Magnetic electrical device
First Claim
1. An electromagnetic component, comprising:
- a plurality of flexible magnetic powder sheets, wherein each of the plurality of flexible magnetic powder sheets is substantially planar and capable of being laminated to adjacent ones of the plurality of flexible magnetic powder sheets when arranged in a stack;
at least one preformed multiple turn conductive winding separately fabricated and separately provided from all of the plurality of flexible magnetic powder sheets, wherein at least one of the plurality of flexible magnetic powder sheets is pressed directly to and around the at least one multiple turn preformed conductive winding to define a magnetic core area for the at least one multiple turn preformed conductive winding, wherein at least two of the plurality of flexible magnetic powder sheets are disposed adjacent to the at least one preformed multiple turn conductive winding without a physical gap being formed adjacent the at least one preformed conductive winding; and
at least a first terminal on a first one of the plurality of flexible magnetic powder sheets and at least a second terminal on a second one of the plurality of flexible magnetic powder sheets.
3 Assignments
0 Petitions
Accused Products
Abstract
A magnetic component and a method for manufacturing a low profile, magnetic component. The method comprises the steps of providing at least one sheet, coupling at least a portion of at least one winding to the at least one sheet, and laminating the at least one sheet with at least a portion of the at least one winding. The magnetic component comprises at least one sheet and at least a portion of at least one winding coupled to the at least one sheet, wherein the at least one sheet is laminated to at least a portion of the at least one winding. The winding may comprise a clip, a preformed coil, a stamped conductive foil, or an etched trace using chemical or laser etching. The sheet may comprise any material capable of being laminated and/or rolled, including, but not limited to, flexible magnetic powder sheets.
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Citations
54 Claims
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1. An electromagnetic component, comprising:
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a plurality of flexible magnetic powder sheets, wherein each of the plurality of flexible magnetic powder sheets is substantially planar and capable of being laminated to adjacent ones of the plurality of flexible magnetic powder sheets when arranged in a stack; at least one preformed multiple turn conductive winding separately fabricated and separately provided from all of the plurality of flexible magnetic powder sheets, wherein at least one of the plurality of flexible magnetic powder sheets is pressed directly to and around the at least one multiple turn preformed conductive winding to define a magnetic core area for the at least one multiple turn preformed conductive winding, wherein at least two of the plurality of flexible magnetic powder sheets are disposed adjacent to the at least one preformed multiple turn conductive winding without a physical gap being formed adjacent the at least one preformed conductive winding; and at least a first terminal on a first one of the plurality of flexible magnetic powder sheets and at least a second terminal on a second one of the plurality of flexible magnetic powder sheets. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22)
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23. An electromagnetic component, comprising:
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a plurality of flexible magnetic powder sheets, wherein the flexible magnetic powder sheets are provided in substantially planar form and are capable of being laminated to adjacent ones of the plurality of flexible magnetic powder sheets when arranged in a stack; at least one preformed multiple turn conductive winding separately fabricated and separately provided from all of the plurality of flexible magnetic powder sheets, wherein the plurality of flexible magnetic powder sheets are laminated in surface contact with one another and at least one of the plurality of flexible magnetic powder sheets is laminated in surface contact with the at least one preformed multiple turn conductive winding to enclose the at least one preformed multiple turn conductive winding and define a magnetic core area therefore wherein at least two of the flexible magnetic powder sheets are disposed adjacent to and in surface contact with the at least one preformed multiple turn conductive winding without a physical gap extending between the at least two flexible magnetic powder sheets and the at least one preformed conductive winding; and at least a first terminal on a first one of the plurality of flexible magnetic powder sheets and at least a second terminal on a second one of the plurality of flexible magnetic powder sheets. - View Dependent Claims (24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40)
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41. An electromagnetic component comprising:
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a laminated structure comprising; a plurality of stacked magnetic powder layers joined to one another; a multiple turn coil surrounded by the joined magnetic powder layers, the coil being separately provided from and fabricated independently from all of the plurality of stacked magnetic powder layers; wherein at least some of the magnetic powder layers are flexibly pressed around an outer surface of the multiple turn coil to form a magnetic core structure around the multiple turn coil without a physical gap; and at least a first terminal on a first one of the plurality of stacked magnetic powder layers and at least a second terminal on a second one of the plurality of stacked magnetic powder layers. - View Dependent Claims (42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52)
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53. An electromagnetic component comprising:
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a laminated structure comprising; a plurality of stacked flexible sheet layers joined to one another; and a multiple turn coil surrounded by the joined flexible sheet layers, the multiple turn coil being separately provided from and fabricated independently from all of the plurality of stacked flexible sheet layers; wherein at least some of the flexible sheet layers are flexibly pressed in surface engagement with and around an outer surface of the multiple turn coil to enclose the multiple turn coil without a physical gap; and wherein all of the plurality of stacked flexible sheet layers comprise magnetic powder sheet layers; wherein at least one of the plurality of stacked flexible sheet layers is pressed in surface engagement to and around an outer surface of the multiple turn coil; and wherein each of the plurality of stacked flexible sheet layers is pressed in surface contact with at least one other of the plurality of stacked flexible sheet layers; and at least a first terminal on a first one of the plurality of flexible sheet layers and at least a second terminal on a second one of the plurality of flexible sheet layers. - View Dependent Claims (54)
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Specification