High current amorphous powder core inductor
First Claim
1. An electromagnetic component, comprising:
- at least one shaped-core fabricated from an amorphous magnetically soft powder material, the at least one shaped core having a top surface and a bottom surface opposing the top surface; and
at least one preformed conductive winding coupled to the at least one shaped-core, the at least one preformed conductive winding formed with a winding portion and opposing first and second leads, the winding portion including opposing major surfaces and lateral side surfaces interconnecting the opposing major surfaces, the winding portion engaging the top surface of the at least one shape-core and the opposing first and second leads engaging the bottom surface of the at least one shaped-core without being bent around the at least one shaped-core;
wherein the amorphous magnetically soft powder material is a nanoamorphous powder material; and
wherein the at least one shaped-core comprises a first shaped-core and a second shaped-core, wherein the winding portion is extended between the first shaped-core and the second shaped-core and wherein the first and second shaped-cores are pressed in surface contact with one another.
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Accused Products
Abstract
A magnetic component and a method of manufacturing the same. The method comprises the steps of providing at least one shaped-core fabricated from an amorphous powder material, coupling at least a portion of at least one winding to the at least one shaped-core, and pressing the at least one shaped-core with at least a portion of the at least one winding. The magnetic component comprises at least one shaped-core fabricated from an amorphous powder material and at least a portion of at least one winding coupled to the at least one shaped-core, wherein the at least one shaped-core is pressed to at least a portion of the at least one winding. The winding may be preformed, semi-preformed, or non-preformed and may include, but is not limited to, a clip or a coil. The amorphous powder material may be an iron-based or cobalt-based amorphous powder material or a nanoamorphous powder material.
165 Citations
14 Claims
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1. An electromagnetic component, comprising:
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at least one shaped-core fabricated from an amorphous magnetically soft powder material, the at least one shaped core having a top surface and a bottom surface opposing the top surface; and at least one preformed conductive winding coupled to the at least one shaped-core, the at least one preformed conductive winding formed with a winding portion and opposing first and second leads, the winding portion including opposing major surfaces and lateral side surfaces interconnecting the opposing major surfaces, the winding portion engaging the top surface of the at least one shape-core and the opposing first and second leads engaging the bottom surface of the at least one shaped-core without being bent around the at least one shaped-core; wherein the amorphous magnetically soft powder material is a nanoamorphous powder material; and wherein the at least one shaped-core comprises a first shaped-core and a second shaped-core, wherein the winding portion is extended between the first shaped-core and the second shaped-core and wherein the first and second shaped-cores are pressed in surface contact with one another. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. An electromagnetic component, comprising:
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a first shaped-core fabricated from an amorphous magnetically soft powder material; a second shaped-core fabricated from an amorphous magnetically soft powder material; an electrically conductive preformed winding clip comprising a first lead, a second lead and a winding portion therebetween, wherein the winding portion of the clip is extended between the first shaped-core and the second shaped-core and the first and second leads extend exterior to the first and second shaped-cores without being bent around either of the first and second shaped-cores; wherein the amorphous magnetically soft powder material is a nanoamorphous powder material, and wherein facing surfaces of the first shaped-core, the second shaped-core, and the winding clip are pressed in surface engagement with one another, thereby eliminating any separation between the winding portion and the amorphous magnetically soft powder material of the first and second shaped-cores. - View Dependent Claims (12)
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13. An electromagnetic component, comprising:
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a first shaped-core fabricated from a magnetically soft powder material, the first shaped-core having a top surface and a bottom surface; a second shaped-core fabricated from a magnetically soft powder material, the second shaped-core having a top surface and a bottom surface; and an electrically conductive preformed winding clip comprising a first lead, a second lead and a winding portion therebetween, wherein the winding portion of the clip is extended between the top surface of the first shaped-core and the bottom surface of the second shaped-core and the first and second leads extend on the bottom surface of the first shaped-core without being bent around the first-shaped core, wherein the top surface of the first shaped-core and the bottom surface of the second shaped-core are pressed in surface engagement with one another and are pressed in surface engagement with the winding clip, thereby completely surrounding the winding portion with the magnetically soft powder material of the first and second shaped-cores and so that no gap exists between the magnetically soft powder material and any portion of the winding portion; wherein at least one of the first and second shaped-cores is shaped from a nanoamorphous magnetically soft powder material. - View Dependent Claims (14)
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Specification