Patent Description:
High-technology devices (such as network routers and/or switches) may necessitate and/or consume large amounts of power. Some conventional high-technology devices may include circuit boards whose power planes and/or layers are unable to carry and/or deliver enough electric current to power certain Application Specific Integrated Circuits (ASICs). Moreover, the increasing performance demands of such high-technology devices may necessitate additional traces throughout the circuit boards to carry and/or deliver certain signals to and from the ASICS.

Further complicating such high-technology matters, industry trends may be moving toward smaller and/or more compact form factors or packaging for such devices. As a result, real estate on such circuit boards may become increasingly limited and/or expensive. The instant disclosure, therefore, identifies and addresses a need for additional and improved apparatuses, systems, and methods for increased current distribution on high-density circuit boards.

As will be described in greater detail below, the instant disclosure generally relates to apparatuses, systems, and methods for increased current distribution on high-density circuit boards. In one example, a current-distribution inductor for accomplishing such a task may include (<NUM>) a magnetic core and (<NUM>) a conductor electrically coupled between a power source and an electrical component of a circuit board, wherein the conductor comprises (A) a bend that passes through the magnetic core and (B) a flying lead that extends from the bend to the electrical component of the circuit board, wherein a majority portion of the flying lead runs parallel with the circuit board.

Similarly, a system for accomplishing such a task may include (<NUM>) a circuit board that includes an electrical component and (<NUM>) a current-distribution inductor that includes (A) a magnetic core and (B) a conductor electrically coupled between a power source and an electrical component of a circuit board, wherein the conductor comprises (A) a bend that passes through the magnetic core and (B) a flying lead that extends from the bend to the electrical component of the circuit board, wherein a majority portion of the flying lead runs parallel with the circuit board.

A corresponding method may include (<NUM>) assembling a current-distribution inductor by (A) forming a bend within a conductor, (B) encasing the bend with a magnetic core, and (C) forming a flying lead within conductor to extend from the bend toward an electrical component of a circuit board, and (<NUM>) electrically coupling the current-distribution inductor between a power source and the electrical component of the circuit board such that a majority portion of the flying lead and the circuit board are parallel to one another.

Features from any of the above-mentioned embodiments may be used in combination with one another in accordance with the general principles described herein. These and other embodiments, features, and advantages will be more fully understood upon reading the following detailed description in conjunction with the accompanying drawings and claims.

<CIT> makes reference to a power module that includes a magnetic component and a switch component. The magnetic component includes a magnetic core, and a winding disposed in the magnetic core. An end of the winding forms a pin of the power module for electrically connecting to an external circuit. The switch component is electrically connected to the magnetic component. An l/<NUM> pin of the power module may be formed from an end of the winding, such that a bonding/contact resistance of connecting the power module to the external circuit can be reduced.

<CIT> makes reference to an inductor that includes a core formed of a magnetic material and a foil winding wound at least partially around or through at least a portion of the core. A first end of the winding extends away from the core to form an extended output tongue configured and arranged to supplement or serve as a substitute for a printed circuit board foil trace. A second end of the winding forms a solder tab. At least a portion of the extended output tongue and the solder tab are formed at a same height relative to a bottom surface of the core.

<CIT> makes reference to a coil device which is easily manufactured and assembled, lessened in size restraining its coil from bulging owing to winding, capable of carrying a high-frequency heavy current, and enhanced in inductance. JPH0794330A refers to a toroidal coil, and <CIT> refers to a winding structure of a transformer.

However, none of these documents describe, at least, a current-distribution inductor in which a majority portion of flying lead that extends from a bend that passes through a magnetic core is elevated from the circuit board such that the majority portion of the flying lead is not in physical contact with the circuit board, such that the flying lead is able to pass over features and components on the circuit board.

Throughout the drawings, identical reference characters and descriptions indicate similar, but not necessarily identical, elements. While the various examples and embodiments described herein are susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. However, the examples and embodiments described herein are not intended to be limited to the particular forms disclosed. Rather, the instant disclosure covers all modifications, equivalents, and alternatives falling within the scope of the appended claims.

The present disclosure describes various apparatuses, systems, and methods for increased current distribution on high-density circuit boards. As will be explained in greater detail below, embodiments of the instant disclosure may involve and/or constitute a current-distribution inductor that includes (<NUM>) a magnetic core and (<NUM>) a conductor electrically coupled between a power source and an electrical component of a circuit board, wherein the conductor comprises (A) a bend that passes through the magnetic core and (B) a flying lead that extends from the bend to the electrical component of the circuit board and runs parallel with the circuit board.

In some examples, a current-distribution system may incorporate and/or combine multiple modular instances of such an inductor. By incorporating and/or combining multiple modular instances in this way, the current-distribution system may be able to increase the amount of current capable of being carried and/or delivered to address and/or satisfy the power needs of the corresponding device and/or circuit board. This current-distribution system may provide various advantages and/or benefits over certain conventional systems. For example, even if the power planes and/or layers of a circuit board are unable to carry and/or deliver enough electric current to power an ASIC, this current-distribution system may be able to carry and/or deliver enough current to that ASIC via the flying leads of the system's modular inductors. In another example, even if the high-density design of a circuit board cannot accommodate enough power planes to carry and/or deliver the necessary amount of current to an ASIC, this current-distribution system may be able to carry and/or deliver enough current to that ASIC via the flying leads of the system's modular inductors.

The following will provide, with reference to <FIG>, detailed descriptions of example apparatuses, systems, configurations, and/or implementations for increased current distribution on high-density circuit boards. In addition, the discussion corresponding to <FIG> will provide a detailed description of an example method for increased current distribution on high-density circuit boards.

In some examples, an inductor may include and/or represent any type or form of electrical component that resists changes in the flow of electric current due to the component's inductance. In one example, inductance may include and/or represent any type or form of property or attribute that causes a conductor (in, e.g., an electrical component or circuit) to induce an electromotive force in response to a change in the flow of electric current. Examples of inductors include, without limitation, common-mode inductors, common-mode chokes, magnetic core inductors, ferromagnetic core inductors, laminated core inductors, toroidal inductors, coupled inductors, multi-layer inductors, steel core inductors, Radio Frequency (RF) inductors, power inductors, shielded inductors, wirewound inductors, switch-mode inductors, honeycomb coils, spiderweb coils, variations or combinations of one or more of the same, or any other suitable inductors.

<FIG> and <FIG> illustrates example current-distribution inductors <NUM> and <NUM>, respectively, for increased current distribution on high-density circuit boards. As illustrated in <FIG> and <FIG>, example current-distribution inductors <NUM> and <NUM> may include and/or represent a conductor <NUM> that facilitates electrically coupling a power source and an electrical component (such as an ASIC, a solder pad, and/or an electrical via) of a circuit board to one another. In some examples, conductor <NUM> may include and/or incorporate a bend <NUM> that passes through a magnetic core <NUM>. In one example, bend <NUM> may include and/or represent an inductive winding and/or coil.

As illustrated in <FIG> and <FIG>, current-distribution inductors <NUM> and <NUM> may include and/or represent a flying lead <NUM> intended and/or designed to extend from bend <NUM> to the electrical component of the circuit board. As will be described in greater detail below, a majority portion of flying lead <NUM> may run and/or be positioned parallel with the circuit board.

In some examples, conductor <NUM> may include and/or represent any type or form of conductive material. In one example, conductor <NUM> may include and/or represent a copper wire, lead, and/or structure. Examples of conductive materials include, without limitation, coppers, steels, alloys, silvers, nickels, aluminums, variations or combinations of one or more of the same, and/or any other suitable type of conductive materials.

In some examples, conductor <NUM> may be of any suitable shape and/or dimensions. Conductor <NUM> may include various bends, turns, levels (e.g., differing elevations), and/or segments. In one example, conductor <NUM> may include and/or form a bridge that rises above one or more features and/or components of the circuit board. In this example, conductor <NUM> may be able to carry and/or deliver electric current from the power source to the electrical component without interfering with and/or passing through the circuit board itself.

In some examples, conductor <NUM> may include and/or represent a single part and/or unit. For example, conductor <NUM> may constitute and/or represent a single piece of molded material and/or injection molding. In other examples, conductor <NUM> may include and/or represent an assembly of discrete parts or units. For example, a set of discrete parts or units may be coupled together by an attachment mechanism and/or fusion technique to form conductor <NUM>.

In some examples, magnetic core <NUM> may include and/or represent any type or form of magnetic material. In one example, magnetic core <NUM> may include and/or represent ferrite and/or ferromagnetic materials. Examples of magnetic core <NUM> include, without limitation, ferromagnetic cores, iron cores, ferrite cores, steel cores, silicon steel cores, nickel cores, alloy cores, permalloy cores, variations or combinations of one or more of the same, and/or any other suitable type of magnetic core.

In some examples, magnetic core <NUM> may be of any suitable shape and/or dimensions. In one example, magnetic core <NUM> may include and/or represent a single part and/or unit. For example, magnetic core <NUM> in <FIG> may constitute and/or represent a single piece of molded material and/or injection molding. In other examples, magnetic core <NUM> may include and/or represent an assembly of discrete parts or units. For example, magnetic core <NUM> in <FIG> may include, represent, and/or be formed from magnetic core segments <NUM>(<NUM>) and <NUM>(<NUM>) in <FIG>. In one example, magnetic core segments <NUM>(<NUM>) and <NUM>(<NUM>) in <FIG> may be adhered and/or combined to form or assemble a single unit that at least partially encompasses and/or encases bend <NUM> of conductor <NUM>. In this example, when adhered and/or combined to one another, magnetic core segments <NUM>(<NUM>) and <NUM>(<NUM>) in <FIG> may be joined by an adhesive (e.g., silicones, glues, tapes, and/or sticky surfaces).

As illustrated in <FIG>, conductor <NUM> may include and/or incorporate bends, turns, and/or levels (e.g., differing elevations). For example, flying lead <NUM> of conductor <NUM> may include and/or incorporate a bend <NUM>, a bend <NUM>, a bend <NUM>, and a bend <NUM>. In this example, conductor <NUM> may also include and/or incorporate a contact segment <NUM> designed and/or intended to make physical contact with a solder pad and/or an electrical via on the circuit board.

In one example, bend <NUM> and/or bend <NUM> of flying lead <NUM> may serve to elevate and/or raise flying lead <NUM> from the circuit board. In this example, bend <NUM> and/or bend <NUM> of flying lead <NUM> may serve to lower and/or descend the flying lead <NUM> to the circuit board. As a result, the majority portion of flying lead <NUM> may be elevated from and/or raised off the circuit board to any suitable level. For example, the majority portion of flying lead <NUM> may be elevated and/or raised to the same level as the top of magnetic core <NUM>. Alternatively, the majority portion of flying lead <NUM> may be elevated and/or raised to the same level as the midpoint or middle of magnetic core <NUM>. The majority portion of flying lead <NUM> may run and/or be positioned parallel to the circuit board.

In one example, conductor <NUM> may include and/or incorporate an entry segment <NUM> that enters a conductor entrance <NUM> on one side of magnetic core <NUM>. In this example, conductor entrance <NUM> may be located and/or formed along a bottom corner of that side of magnetic core <NUM>.

In one example, conductor <NUM> may also include and/or incorporate an exit segment that exits a conductor exit <NUM> on the opposite side of magnetic core <NUM>. In this example, conductor exit <NUM> may be located and/or formed along a bottom corner of that opposite side of magnetic core <NUM>. Further, magnetic core <NUM> may include and/or form an aperture <NUM> on its top side.

<FIG> illustrates an example system <NUM> for increased current distribution on high-density circuit boards. As illustrated in <FIG>, example system <NUM> may include and/or represent an array of inductors <NUM>(<NUM>), an array of inductors <NUM>(<NUM>), an array of inductors <NUM>(<NUM>), and an array of inductors <NUM>(<NUM>) coupled to a circuit board <NUM>. In one example, each of these arrays may include and/or represent a set of current-distribution inductors <NUM>. In this example, by deploying and/or implementing these arrays in this way, system <NUM> may provide and/or facilitate the carrying and/or delivery of enough current to power an ASIC via the flying leads of the individual inductors. In one embodiment, these arrays of inductors may be formed and/or created by joining and/or adhering the magnetic cores of individual current inductors together by an adhesive.

In some examples, these arrays of inductors may be coupled to one side of circuit board <NUM>. In one example, these arrays of inductors may carry and/or deliver electric current to a power-consuming device (not illustrated in <FIG>) coupled to the opposite side of circuit board <NUM>. For example, an ASIC may be coupled to and/or deployed on the top side of circuit board <NUM>, and these arrays of inductors may be coupled to and/or deployed on the bottom side of circuit board <NUM>. In this example, the flying leads of these inductors may be electrically coupled to solder pads on the bottom side of circuit board <NUM>.

In one example, these solder pads may each be electrically coupled to the top side of circuit board <NUM> by way of an electrical via (similar to electrical via <NUM> in <FIG>). In this example, these electrical vias may carry and/or deliver electric current from the bottom side of circuit board <NUM> to the top side of circuit board <NUM>. On the top side of circuit board <NUM>, the electric current may traverse toward and/or reach the ASIC on circuit board <NUM>.

As illustrated in <FIG>, the flying leads of the inductors may be elevated from and/or raised off circuit board <NUM>. For example, a majority portion of each flying lead may be elevated and/or raised off circuit board <NUM>. In this example, the majority portion of each flying lead may avoid physical contact with circuit board <NUM>. By doing so, each flying lead may be able to jump and/or pass over certain features and/or components placed between the magnetic core and the contact segment on circuit board <NUM>.

<FIG> and <FIG> illustrate example systems <NUM> and <NUM>, respectively, for increased current distribution on high-density circuit boards. As illustrated in <FIG> and <FIG>, example systems <NUM> and <NUM> may include and/or represent array of inductors <NUM>(<NUM>) coupled to circuit board <NUM>. In one example, by deploying and/or implementing array of inductors <NUM>(<NUM>) in this way, systems <NUM> and <NUM> may provide and/or facilitate the carrying and/or delivery of enough current to power an ASIC via the flying leads of the individual inductors. In this example, array of inductors <NUM>(<NUM>) may be formed and/or created by joining and/or adhering the magnetic cores of individual current inductors together by an adhesive.

<FIG>, <FIG>, and <FIG> illustrate example systems <NUM>, <NUM>, and <NUM>, respectively, for increased current distribution on high-density circuit boards. As illustrated in <FIG>, example systems <NUM>, <NUM>, and <NUM> may include and/or represent arrays of inductors <NUM>(<NUM>)-(<NUM>) coupled to the top side of circuit board <NUM>. In one example, by deploying and/or implementing array of inductors <NUM>(<NUM>)-(<NUM>) in this way, systems <NUM>, <NUM>, and <NUM> may provide and/or facilitate the carrying and/or delivery of enough current to power an electrical component <NUM> via the flying leads of the individual inductors. In this example, systems <NUM>, <NUM>, and <NUM> may also include and/or represent a power source <NUM>(<NUM>), a power source <NUM>(<NUM>), a power source <NUM>(<NUM>), and a power source <NUM>(<NUM>). Each of power sources <NUM>(<NUM>)-(<NUM>) in <FIG> and <FIG> may include and/or represent a power supply that sources electric current to arrays of inductors <NUM>(<NUM>)-(<NUM>).

In one example, power source <NUM>(<NUM>) may be electrically coupled to array of inductors <NUM>(<NUM>) to provide and/or deliver current to electrical component <NUM> via array of inductors <NUM>(<NUM>). In this example, power source <NUM>(<NUM>) may be electrically coupled to array of inductors <NUM>(<NUM>) to provide and/or deliver current to electrical component <NUM> via array of inductors <NUM>(<NUM>). Similarly, power source <NUM>(<NUM>) may be electrically coupled to array of inductors <NUM>(<NUM>) to provide and/or deliver current to electrical component <NUM> via array of inductors <NUM>(<NUM>). Finally, power source <NUM>(<NUM>) may be electrically coupled to array of inductors <NUM>(<NUM>) to provide and/or deliver current to electrical component <NUM> via array of inductors <NUM>(<NUM>).

In some examples, electrical component <NUM> may include and/or represent any type or form of component, device, and/or circuit that consumes electric power. Examples of electrical component <NUM> include, without limitation, ASICs, Systems on a Chip (SoCs), Central Processing Units (CPUs), microprocessors, microcontrollers, Field-Programmable Gate Arrays (FPGAs) that implement softcore processors, integrated circuits, portions of one or more of the same, variations or combinations of one or more of the same, and/or any other suitable electrical component.

<FIG> illustrates an example system <NUM> for increased current distribution on high-density circuit boards. As illustrated in <FIG>, example system <NUM> may include and/or represent arrays of inductors <NUM>(<NUM>)-(<NUM>) coupled to the bottom side of circuit board <NUM>. In one example, example system <NUM> may include and/or represent a solder pad <NUM>(<NUM>), a solder pad <NUM>(<NUM>), a solder pad <NUM>(<NUM>), a solder pad <NUM>(<NUM>), a solder pad <NUM>(<NUM>), a solder pad <NUM>(<NUM>), a solder pad <NUM>(<NUM>), a solder pad <NUM>(<NUM>), a solder pad <NUM>(<NUM>), and a solder pad <NUM>(<NUM>) incorporated into the bottom side of circuit board <NUM>. The flying leads of the inductors included in array <NUM>(<NUM>) may be electrically coupled to solder pads <NUM>(<NUM>)-(<NUM>).

As illustrated in <FIG>, solder pads <NUM>(<NUM>) and <NUM>(<NUM>) may be electrically coupled to electrical vias <NUM>(<NUM>) and <NUM>(<NUM>), respectively. Solder pads <NUM>(<NUM>)-(<NUM>) may also be electrically coupled to other electrical vias (although not explicitly illustrated in <FIG>). In one example, these electrical vias may carry and/or deliver electric current from the bottom side of circuit board <NUM> to the top side of circuit board <NUM>. In this example, a power-consuming device (such as an ASIC) may be electrically coupled to the top side of circuit board <NUM>. This power-consuming device may receive the electric current passed though the electric vias from the bottom side of circuit board <NUM>.

<FIG> illustrates an example system <NUM> for increased current distribution on high-density circuit boards. As illustrated in <FIG>, example system <NUM> may include and/or represent array of inductors <NUM>(<NUM>) coupled to the top side of circuit board <NUM>. In one example, by deploying and/or implementing array of inductors <NUM>(<NUM>) in this way, system <NUM> may provide and/or facilitate the carrying and/or delivery of enough current to power electrical component <NUM> via the flying leads of the individual inductors. In this example, system <NUM> may also include and/or represent power source <NUM>(<NUM>) that supplies and/or provides electric current to electrical component <NUM> via array of inductors <NUM>(<NUM>). Array of inductors <NUM>(<NUM>) may be electrically coupled between electrical component <NUM> and power source <NUM>(<NUM>).

<FIG> illustrate example system <NUM> for increased current distribution on high-density circuit boards. As illustrated in <FIG>, example system <NUM> may include and/or represent arrays of inductors <NUM>(<NUM>)-<NUM>(<NUM>) coupled to the top side of circuit board <NUM>. In one example, by deploying and/or implementing arrays of inductors <NUM>(<NUM>)-(<NUM>) in this way, system <NUM> may provide and/or facilitate the carrying and/or delivery of enough current to power electrical component <NUM> via the flying leads of the individual inductors. In this example, system <NUM> may also include and/or represent power source <NUM>(<NUM>)-(<NUM>) electrically coupled to arrays of inductors <NUM>(<NUM>)-(<NUM>). Each of power sources <NUM>(<NUM>)-(<NUM>) in <FIG> and <FIG> may include and/or represent a power supply that sources electric current to electrical component <NUM> via arrays of inductors <NUM>(<NUM>)-(<NUM>).

<FIG> illustrate example system <NUM> for increased current distribution on high-density circuit boards. As illustrated in <FIG>, example system <NUM> may include and/or represent arrays of inductors <NUM>(<NUM>)-<NUM>(<NUM>) coupled to the top side of circuit board <NUM>. In one example, by deploying and/or implementing arrays of inductors <NUM>(<NUM>)-(<NUM>) in this way, system <NUM> may provide and/or facilitate the carrying and/or delivery of enough current to power electrical component <NUM> via the flying leads of the individual inductors. In this example, system <NUM> may also include and/or represent power source <NUM>(<NUM>)-(<NUM>) electrically coupled to arrays of inductors <NUM>(<NUM>)-(<NUM>). Each of power sources <NUM>(<NUM>)-(<NUM>) in <FIG> may include and/or represent a power supply that sources electric current to electrical component <NUM> via arrays of inductors <NUM>(<NUM>)-(<NUM>).

<NUM> is a flow diagram of an example method <NUM> for increased current distribution on high-density circuit boards. Method <NUM> may include the step of assembling a current-distribution inductor (<NUM>). Step <NUM> may be performed in a variety of ways, including any of those described above in connection with <FIG>. For example, a computing equipment manufacturer or subcontractor may assemble and/or manufacture a current-distribution inductor. In this example, the computing equipment manufacturer or subcontractor may form a bend within a conductor (<NUM>(A)), encase the bend with a magnetic core (<NUM>(B)), and form a flying lead within the conductor to extend from the bend toward an electrical component of a circuit board (<NUM>(C)).

Method <NUM> may also include the step of electrically coupling the current-distribution inductor between a power source and the electrical component of the circuit board such that a majority portion of the flying lead and the circuit board are parallel to one another (<NUM>). Step <NUM> may be performed in a variety of ways, including any of those described above in connection with <FIG>. For example, the computing equipment manufacturer or subcontractor may electrically couple the current-distribution inductor between a power source and the electrical component of the circuit board such that a majority portion of the flying lead and the circuit board are parallel to one another. In this example, the power source may supply and/or provide electric current to the electrical component via the current-distribution inductor.

Therefore, from one perspective, there has been described that a current-distribution inductor may include a magnetic core and a conductor electrically coupled between a power source and an electrical component of a circuit board, wherein the conductor comprises a bend that passes through the magnetic core and a flying lead that extends from the bend to the electrical component of the circuit board and runs parallel with the circuit board. Various other apparatuses, systems, and methods are also disclosed.

While the foregoing disclosure sets forth various embodiments using specific block diagrams, flowcharts, and examples, each block diagram component, flowchart step, operation, and/or component described and/or illustrated herein may be implemented, individually and/or collectively, using a wide range of hardware, software, or firmware (or any combination thereof) configurations. In addition, any disclosure of components contained within other components should be considered as being by way of example in nature since many other architectures can be implemented to achieve the same functionality.

The process parameters and sequence of the steps described and/or illustrated herein are given by way of example only and can be varied as desired.

The preceding description has been provided to enable others skilled in the art to best utilize various aspects of the example embodiments disclosed herein. This description is not intended to be exhaustive or to be limited to any precise form disclosed. Many modifications and variations are possible without departing from the scope of the instant disclosure. The embodiments disclosed herein should be considered in all respects illustrative and not restrictive. Reference should be made to the appended claims in determining the scope of the instant disclosure.

Claim 1:
A current-distribution inductor (<NUM>) comprising:
a magnetic core (<NUM>); and
a conductor (<NUM>) electrically coupled between a power source (<NUM>) and an electrical component (<NUM>) of a circuit board (<NUM>), wherein the conductor comprises:
a bend (<NUM>) that passes through the magnetic core; and
a flying lead (<NUM>) that extends from the bend to the electrical component of the circuit board; wherein
a majority portion of the flying lead runs parallel to the circuit board and is elevated from the circuit board such that the majority portion of the flying lead is not in physical contact with the circuit board,
wherein the flying lead further comprises a first bend formed between the majority portion of the flying lead and the bend that passes through the magnetic core, the first bend serving to elevate the flying lead from the circuit board,
such that the flying lead is able to pass over features and components on the circuit board.