Method and apparatus for forming a magnetic component on a printed circuit board

Abstract

A method and apparatus for forming a magnetic component on a printed circuit board. The printed circuit board has at least one layer including a trace that forms a winding of the magnetic component. Another winding of the magnetic component is formed by a length of wire that is disposed externally to the printed circuit board.

1 . A method for forming a magnetic component on a printed circuit board, comprising providing the circuit board with at least one layer having a trace that forms a winding for the magnetic component, forming a first length of wire into a loop that forms another winding for the magnetic component, and disposing said first length of wire externally to the printed circuit board.  
     
     
         2 . The method of  claim 1 , wherein said step of disposing said first length of wire includes placing said first length of wire on a first external surface of the printed circuit board.  
     
     
         3 . The method of  claim 2 , further comprising tacking said first length of wire to said external surface with an adhesive.  
     
     
         4 . The method of  claim 2 , further comprising forming a second length of wire into a loop that forms yet another winding for the magnetic component, and disposing said second length of wire on a second, opposite external surface of the printed circuit board.  
     
     
         5 . The method of  claim 1 , further comprising interconnecting electrical components to the magnetic component by soldering a lead of the electrical components directly to an end of said first length of wire.  
     
     
         6 . An apparatus for forming a magnetic component, comprising a printed circuit board having at least one layer having a trace that forms a winding for the magnetic component, and a first length of wire that is formed in a loop that forms another winding for the magnetic component, said first length of wire being disposed externally to said printed circuit board.  
     
     
         7 . The apparatus of  claim 6 , wherein said first length of wire is disposed on a first external surface of said printed circuit board.  
     
     
         8 . The apparatus of  claim 7 , further comprising a second length of wire that is formed as a loop that forms yet another winding for the magnetic component, said second length of wire being disposed on a second, opposite external surface of said printed circuit board.  
     
     
         9 . The apparatus of  claim 6 , further comprising an electrical shield element disposed over said length of wire.  
     
     
         10 . The apparatus of  claim 6 , wherein the magnetic component includes a ferrite core element, and wherein said printed circuit board includes cut-out areas to permit at least a portion of said ferrite core element to extend through said printed circuit board.