Method for making a high current low profile inductor

• US 7,345,562 B2
• Filed: 07/24/2007
• Issued: 03/18/2008
• Est. Priority Date: 07/18/1995
• Status: Expired due to Fees

• Current Assignee: Vishay Dale Electronics (Vishay Intertechnology Incorporated)
• Original Assignee: Vishay Dale Electronics (Vishay Intertechnology Incorporated)
• Inventors: Shafer, Timothy M., Jelkin, Brett W.
• Primary Examiner(s): Nguyen; Tuyen T.
• Application Number:
  US11/782,020
• Publication Number:
  US 20070262841A1
• Time in Patent Office: 238 Days
• Field of Search: 336/65, 336/83, 336 90- 96, 336/192, 336/200, 336/232, 336206-208, 296/021
• US Class Current: 336/83
• 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 1/26 by macromolecular organic substances
• 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 41/127 Encapsulating or impregnating encapsulating coil and core H01F41/005
• CPC Class Codes: Y10T 29/49002 Electrical device making
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

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. A high current low profile (IHLP) inductor comprising:

a conductive coil having an open center, an outside surface, and first and second coil ends;

a powdered magnetic conductive material comprising a plurality of powdered conductive particles;

an insulation material surrounding the powdered conductive particles and providing insulation to the powdered conductive particles;

a resin comprising resin particles;

a mixture comprising the powdered conductive particles, the insulation material, and the resin particles;

an inductor body comprising the compressed mixture while dry of the conductive particles of conductive material, the insulation material, and the resin particles;

the inductor body surrounding the conductive coil and contacting the conductive coil both inside the open center and on the outside surface of the conductive coil;

the first and second ends being outside the inductor body.

2. A high current low profile (IHLP) inductor according to claim 1 wherein the powdered conductive particles comprise powdered iron.

3. A high current low profile (IHLP) inductor according to claim 2 wherein the mixture further comprises a lubricant to facilitate the mixture to move into contact with the open center of the coil and the outside surface of the conductive coil.

4. A high current low profile (IHLP) inductor according to claim 3 wherein the mixture further comprises a filler therein.

5. A high current low profile (IHLP) inductor according to claim 1 wherein the first and second coil ends are integral with the coil.

6. A high current low profile (LHLP) inductor according to claim 1 wherein the insulation material and the resin cause the conductive particles of conductive material to have high resistance exceeding 3 mega ohms.