Inductor coil and method for making same
DCFirst Claim
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1. A method for making an inductor comprising:
- forming an inductor element having first and second inductor ends from an electrically conductive material;
creating first and second terminal ends for the inductor element either by attaching the first and second terminal ends to first and second inductor ends of the inductor element or by forming the first and second terminal ends from the first and second inductor ends of the inductor element;
making a mixture comprising a resin and an electrically insulated non-ferrite powdered magnetic material;
compressing the mixture of resin and powdered magnetic material without liquefying the resin tightly around the inductor element to create an inductor body, the insulated magnetic material shielding the inductor element and being in contact with the inductor element without shorting out against the inductor element;
the compressing step being accomplished without injection molding;
leaving the first and second terminal ends outside the inductor body during the compressing step.
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Abstract
A high current, low profile inductor (IHLP) includes a conductive coil molded within an inductor body substantially free from ferrite materials and comprising powdered iron materials. The method comprises pressure molding the inductor body substantially free from ferrite materials and comprising a powdered magnetic material within the hollow core of the coil and completely around the coil so that the magnetic material is substantially free from voids therein without shorting out the coil.
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Citations
11 Claims
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1. A method for making an inductor comprising:
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forming an inductor element having first and second inductor ends from an electrically conductive material;
creating first and second terminal ends for the inductor element either by attaching the first and second terminal ends to first and second inductor ends of the inductor element or by forming the first and second terminal ends from the first and second inductor ends of the inductor element;
making a mixture comprising a resin and an electrically insulated non-ferrite powdered magnetic material;
compressing the mixture of resin and powdered magnetic material without liquefying the resin tightly around the inductor element to create an inductor body, the insulated magnetic material shielding the inductor element and being in contact with the inductor element without shorting out against the inductor element;
the compressing step being accomplished without injection molding;
leaving the first and second terminal ends outside the inductor body during the compressing step. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A method for making an inductor comprising:
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making an inductor coil having first and second coil ends from an electrically conductive material;
forming first and second terminal ends for the inductor coil either by attaching the first and second terminal ends to the first and second coil ends or by forming the first and second terminal ends from the first and second coil ends of the inductor coil;
making a mixture comprising a resin and an electrically insulated non-ferrite powdered magnetic material;
adding a lubricant to the mixture;
compressing the mixture having the lubricant added without liquefying the resin tightly round the inductor coil and within the coil center to create an inductor body, the insulated magnetic material shielding the inductor coil and being in contact with the inductor coil both within and outside the coil center without shorting our against the inductor coil;
the compressing step being accomplished without injection molding;
leaving the first and second terminal ends outside the inductor body during the compressing step; and
baking the inductor body at a predetermined temperature to set the resin after the compressing step is completed. - View Dependent Claims (9, 10, 11)
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Specification