be added after Ik (and if covered).

In another variation of the device 1650 (...circle)', a short cylinder or portion of unwound and gapped core 1654 having a permalloy strip 4652 and a heat shrink tubing is used. The shrinkage of the poly-smoke exposure is used in the illustrated embodiment, however it will be appreciated that other materials and material architectures can be used. For example, 'can use other materials that are sensitive or responsive to other types of exposure (eg, UV or electromagnetic or specific radiation, such as Μ 'chemicals, etc.), In the illustrated embodiment, the thin, transmissive sized portion is divided into positive and negative grooves by a roll of the cross-belt and wound around the periphery # / portion of each side of the gap. Optionally, a strip-shaped drum having a thickness of 'eight' is allowed, from the quantity "putting the strip in the heat-shrinkable cylinder (10), 45 1278877 and embedding the core so that the gap of the core is directly Consistent with the permalloy strip 1 652. The assembly is then heated to the correct temperature (or otherwise caused to shrink around the core 1654). Just as the shrink material shrinks, it is tightly held against the periphery of the core by the strip 1652 The edge is pressed into the gap region, thereby completing the ''bridge'' through the gap and permanently securing the strip at the proper location of the core. The assembly is then wound.

In another embodiment (not shown), a permalloy (or other) is attached to the core and spans the gap for electrical/magnetic coupling thereto, such as by using a micro-adhesive on top of the mating joint. (or alternatively some other device that secures it in place, such as an edge band). The entire assembly is then tilted, atomized, or vacuum/vaporized to cover the polymer, such as a deposit of parylene. This cover actually ''condenses' the band in place and provides a means for the device coil to wrap around. U.S. Patent Application Serial No.

09/661, 628 (now U.S. Patent No. 6,642,847, issued on Sep. 13, 2000), entitled "Advanced Electronic Microminiature Coil And Method Of Manufacturing," An exemplary method of a face device. Referring now to Figures 17a-17d, other embodiments of the improved inductive component of the present invention are disclosed. In general, in order to provide the desired inductive characteristics and saturation control, each of these embodiments utilizes a gapped core (e.g., an annulus) that incorporates an external control element paired with the core. Other desirable characteristics of these embodiments are related to cost and ease of manufacture; as discussed in detail in paragraph 46 1278877 below, in order to create an inductive component, the external control component can comprise a low cost pre-fabricated component, such as simply lapped to the core, and used One or more coil wound gaskets. As shown in Figures 17a-17b, the first embodiment of the aforementioned device 17A includes a gap annulus core 7〇1 of the type previously described herein. The illustrated core 170 has a somewhat rectangular cross section (see Figure 17b), however it should be understood that any cross-sectional shape that is accurate consistent with the present invention can be used. The controlled saturation element 1703 is matched to the core 1701 using a binder or other binder, such as an epoxy resin, an acrylate binder, a bismuth organic resin, or even a melting (welding or welding) process. Alternatively, element 17〇3 can be mechanically lapped onto the core (eg, through rivets, posts, friction fits, splints, or other fixture devices). However, these latter solutions often add cost and device manufacturing processes. the complexity. As another alternative, the jaws 1703 can only be positioned in a desired position and orientation closest to the core, and in order to fix the relative positions of the components, the entire assembly (core 7 和 and element 1 7 0 3 ) It is then overcoated or overmolded (for example with eucalyptus or a paraxyl based sealant or other material). However, even other methods are possible, so the foregoing description is merely exemplary. In the embodiment of Figures 17a-17b, element 17〇3 contains a standard metal "flat", gasket, which is ubiquitous in the mechanical field. The gasket 17〇3 has a central aperture 17〇4 that facilitates winding of the coil 1702 (whether By hand or by automatic means such gaskets are usually made of different percentages of metal alloys depending on their mechanical requirements and appear in excess of different shapes and sizes, and 47 1278877 and thus exhibit an important property; that is, diameter, thickness Commercial availability of aperture size, material, etc. at low cost and wide alignment. Therefore, the manufacturer of the inductive component 1700 can only experimentally find the desired size, shape, etc. of the gasket for the desired application, and then at a low cost. They are commercially available. Alternatively, the gasket can be composed of the same material as the core 1 701, for example through a transverse cutting core to produce a series of stacked "washers." Source of gasket element 1 703. As can be appreciated, the thickness (and other physical parameters of the smaller extent of the gasket 1 703) determines The saturation characteristic of the core 1 701, however, the outstanding permeability contributes to its inductive performance. In particular, the illustrated embodiment of the present application has a variation from about lk to l〇k Henrys per meter (H/m). Permeability. The higher the permeability of component 1 0 3 3 , the greater the difference between the values of no current (eg standby) and operating current (eg when used). For example, the thickness of the gasket selected 1705 is approximately washer 1703 and The total thickness of the toroidal core 1701 is 20%; this ratio can be varied to adjust the saturation rate as the current through the device 1700 increases. The thicker the gasket, the greater the current required to saturate the device. A thickness of 1 705 varies from 5% to 4% for a specific thickness (core plus gasket) for any particular application. It should also be understood that the thickness, shape (including width) of element 1 703, or Even material mixtures need not be uniform, but can vary with the particular properties or characteristics desired to be obtained. For example, in one variation, multiple layers of gasket arrangements (not shown) can be used, where to provide delamination with respect to the core Magnetic flux The pattern varies in thickness and/or permeability on one side of the core 1 710. 1 1278877 Rain or multiple gaskets are actually clamped together. As another alternative, in the radial and/or axis of the element Different types of gasket 1703 thickness and/or permeability can be made in position, for example, the remainder of the different thicknesses and/or permeability of the element 1703 constitutes the "embedded" portion of the gasket 171, and this embedded portion is disposed at Where is the inner gap of the core. Therefore, if desired, element 1 703 can be fabricated to provide the desired characteristics and performance. In terms of manufacturing, the first 7 a-1 7b is manufactured by first providing a gapped core of the type previously described. An exemplary device of the figure 1 7 〇〇. One or more components 1 703 (e.g., gaskets) are selected and then joined to one or both sides of the core using a bonding agent, a lap process, or other mechanical means (see discussion of Figure l7d below). If desired, these two components can also remain unconnected until the outer mold. Next, if desired, a plurality of standard process outer mold core and gasket elements including dip coating, spray, vacuum/vaporization deposition, and the like. This step creates an (insulating) overlay on the component, which is finally wound on top of the component. Figure 17c is a cross-sectional view of another embodiment of device 1710 showing the use of a curved (hemispherical) gasket element 1713 and a complementary core 17U. In this embodiment, the curvature of the washer member 丨7丨3 is selected to be close to the curvature of the core 7丨i portion, at least on its inner surface. This embodiment is useful when using a cross section with more circles (and fewer rectangles). In a variant, in order to avoid the conventional machining that has to provide a flat washer, the well-known Belleville ring is applied; that is, the assembler only selects the Belleville washer of the pre-49 1278877 and The core is attached using, for example, a binder 17 16 as previously described. As in the embodiment of Figures 17a-17b, the assembly can be overmolded if desired and finally wound with a desired number and number of coils 1 71. As described in the previous embodiment, the gasket,][7丨3 thickness 1 7 1 5 also affects the saturation and inductance characteristics of the device 1 7 10 ; however, the magnetoelasticity is slightly different due to the curvature of the ring of. Figure 17d is a perspective view of another embodiment of an inductive component 1720 in which two planar control elements 1 723^1 7231 are distributed on opposite sides of the toroidal core P21. As can be appreciated, such an architecture having a core of any shape can be used (including, for example, the anger 17 1 1 and the circular element 1713 of Fig. 17c). The two elements 1 723 may be identical in physical properties (size, thickness, permeability, etc.) or alternatively may be similar in one or more characteristics in order to introduce asymmetry into the magnetic flux pattern of the device. For example, it is desirable to saturate the first portion of the first element 1723a and/or the core 1721 prior to the increase in current compared to the other portion; in this case, a thinner washer 1 723a may be used as the first element 1723a, A relatively thick washer is used as the second element l 723b. Consistent with the arrangement of Figure 17d, many other such variations can be used (including those previously described for the single gasket embodiment of Figures 17a-17b). As another alternative, springs of the type known in the mechanical arts are used. The gasket is as shown in Figure 1. The full circle of the spring is essentially non-planar but has no gaps. Therefore, the height variation of the gasket surface is a function of the polar axis angle. Therefore, when placed closest to the core, the spring washer provides a series of intermittent contact points 173 7 between the washer 1733 50 1278877 and the core 1 73 1 . Then in a substantially continuous mode, or alternatively in an isolated mode (eg, consistent with the aforementioned contact point 1 737, where the highest density coil occurs in the "hole" 1 738 of the washer 1 73 3) in the core and A coil is wound on the gasket (not shown). It should also be understood that, in accordance with the foregoing embodiments, a planar gap or a split gasket may be used. The gap can be placed closest to the gap in the core or, alternatively, at another pole angle away from the gap.

Furthermore, non-planar split gaps may be used in certain applications where there is a difference in height between the gasket material on the first side of the gasket gap and the gasket material on the other side, as is well known in the mechanical arts. . Thus, when such a gasket is placed on one side of the core, it presents an uneven surface, thus causing a gradient in the magnetic flux pattern as a function of the polar axis angle on the device. The coil is only selectively wound on certain areas and even wound in certain areas under the gasket (that is, the gasket plane is not adjacent to the face of the core).

In another embodiment (Fig. 1f), one or more washers or gasket-like structures are used between the portions of the toroidal core. In the exemplary embodiment of Figure 1 7f, the core 1 75 50 contains two core portions 1 7 5 1,1 7 5 2 . In the illustrated embodiment, the core portion includes half of the entire core 1750, although other relationships may be used, such as here, the two portions are integral unequal segments. The gasket 1 753 contains a high permeability ferrite gasket and is placed substantially between the two portions 1751, 1752. However, other materials having suitable permeability and physical properties can be used in place of the ferrite. 51 1278877 In order to provide the desired degree of magnetic coupling, the inner and/or outer diameter of the washer 1753 and/or the core portion 1 7 5 1,1 7 5 2 may be adjusted. Moreover, the magnetic properties of the device can be varied, for example, by using multiple washers 1 753 in a stacked configuration. In such an architecture, the turns are similar (that is, the same model, size, permeability, and material), or alternatively can be of a different type, such as thickness, permeability, or material. Moreover, the material filling the gap is inserted between the two separate gaskets 753 or between the gasket surface and the core portion to control the magnetic characteristics of these gaps. Bands and/or binders may be used to secure the spatial relationship between the different elements'. An outer sealant of the type well known in the electronics art may be used. However, because of its mechanical strength, it is generally preferred to use a binder. Furthermore, it should be understood that, optionally, a crack can be created for the device of the 1st 7f', as shown in the figure i i ff, one or two of the two core portions 1 7 5 1 ' 1 7 5 2 A gap is formed in both. Although it is possible to form a gap after or after the core 丨 7 5 〇 is cut, it is most easily formed before the single core is formed into two core members 1 7 5 1,1 7 5 2 . Since the core portions are actually free from each other, the portions can be rotated for each other (and due to their gaps), and thus there can be gap offsets between each other if necessary. Alternatively, in order to obtain desired magnetic/electrical properties, a gap may be formed in the gasket member 1 7 5 3 if necessary. Through the given current disclosure, those skilled in the art will recognize many different combinations of gap and gap arrangements. It will be appreciated that while certain aspects of the invention have been described in terms of specific sequential steps of a method, these descriptions are merely exemplary of the broad method of the invention, and may not necessarily be used or used in accordance with certain steps in the context. The requirements are modified. It is optionally implemented in some loops. In addition, some of the steps or functions may be performed in multiple steps, or in the disclosed embodiments, or the two sequences of execution may be changed. All such variations are considered to be included within the scope of the present invention as disclosed and claimed herein, as applied to the various embodiments of the invention. Should understand,

Numerous omissions, substitutions, and changes may be made in the form and the details of the embodiments of the present invention without departing from the invention. The foregoing description is the best mode of carrying out the presently contemplated invention. This description is in no way meant to be limiting, but rather as an illustration of the general principles of the invention. The scope of the present invention should be determined with reference to the scope of the patent application. BRIEF DESCRIPTION OF THE DRAWINGS The features and advantages of the present invention will become more apparent in the detailed description of the drawings and the foregoing description. A block diagram of a technical DSL, including a microfilter installed on a multi-telephone extension of the prior art. Fig. 1 is a schematic diagram of a conventional DSL microfilter shown in Fig. 1. Figure 2a is a diagram of the core current characteristics of a conventional fixed-inductance device ("Inductance of Inductance Characteristics. 53 1278877 Figure 2b is a typical variable inductance (linear and "moderate step,") A graphical representation of the inductive characteristics of the device. 'Figure 3 is a top plan view of an exemplary conventional inductive component (Coilcraft) with variable inductance characteristics. Figure 4 is a pot shape with controlled saturation improved in accordance with the present invention. A perspective view of a first embodiment of a core inductive component. Figure 4a is a side plan view of the inductive component of Figure 4 along line 4-4. Figure 4b is the bottom of the first core component of the inductive component of Figure 4. The top view shows the gap of the variable body. Fig. 4c is a schematic diagram of the dc current of an inductor to the inductance element of Fig. 4. Fig. 4d-4f shows the variable body gap of the inductor element of the present invention. Another alternative embodiment 'shows the use of a three-layer gap; (ii) a concentric double-layer gap; and (丨丨1) intermittent concentric double-layer gaps, respectively.

Figure 5 is a perspective view of a first embodiment of an improved drum core sensing element (single coil) having controlled saturation in accordance with the present invention. Figure 5a is a perspective view of a first alternative embodiment of a drum core assembly having a plurality of controlled saturation elements of the present invention. Figure 5b is a cross-sectional view of a second alternative embodiment of the drum apparatus of the present invention having a sheet for controlled continuous saturation of substantially saturated elements. Fig. 5c is a perspective view of a third alternative embodiment of the drum core unit having an L-type terminal attached to the drum core of the present invention. Figure 6 is a perspective view of a first embodiment of an improved drum core inductor 54 1278877 component (multi-coil) having controlled saturation in accordance with the present invention. Fig. 7 is a schematic view showing a filter circuit of a first embodiment using the improved inductance element of the present invention. Fig. 8 is a schematic view showing a filter circuit of a second embodiment of the double-coil drum core device of Fig. 6 using the improved inductance element of the present invention. Figure 9 is a schematic diagram of the filter circuit of Figure 8, including a selective third-order filter.

Figure 10a is a logic flow diagram illustrating an exemplary method of fabricating a can core inductive component of Figures 4-4f. Figure 10b is a logic flow diagram illustrating the fabrication of the drum core inductive components of Figures 5-6. Figure 11 is a top perspective, partially exploded view of a first exemplary embodiment of a controlled inductive component in accordance with the present invention. Figure 11a is a side cross-sectional exploded view of the device of Figure 11.

Figure 1 1b is a top plan view of another embodiment of the controlled inductive component of the present invention showing variable strip width. Figure 11c is an exploded perspective view of another embodiment of a controlled inductive component having a plurality of inductive components. Fig. 12 is a logic flow chart illustrating an exemplary embodiment of the apparatus manufacturing method of Fig. 11. Figure 13 is a top elevational view of an embodiment of the annulus of the present invention. Figure 14 is a cross-sectional view (without coils) of the exemplary torus gap of Figure 13, showing the gaps therein and the components placed therein. 55 1278877 Figure 14a is a side plan view of the torus gap device of Figure 14. Figure 14b is a cross-sectional view of a second exemplary embodiment of a torus gap (without coils) in which a "V" shaped gap is used. Figure 14c is a cross-sectional view of a third exemplary embodiment of a torus gap (without coils) in which a "V" shaped gap with a top end cut away is used. Figure 15 is a logic flow diagram illustrating an exemplary embodiment of the method of fabricating the device of Figures 13-14c.

Figure 16 is a side cross-sectional view showing another embodiment of the toroidal gap device of the present invention. Figure 16a is a side cross-sectional view of another embodiment of the toroidal gap device of the present invention in which a heat shrink coating is used. Figure 17a is a perspective cross-sectional view of another embodiment of the present invention in which a planar loop control element is used to connect to the toroidal gap core. Figure 17b is a cross-sectional view of the device of Figure 17a along line 17a-17a showing the architecture therein.

Figure 17c is a cross-sectional view of another embodiment of the apparatus showing the use of a curved (hemispherical) gasket and a complementary core. Figure 17d is a cross-sectional view of another embodiment of the present invention in which two planar control elements are placed on opposite faces of the annulus. Figure 17E is a perspective exploded view of another embodiment of the present invention in which a non-planar control element is used to connect to the toroidal gap core. Figure 17F is a top perspective exploded view of another embodiment of the present invention. 56 1278877 [Explanation of main component symbols] 102 Inductance characteristics 106 Basic linear mode 108 Moderate ladder 300 Device 304 Base 306 Column 308 Center block 310 Aperture 400 Inductive component 402 Can 406 Column 408 Slot 409 Aperture 410 Device 413 Conductive coil 425 Terminal 416 Region 418 Region 427 Non-inductive Matrix Architecture 429 Face Terminal 450 Inductance Characteristics 452 First Port 454 Second Port 456 Third Port 458 Fourth Port 470 Third Region 500 Device 502 Drum Core 504 Center Bobbin Region 506 Terminal Element 508 Element 510 Coil 529 Terminal 535 Aperture 561 Band 563 Heat Shrink Tubing 586 L-Type Terminal 588 Notch 600 Device 602 Double Drum Core 604 Spool Area 608 Center Element 610 Controlled Saturation Element 611 Axis 700 Filter Circuit 702 Input Section

57 1278877 704 Input terminal 706 Inductor 708 Inductor 720 Output section 724 Inductor 726 Inductor 727 Capacitor 728 Capacitor 730 Capacitor 736 Capacitor 740 Side Socket 752 Electronic path 762 Reed switch 764 Reed switch 770 Dual inductor 780 Resistor 782 Resistor 790 Capacitor 791 Shock Capacitor 792 Capacitor 794 Resistor 796 Resistor 800 Circuit 840 Inductance 842 Inductance 866 Input 868 Input 900 Circuit 942 Inductance 966 Input 968 Input 1100 Device 1102 Magnetic Core Element 1104 Double Strand Coil 1112 Flange 1117 Aperture 1119 Terminal 1120 Cap 1123 Inner edge 1124 Lip 1127 Mating surface 1130 Inductive component 1180 Bending 1300 Device 1302 Magnetic core 1304 Clearance 1306 Coil lead 1308 Control element

58 Conductive Coil Permeable Alloy with Permeable Alloy with Heat Shrink Cylindrical Core Controlled Saturation Element Thickness Core Washer Element Adhesive Control Element Washer Core Part Washer 1600 Device 1604 Clearance 1 654 Core 1700 Device 1702 Coil 1704 Aperture 1710 Device 1712 Coil 1715 Thickness 1720 Inductive Element 1731 Core 1 737 Contact Point 1750 Core 1752 Core Section 59

Claims (1)

1278877 Pickup, Patent Application Range: 1 - An inductive component comprising at least: a magnetically permeable core having a gap formed therein; " at least one coil disposed adjacent to the core; and * at least a substantially planar magnetically permeable member disposed adjacent the gap; wherein the at least one permeable member and the core are coupled to provide a desired inductance characteristic as a function of current. 2. The inductive component of claim 1, wherein the at least one magnetically transmissive component comprises at least one metal alloy. 3. The inductive component of claim 1, wherein the coil is disposed at a specified distance from the gap. 4. The inductive component of claim 1, wherein the gap is substantially "V" shaped. 5. The inductive component of claim 1, wherein the inductance characteristic comprises at least an inductance value associated with a first state, the inductance value being substantially greater than an inductance value associated with a second state. 6. The inductive component of claim 5, wherein the component is suitable for use in a telecommunications circuit, and the first state includes at least one "on-hook" current, and the second state At least an "off-hook" current is provided. 7. The inductive component of claim 1, wherein the at least one substantially planar component is placed such that a vector perpendicular to the plane of the component is substantially Parallel to the central axis of the core. The inductive component of claim 7, wherein the at least one substantially planar component comprises at least one flat and substantially annular gasket. 9. The inductive component of claim 1, wherein the at least one substantially planar component comprises at least one substantially annular gasket having a curved inner surface and the inner surface is disposed on at least one side of the core The proximity of the place. The inductive component of claim 9, wherein the substantially annular loop comprises at least one Belleville washer. The inductive component of claim 1, wherein the at least one substantially planar magnetically transmissive component comprises at least two components disposed adjacent to the gap and respective opposing faces of the core component. The inductive component of claim 1, wherein each of the two substantially planar components comprises at least one flat and substantially annular gasket, the gaskets being in each other in at least one aspect Not the same. 13. The inductive component of claim 12, wherein the at least one aspect comprises a thickness. The inductive component of claim 12, wherein the at least one aspect comprises a magnetic permeability. The inductive component of claim 1, wherein the substantially planar component comprises a multilayer device having at least first and second layers, the first layer having at least one property different from the second layer. 16. A method of making a controlled inductive component, comprising the steps of: providing a magnetically permeable toroidal core having a gap extending through at least a portion thereof; placing a magnetically transmissive component in the gap and the core Adjacent; and a plurality of conductive turns surrounding the core and the element Pieces. 17. The method of claim 16, wherein the placing action to 62 1278877 comprises the following steps: placing a bonding agent on at least one of the following (i) one side of the core (ii) one of the elements a mating surface; and placing the permeable element adjacent the core such that the bonding agent can bond the element to the core. 18. The method of claim 17, further comprising sealing at least a portion of the core within the polymer prior to the surrounding action. The method of claim 18, further comprising sealing at least a portion of the component within the polymer prior to the wrapping action. 20. The method of claim 16, further comprising placing a second magnetically permeable element adjacent the gap and the core, the action surrounding the plurality of turns also surrounding the second component At least part. 21. An inductive component suitable for use in a telecommunications circuit, the component having a controlled inductance characteristic comprising at least: a magnetically transparent toroidal core having a gap formed therein; at least one magnetically transmissive component adapted for magnetically bridging the At least a portion of the gap; and at least one coil wound around the core and at least one permeable member; wherein the inductance characteristic includes an inductance value associated with the "standby" current 63 1278877 substantially greater than the "usage" current Inductance value. The component of claim 21, wherein: the at least one component is formed by a magnetically permeable material and formed by a first predetermined structure; and the gap is formed in a second predetermined structure The first and second predetermined structures and the material cooperate to provide the inductive characteristic. The element of claim 22, wherein the first predetermined frame comprises a substantially annular element and the second predetermined structure comprises a specific gap width and shape. 24. A telecommunications component having: a first port for communicating with an external telephone line; a second port for transmitting a first signal between the first port and a first user element; a third port for transmitting a second signal between the first port and a second user element; and a a filter circuit adapted to selectively block the first signal from being transmitted to the second port, the filter circuit comprising at least one annular core element having an inductive characteristic, the inductive characteristic being at least partially comprised by the at least one toroidal core Depending on the thickness of one of the magnetically permeable elements in the vicinity, 64 1278877 wherein the inductance characteristic includes an inductance value associated with the "standby" current 'which is substantially greater than the inductance value associated with the "in use" current. An inductive component comprising: at least: a magnetically permeable core having a gap formed therein; at least one coil disposed adjacent to the core; and at least one magnetically permeable element disposed adjacent the gap; wherein the at least A permeable element and a core are coupled to provide a current function as a function of current, the inductance characteristic comprising a ratio of the at least _ component 趟 and the time, the ratio being at least partially related to the thick sound of the at least one component. a low-cost inductive component comprising: a magnetically transparent and substantially toroidal core having a gap formed therein; at least one substantially planar gasket disposed adjacent the gap and utilizing a bonding agent and At least one side of the core is mated, the at least one gasket being magnetically permeable and having a selected thickness that at least partially determines a saturation rate during a change in current between standby and use states; and wherein At least one permeable element and core are mated to provide a desired inductance characteristic as a function of the current. An inductive component comprising: a magnetically permeable core having a / gap formed therein, the core having a 65 1278877 cross section at least partially rounded at its periphery adjacent to at least a first side of the core At least one magnetically transmissive element disposed adjacent the first face and the gap, the element having an inner surface having at least one curved region adapted to cooperate with at least a portion of the periphery of the core Providing a closed coupling between them; and a plurality of coil turns surrounding the core and at least a portion of the component The at least one permeable element and the core are coupled to provide a desired inductance characteristic as a function of current. 28. An inductive component comprising: a magnetically permeable core comprising first and second substantially separate core portions; At least one magnetically transmissive element at least partially disposed between the first and second core portions; wherein the at least one permeable element and the core are mated to provide a desired inductance characteristic as a function of current. 29. The element of claim 28, wherein the core is substantially annular in shape and the first and second portions comprise a plurality of intersecting the core parallel to the major face of the core The part defined by the face. The element of claim 29, wherein the at least one gasket-like ring-shaped member is disposed substantially between the first and second portions. 3. The component of claim 30, wherein at least one of the core-like gasket elements comprises a gap formed in a substantially radial diameter. The component or direction of a component core 67