Method of manufacturing an electromagnetic component
First Claim
Patent Images
1. A method of manufacturing an electromagnetic component, the method comprising:
- providing a plurality of substantially planar and flexible magnetic powder sheets, wherein each of the plurality of substantially planar and flexible magnetic powder sheets is capable of being laminated to another one of the plurality of substantially planar and flexible magnetic powder sheets;
providing at least one preformed multiple turn conductive winding including a flexible wire conductor that is wound in multiple turns about an open center area and further including first and second leads, wherein the at least one preformed multiple turn conductive winding is separately fabricated from all of the plurality of substantially planar and flexible magnetic powder sheets;
stacking the plurality of substantially planar and flexible magnetic powder sheets;
locating the at least one preformed multiple turn conductive winding between at least two of the plurality of substantially planar and flexible magnetic powder sheets in the stack;
pressure laminating the substantially planar and flexible magnetic powder sheets around the at least one preformed multiple turn conductive winding to define a magnetic core containing the at least one preformed multiple turn conductive winding, wherein at least one of the plurality of substantially planar and flexible magnetic powder sheets is pressed directly to and around the at least one preformed multiple turn conductive winding, and wherein at least two of the plurality of substantially planar and 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 multiple turn conductive winding;
providing first and second terminals on at least one of the plurality of substantially planar and flexible magnetic powder sheets; and
connecting the first and second terminals to the respective first and second leads.
3 Assignments
0 Petitions
Accused Products
Abstract
A method for manufacturing a low profile, magnetic component. The method includes stacking a the plurality of substantially planar and flexible magnetic powder sheets, locating a preformed multiple turn conductive winding between at least two of the plurality of substantially planar and flexible magnetic powder sheets in the stack, and pressure laminating the flexible magnetic powder sheets around the preformed multiple turn conductive winding to define a magnetic core containing the winding.
-
Citations
48 Claims
-
1. A method of manufacturing an electromagnetic component, the method comprising:
-
providing a plurality of substantially planar and flexible magnetic powder sheets, wherein each of the plurality of substantially planar and flexible magnetic powder sheets is capable of being laminated to another one of the plurality of substantially planar and flexible magnetic powder sheets; providing at least one preformed multiple turn conductive winding including a flexible wire conductor that is wound in multiple turns about an open center area and further including first and second leads, wherein the at least one preformed multiple turn conductive winding is separately fabricated from all of the plurality of substantially planar and flexible magnetic powder sheets; stacking the plurality of substantially planar and flexible magnetic powder sheets; locating the at least one preformed multiple turn conductive winding between at least two of the plurality of substantially planar and flexible magnetic powder sheets in the stack; pressure laminating the substantially planar and flexible magnetic powder sheets around the at least one preformed multiple turn conductive winding to define a magnetic core containing the at least one preformed multiple turn conductive winding, wherein at least one of the plurality of substantially planar and flexible magnetic powder sheets is pressed directly to and around the at least one preformed multiple turn conductive winding, and wherein at least two of the plurality of substantially planar and 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 multiple turn conductive winding; providing first and second terminals on at least one of the plurality of substantially planar and flexible magnetic powder sheets; and connecting the first and second terminals to the respective first and second leads. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
-
-
17. A method of manufacturing an electromagnetic component including:
-
a magnetic core defined by a plurality of substantially planar and flexible magnetic powder sheets, wherein each of the plurality of substantially planar and flexible magnetic powder sheets is capable of being laminated to another one of the plurality of substantially planar and flexible magnetic powder sheets, wherein first and second terminals are provided on at least one of the plurality of substantially planar and flexible magnetic powder sheets; and at least one preformed multiple turn conductive winding including a flexible wire conductor that is wound in multiple turns about an open center area and that includes first and second leads, wherein the at least one preformed multiple turn conductive winding is separately fabricated from all of the plurality of substantially planar and flexible magnetic powder sheets; wherein the method comprises; stacking the plurality of substantially planar and flexible magnetic powder sheets; locating the at least one preformed multiple turn conductive winding between at least two of the plurality of substantially planar and flexible magnetic powder sheets in the stack; pressure laminating the plurality of substantially planar and flexible magnetic powder sheets around the at least one preformed multiple turn conductive winding to define the magnetic core, wherein at least one of the plurality of substantially planar and flexible magnetic powder sheets is pressed directly to and around the at least one preformed multiple turn conductive winding, and wherein at least two of the plurality of substantially planar and 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 multiple turn conductive winding; and connecting the first and second terminals to the respective first and second leads. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32)
-
-
33. A method of manufacturing an electromagnetic component including:
-
a magnetic core defined by a plurality of substantially planar and flexible magnetic powder sheets, wherein each of the plurality of substantially planar and flexible magnetic powder sheets is capable of being laminated to another one of the plurality of substantially planar and flexible magnetic powder sheets when the plurality of substantially planar and flexible magnetic powder sheets are arranged in a stack, and wherein first and second terminals are provided on one of the first and second ones of the plurality of substantially planar and flexible magnetic powder sheets; and at least one preformed multiple turn conductive winding having multiple turns extending about an open center area, wherein the at least one preformed multiple turn conductive winding is separately fabricated from all of the plurality of substantially planar and flexible magnetic powder sheets, wherein the at least one preformed multiple turn conductive winding is fabricated from a flexible wire conductor having first and second leads; wherein the method comprises; locating the at least one preformed multiple turn conductive winding between first and second ones of the plurality of substantially planar and flexible magnetic powder sheets; pressure laminating the plurality of substantially planar and flexible magnetic powder sheets around the at least one preformed multiple turn conductive winding to define the magnetic core, wherein the first and second ones of the plurality of substantially planar and flexible magnetic powder sheets is are pressed directly to and around the at least one preformed multiple turn conductive winding, and wherein at least first and second ones of the plurality of substantially planar and 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 multiple turn conductive winding; completing first and second surface mount terminals respectively connected to the first and second leads of the at least one preformed multiple turn conductive winding; and connecting the first and second terminals to the respective first and second leads. - View Dependent Claims (34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48)
-
Specification