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Method for making inductor coil structure

  • US 6,449,829 B1
  • Filed: 04/10/2000
  • Issued: 09/17/2002
  • Est. Priority Date: 03/16/1999
  • Status: Expired due to Term
First Claim
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1. A method for making a high current low profile inductor comprising:

  • taking an elongated plate conductor having a first end, a second end, opposite side edges, opposite flat surfaces, and a longitudinal plate axis;

    cutting a plurality of slots in each of said opposite side edges of said plate conductor so as to form said plate conductor into a plurality of cross segments extending transversely with respect to said plate axis and a plurality of connecting segments extending approximately axially with respect to said plate axis, said connecting segments connecting said cross segments together into a continuous conductor which extends in a sine shaped path;

    said cross segments each having opposite flat surfaces formed from said opposite surfaces of said plate conductor;

    bending said connecting segments transversely with respect to said plate axis so as to form said plate conductor into a plurality of accordion folds, each of which comprise one of said cross segments and a portion of one of said connecting segments, whereby said cross segments and said connecting segments form a continuous conductor coil formed into an approximate helical shape and having first and second opposite ends;

    said bending step being done so as to place said opposite flat surfaces of said cross segments in planes parallel to one another and perpendicular to said longitudinal plate axis.

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