LAMINATED MAGNETIC COMPONENT AND MANUFACTURE WITH SOFT MAGNETIC POWDER POLYMER COMPOSITE SHEETS
First Claim
Patent Images
1. A magnetic component comprising:
- at least one conductive wire coil including a first lead, a second lead, and a plurality of turns between the first and second lead; and
at least one insulating, dielectric, and magnetic sheet comprising a composite mixture of soft magnetic powder particles with no shape anisotropy and a binder material, the composite being provided as a freestanding, solid sheet layer;
wherein the at least one insulating, dielectric, and magnetic sheets is laminated to the coil, thereby defining a monolithic core structure embedding the at least one coil.
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Accused Products
Abstract
Miniaturized magnetic components for electronic circuit board applications include enhanced magnetic composite sheets facilitating increased direct current capacity and higher inductance values. The components may be manufactured using relatively simple and straightforward lamination processes.
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Citations
38 Claims
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1. A magnetic component comprising:
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at least one conductive wire coil including a first lead, a second lead, and a plurality of turns between the first and second lead; and at least one insulating, dielectric, and magnetic sheet comprising a composite mixture of soft magnetic powder particles with no shape anisotropy and a binder material, the composite being provided as a freestanding, solid sheet layer; wherein the at least one insulating, dielectric, and magnetic sheets is laminated to the coil, thereby defining a monolithic core structure embedding the at least one coil. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A magnetic component comprising:
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first and second insulating, dielectric, and magnetic sheets; at least one conductive wire coil including a first lead, a second lead, and a plurality of turns between the first and second lead; wherein the at least one conductive coil is interposed between the first and second insulating, dielectric, and magnetic sheets; wherein the first and second insulating, dielectric, and magnetic sheets are laminated to the coil to embed the coil therebetween and define a monolithic core structure without creating a physical gap; and the first and second insulating, dielectric, and magnetic sheets each comprising; a composite sheet including soft magnetic powder particles with no shape anisotropy and a polymer binder consisting of thermoplastic or thermoset resin which can be laminated with heat and pressure; the composite being provided as a freestanding, solid sheet layer; wherein a density of the composite is at least 3.3 grams per cubic centimeter; wherein the magnetic powder particles comprise at least 90% by weight percent of the composite; and wherein the effective magnetic permeability of the composite is at least 10. - View Dependent Claims (16, 17, 18, 19, 20)
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21. A magnetic component comprising:
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first and second insulating, dielectric, and magnetic sheet each comprising a composite being provided as a freestanding, solid sheet layer; at least one conductive wire coil including a first lead, a second lead, and a plurality of turns between the first and second lead; a magnetic core piece separately provided from the first and second insulating, dielectric and magnetic sheets; the plurality of turns extending about the magnetic core piece; wherein the at least one conductive coil and the magnetic core piece is interposed between the first and second insulating, dielectric, and magnetic sheets; wherein the first and second insulating, dielectric, and magnetic sheets are laminated to the coil and the magnetic core piece to embed the coil and the magnetic core piece and define a monolithic core structure without creating a physical gap; and surface mount terminations connected to the first and second coil leads. - View Dependent Claims (22, 23, 24, 25)
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26. A method of fabricating a magnetic component including a wire coil and at least one insulating, dielectric and magnetic sheet,
the method comprising: -
assembling at least one wire coil with the at least one insulating, dielectric and magnetic sheet layer;
the at least one sheet comprising a composite provided as a freestanding, solid sheet layer, the composite including soft magnetic powder particles with no shape anisotropy; andlaminating the at least one insulating, dielectric, and magnetic sheet to the at least one wire coil, thereby forming a monolithic core structure embedding the coil therein without a physical gap. - View Dependent Claims (27, 28, 29, 30, 31, 32, 33, 34, 35)
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36. A magnetic component comprising:
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at least one conductive wire coil including a first lead, a second lead, and a plurality of turns between the first and second lead; and a magnetic composite material defining a monolithic core structure embedding the at least one coil without creating a physical gap; wherein the magnetic composite material includes metal powder particles with no shape anisotropy and a binder; wherein a density of the composite is at least 3.3 grams per cubic centimeter; wherein the metal powder particles comprise at least 90% by weight percent of the composite; and wherein the effective magnetic permeability of the composite is at least 10. - View Dependent Claims (37, 38)
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Specification