Low profile high current multiple gap inductor assembly
First Claim
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1. An inductor assembly comprising:
- at least one coil of insulated conductor material defining an inside volume, an inner core of magnetic core material located within the inside volume, and an outer core of magnetic core material including topwall and sidewall structure overlying the coil and inner core and having opposite inner wall portion facing polar ends of the coil and inner core such that at least two magnetic gaps exist between ends of the inner core and the opposite inner wall portion of the outer core.
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Abstract
An inductor assembly includes a coil or coils of insulated conductor material defining an inside volume, an inner core of magnetic core material located within the inside volume, and an outer core of magnetic core material including structure overlying the coil and inner core and having opposite inner walls facing polar ends of the coil and core, such that at least two magnetic gaps exist between ends of the inner core and the opposite inner walls of the outer core. A method for making the assembly is also disclosed.
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Citations
24 Claims
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1. An inductor assembly comprising:
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at least one coil of insulated conductor material defining an inside volume, an inner core of magnetic core material located within the inside volume, and an outer core of magnetic core material including topwall and sidewall structure overlying the coil and inner core and having opposite inner wall portion facing polar ends of the coil and inner core such that at least two magnetic gaps exist between ends of the inner core and the opposite inner wall portion of the outer core. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A method for constructing an inductor assembly comprising steps of:
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forming at least one coil of insulated conductor material to define an inside volume, forming an inner core from magnetic core material having a size and geometry adapted to be located within the inside volume, securing the inner core in place within the inside volume to form a subassembly, forming an outer core of magnetic core material having a continuous topwall and sidewall to provide a structure overlying the coil and inner core and opposite inner wall portions facing polar ends of the coil and inner core, and locating and securing the subassembly in the outer core between the opposite inner walls such that at least two magnetic gaps exist between ends of the inner core and the opposite inner walls of the outer core. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19, 20, 24)
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21. A low profile high current multiple gap inductor assembly comprising:
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at least one insulated electrical conductor sized to carry a relatively high current formed into a helical coil having a generally flattened shape and formed by at least one turn around an inside open volume defined by the coil, an inner core of magnetic core material having a generally flattened shape sized to fit within the open volume of the coil, a low profile box-shaped outer core of magnetic core material including continuous topwall and sidewall portions and having opposite inner wall segments facing polar ends of the coil and inner core such that at least two magnetic gaps exist between ends of the inner core and inner wall segments of the outer core, potting material encapsulating the inner core and coil within an interior volume of the outer core to maintain the two magnetic gaps, and electrical contact regions defined at opposite ends of the electrical conductor for enabling surface mounting and electrical connection of the inductor assembly to conductive traces of a printed circuit board. - View Dependent Claims (22, 23)
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Specification