METHOD FOR MAKING A HIGH CURRENT LOW PROFILE INDUCTOR

• US 20120086535A1
• Filed: 05/17/2011
• Published: 04/12/2012
• Est. Priority Date: 07/18/1995
• Status: Abandoned Application

• Current Assignee: Vishay Dale Electronics (Vishay Intertechnology Incorporated)
• Original Assignee: Vishay Dale Electronics (Vishay Intertechnology Incorporated)
• Inventors: Shafer, Timothy M., Jelkin, Brett W.
• Application Number:
  US13/109,576
• Publication Number:
  US 20120086535A1
• Time in Patent Office: Days
• US Class Current: 336/90
• CPC Class Codes: B29C 43/003 characterised by the choice of material
• CPC Class Codes: B29C 43/18 incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles B29C43/206 takes precedence
• CPC Class Codes: B29K 2303/06 Metal powders, metal carbides or the like
• CPC Class Codes: B29K 2995/0008 Magnetic or paramagnetic
• CPC Class Codes: H01F 2017/048 with encapsulating core, e.g. made of resin and magnetic powder
• CPC Class Codes: H01F 2027/2861 Coil formed by folding a blank
• CPC Class Codes: H01F 27/027 specially adapted for combination of signal type inductors or transformers with electronic circuits, e.g. mounting on printed circuit boards
• CPC Class Codes: H01F 27/2847 Sheets; Strips H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 37/00 Fixed inductances not covered by group H01F17/00
• CPC Class Codes: H01F 41/0246 Manufacturing of magnetic circuits by moulding or by pressing powder magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36
• CPC Class Codes: H01F 5/00 Coils superconducting coils H01F6/06; fixed inductances of the signal type H01F17/00
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor
• CPC Class Codes: Y10T 29/49073 by assembling coil and core
• CPC Class Codes: Y10T 29/49076 From comminuted material
• CPC Class Codes: Y10T 29/49146 with encapsulating, e.g., potting, etc.
• CPC Class Codes: Y10T 29/49158 with molding of insulated base
• CPC Class Codes: Y10T 29/49172 by molding of insulating material
• CPC Class Codes: Y10T 29/49176 with molding of electrically insulating material

Abstract

A high current, low profile inductor includes a conductor coil surrounded by magnetic material to form an inductor body. An inductor body is formed around the inductor coil and includes a resin and a magnetic material compressed while it is dry and surrounding the inside and the outside of the coil.

Claims

1. An inductor comprising:

an electrical coil having an open center;

terminals for connecting the electrical coil to an electrical circuit; and

a compressed body comprised of insulated conductive particles that tightly and completely surround and magnetically shield the coil.

2. The inductor of claim 1 wherein the coil comprises copper.

3. The inductor of claim 2 wherein the copper is greater than approximately 99% pure.

4. The inductor of claim 1 wherein the electrical coil comprises a plurality of L-shaped coil segments.

5. The inductor of claim 4 wherein each of the plurality of L-shaped coil segments comprises at least one vertical leg and at least one horizontal leg.

6. The inductor of claim 1 wherein the electrical coil is helical.

7. The inductor of claim 1 wherein the magnetic shielding prevents electrical shorting of the terminals.

8. The inductor of claim 1 wherein the insulated conductive particles comprise iron.

9. The inductor of claim 1 wherein the insulated conductive particles are dry.

10. The inductor of claim 1 wherein the inductor is substantially devoid of air spaces.

11. The inductor of claim 1 wherein the electrical coil and the compressed body provides a closed magnetic system.

12. The inductor of claim 1 wherein the compressed body comprises at least powdered iron, a filler, a resin and a lubricant.

13. The inductor of claim 12 wherein the resin comprises an epoxy resin.

14. The inductor of claim 12 wherein the lubricant comprises zinc stearate.

15. The inductor of claim 1 wherein the compressed body is pressed with a pressure within the range of 15 to 25 tons per square inch.

16. The inductor of claim 1 wherein the series resistance of the inductor is reduced.

17. An inductor comprising:

an electrical coil having an open center;

terminals for connecting the electrical coil to an electrical circuit; and

a compressed body comprised entirely of insulated magnetic materials that tightly and completely surround and shield the coil.

18. The inductor of claim 17 wherein the coil comprises copper.

19. The inductor of claim 18 wherein the copper is greater than approximately 99% pure.

20. The inductor of claim 17 wherein the electrical coil is helical.

21. The inductor of claim 17 wherein the magnetic shielding prevents electrical shorting of the terminals.

22. The inductor of claim 17 wherein the insulated magnetic materials comprise iron.

23. The inductor of claim 17 wherein the insulated magnetic materials are dry.

24. The inductor of claim 17 wherein the inductor is substantially devoid of air spaces.

25. The inductor of claim 17 wherein the compressed body comprises at least powdered iron, a filler, a resin and a lubricant.

26. The inductor of claim 25 wherein the resin comprises an epoxy resin.

27. The inductor of claim 25 wherein the lubricant comprises zinc stearate.

28. The inductor of claim 17 wherein the compressed body is pressed with a pressure within the range of 15 to 25 tons per square inch.

29. The inductor of claim 17 further comprising a reduced series resistance.