High current inductor and the manufacturing method

• US 7,142,084 B2
• Filed: 01/31/2005
• Issued: 11/28/2006
• Est. Priority Date: 07/02/2004
• Status: Expired due to Fees

• Current Assignee: Chang Mao Cheng
• Original Assignee: Chang Mao Cheng
• Inventors: Cheng, Chang Mao
• Primary Examiner(s): Nguyen, Tuyen T
• Application Number:
  US11/045,278
• Publication Number:
  US 20060001517A1
• Time in Patent Office: 666 Days
• Field of Search: 336/65, 336/83, 336/192, 336/200, 336/232, 336/233
• US Class Current: 336/200
• CPC Class Codes: H01F 2017/046 helical coil made of flat wire, e.g. with smaller extension of wire cross section in the direction of the longitudinal axis
• CPC Class Codes: H01F 2017/048 with encapsulating core, e.g. made of resin and magnetic powder
• CPC Class Codes: H01F 27/255 made from particles H01F27/26 takes precedence
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 41/005 Impregnating or encapsulating insulating of windings H01F41/12
• 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 41/10 Connecting leads to windings making electric connections in general H01R43/00
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

Abstract

An inductor with the characteristic of resisting high current comprising a conductor coil and a magnet envelope, the magnet envelope tightly wraps the periphery of the conductor coil and forms the main body of the inductor, and the two extending parts of the conductor coil extend to outside of the main body of the inductor, forming terminal electrode. As of the manufacturing method, it includes the part of toroid coil and the extending parts composing the conductor coil. After the toroid coil part is winded into rings, the unwinded wire ends form the extending parts. Through magnet envelope die-casting and wrapping the molded magnet core of the conductor coil to form the main body of the inductor, and the extending parts of the conductor coil extend to outside of the main body to form the terminal electrode.

Claims

1. A high current inductor, comprising:

a conductor coil, said conductor coil including a toroid coil of a substantially circularly contoured cross-section,

two extending parts of the toroid coil extending in the opposite directions of the toroid coil, and

a pair of hollow copper sheathings, each placed on a respective one of said two extending parts in surrounding relationship with said substantially circularly contoured cross-section thereof,

said each hollow copper sheathing and said respective extending part forming together a substantially flat extending portion of said high current inductor, said flat extending portion being formed by simultaneous pressing of said two extending parts and said pair of hollow copper sheathings placed respectively over said two extending parts; and

a magnet envelope wrapping around a periphery of said conductor coil, said magnet envelope being formed from powdery moulding materials and fixed at the periphery of the toroid coil of the conductor coil through die-casting, said two extending portions of said conductor coil extending beyond said magnet envelope and being bent to extend along walls of said magnet envelope, thereby forming a Surface Mount Design (SMD) inductor.