Method for making a high current low profile inductor

• US 7,921,546 B2
• Filed: 01/14/2008
• Issued: 04/12/2011
• 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): Kim; Paul D
• Application Number:
  US12/013,725
• Publication Number:
  US 20080110014A1
• Time in Patent Office: 1,184 Days
• Field of Search: 296/021, 296/06, 298/41, 298/48, 298/56, 298/58, 298/83, 336/65, 336/83, 336 90- 96, 336/192, 336/200, 336206-208, 336/232, 363/17, 363/48, 363/58
• US Class Current: 29/606
• 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 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 5/00 Coils superconducting coils H01F6/06; fixed inductances of the signal type H01F17/00
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor
• CPC Class Codes: Y10T 29/49073 by assembling coil and core
• CPC Class Codes: Y10T 29/49076 From comminuted material
• CPC Class Codes: Y10T 29/49146 with encapsulating, e.g., potting, etc.
• CPC Class Codes: Y10T 29/49158 with molding of insulated base
• CPC Class Codes: Y10T 29/49172 by molding of insulating material
• CPC Class Codes: Y10T 29/49176 with molding of electrically insulating material

Abstract

A method for making a high current low profile inductor includes forming an inductor element comprising a coil having an open center and an outside surface, the coil also having first and second coil ends, making a dry mixture comprising a dry resin and an insulated dry powdered magnetic powder, and compressing the dry mixture around the outside surface of the coil and within the open center of the coil to create an inductor body without liquefying the dry mixture, whereby the inductor body engages the coil both within the coil open center and also the coil outside surface.

Claims

1. A method for making a high current low profile inductor comprising:

forming an inductor element comprising a coil having and open center and an outside surface;

insulating a magnetic powder;

making a dry mixture comprising a dry resin and a dry insulated magnetic powder by wetting the mixture of resin and magnetic powder and then drying the wetted mixture and then screening the mixture to a predetermined particle size, and then;

compressing the mixture while the mixture is dry around the outside surface of the coil and within the open center of the coil to create an inductor body, whereby the inductor body engages the coil both within the coil open center and also the coil outside surface.

2. The method of claim 1 wherein the predetermined particle size being a particle size of −

50 mesh.