Inductive device assemblies and methods

Abstract

Improved form-less electronic apparatus and methods for manufacturing the same. In one exemplary embodiment, the apparatus comprises a shape-core inductive device having a bonded-wire coil which is formed and maintained within the device without resort to a bobbin or other form(er). The absence of the bobbin simplifies the manufacture of the device, reduces its cost, and allows it to be made more compact (or alternatively additional functionality to be disposed therein). One variant utilizes a termination header for mating to a PCB or other assembly, while another totally avoids the use of the header by directly mating to the PCB. Multi-core variants and methods of manufacturing are also disclosed.

What is claimed is: 
     
         1 .- 45 . (canceled) 
     
     
         46 . An electronic assembly, comprising:
 at least three core elements mated to one another, the mated core elements collectively forming a plurality of winding channels, each winding channel having a respective aperture associated therewith;   a plurality of windings, each having a plurality of turns and disposed at least partly within respective ones of the plurality of winding channels, each of the plurality of windings further comprising at least two ends which are routed through their respective aperture; and   a termination element comprising a plurality of electrically conductive terminals associated therewith, the at least two ends of each of the windings being coupled with ones of the terminals.   
     
     
         47 . The assembly of  claim 46 , wherein at least two of the mated core elements are substantially identical to one another and are oriented in a face-to-face fashion. 
     
     
         48 . The assembly of  claim 47 , further comprising a printed circuit board having a signal interface for use with a broadband data connection. 
     
     
         49 . The assembly of  claim 48 , wherein the printed circuit board further comprises an electronic circuit that, in combination with the plurality of windings and the mated core elements, is compliant with a prescribed DSL configuration or service. 
     
     
         50 . The assembly of  claim 49 , wherein the at least three core elements are utilized in conjunction with a single termination element so as to reduce and/or eliminate the spacing or stand-off required between conventional designs that necessitate the use of multiple termination elements. 
     
     
         51 . The assembly of  claim 50 , wherein the at least three core elements are disposed together so as to form an array. 
     
     
         52 . The assembly of  claim 51 , wherein each of the plurality of electrically conductive terminals are in signal communication with the printed circuit board. 
     
     
         53 . An electronic assembly useful in a digital subscriber line (DSL) application, comprising:
 a printed circuit board (PCB) having an inductive device mounted thereon, the inductive device comprising:
 a plurality of core elements that are mated to one another, at least a portion of the plurality of core elements comprising a plurality of winding channels, each of the plurality of winding channels having a post foiled from a magnetically permeable material disposed therein; 
 wherein the plurality of mated core elements also collectively form a plurality of apertures that communicate with respective ones of the winding channels; 
 a plurality of windings, each comprising a plurality of turns and disposed at least partly within one of the winding channels, each winding further comprising at least two ends which are routed through respective ones of the plurality of apertures; and 
 a termination element comprising a plurality of electrically conductive terminals associated therewith. 
   
     
     
         54 . The assembly of  claim 53 , wherein at least two of the mated core elements are substantially identical to one another and are oriented in a face-to-face fashion. 
     
     
         55 . The assembly of  claim 54 , wherein the plurality of mated core elements comprises at least three core elements that are ganged together in an array. 
     
     
         56 . The assembly of  claim 55 , further comprising a printed circuit board having a signal interface for use with a broadband data connection. 
     
     
         57 . The assembly of  claim 56 , wherein the termination element comprises:
 a body having a bottom surface;   wherein the plurality of electrically conductive terminals protrude from the bottom surface, the plurality of electrically conductive terminals being in electrical communication with a plurality of traces disposed on the PCB.   
     
     
         58 . The assembly of  claim 57 , wherein the plurality of core elements are utilized in conjunction with a single termination element so as to reduce and/or eliminate the spacing or stand-off required between conventional designs that necessitate the use of multiple termination elements. 
     
     
         59 . The assembly of  claim 53 , wherein the plurality of core elements are disposed together so as to form an array. 
     
     
         60 . An electronic assembly, comprising:
 at least three core elements mated to one another so as to form a plurality of winding channels, each winding channel comprising a respective aperture associated therewith;   a winding having a plurality of turns and disposed at least partly within at least one of the winding channels; and   a termination element comprising a plurality of electrically conductive terminals associated therewith that protrude from a bottom surface of the termination element, the winding being coupled with at least a portion of the terminals.   
     
     
         61 . The assembly of  claim 60 , wherein the at least three core elements are disposed in a substantially side-by-side fashion that includes a face-to-face mating orientation, and at least one other type of orientation. 
     
     
         62 . The assembly of  claim 61 , further comprising a printed circuit board having an electronic circuit disposed thereon that, in combination with the at least three core elements and the winding, is compliant with a DSL compliant standard or service. 
     
     
         63 . The assembly of  claim 62  wherein the printed circuit board comprises a signal interface for use with a broadband data connection. 
     
     
         64 . The assembly of  claim 63 , wherein the at least three core elements are disposed proximate one another in a common orientation so as to form an array. 
     
     
         65 . The assembly of  claim 64 , wherein the at least three core elements are ganged together in a plurality of formations.