Method for making a high current low profile inductor

• US 7,986,207 B2
• Filed: 08/05/2009
• Issued: 07/26/2011
• 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): NGUYEN, TUYEN T
• Application Number:
  US12/535,757
• Publication Number:
  US 20100007455A1
• Time in Patent Office: 720 Days
• Field of Search: 336/65, 336/83, 336/200, 336220-223, 336232-233
• 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 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 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. An inductor comprising:

an electrical coil having an open inside diameter;

external terminals for connecting the electrical coil to an electrical circuit; and

a compressed body of insulated conductive particles that are tightly and completely compressed about and inside the coil while magnetically shielding the coil.

2. The inductor of claim 1, wherein the compressed body of insulated conductive particles prevents the external terminals from electrical shorting.

3. The inductor of claim 1, wherein the coil has a plurality of turns.

4. The inductor of claim 1, wherein the external terminals comprise leads.

5. The inductor of claim 1 wherein the compressed body further comprises a resin.

6. The inductor of claim 5, wherein the resin is a polymer resin.

7. The inductor of claim 6, wherein the polymer resin is selected from a group comprised of polyester, silicon, polyurethane.

8. An inductor comprising:

an electrical coil having an open center;

terminals for connecting the electrical coil to an electrical circuit; and

a body, comprised solely of insulated conductive particles compressed tightly and completely about and inside the open center of the coil, that prevents electrical shorting of the terminals and magnetically shields the coil.

9. An electrical component comprising:

an electrical coil having inside and outside surfaces;

external terminals for connecting the electrical coil to an electrical circuit; and

a body of compressed, insulated conductive particles in contact with the inside and outside surfaces of the coil that prevents electrical shorting of the external terminals and magnetically shields the coil.

10. An inductor comprising:

an electrical coil having an open center;

external terminals for connecting the electrical coil to an electrical circuit; and

a body that is comprised solely of dry, insulated conductive particles that are tightly and completely compressed about and inside the open center of the coil while preventing the external terminals from electrical shorting and magnetically shielding the coil.

11. An inductor comprising:

an electrical coil having inside and outside surfaces;

external terminals for connecting the electrical coil to an electrical circuit; and

dry and insulated conductive particles that are compressed into contact with the inside and outside surfaces of the coil to form a body that prevents the external terminals from electrical shorting and magnetically shields the coil.

12. An inductor comprising:

an electrical coil having an open center;

external terminals for connecting the electrical coil to an electrical circuit; and

a body that is comprised of dry powdered insulated iron particles that are tightly and completely compressed about and inside the open center of the coil while preventing the external terminals from electrical shorting and magnetically shielding the coil.

13. An electrical component comprising:

a current conducting coil having inside and outside surfaces;

external terminals that electrically connect the coil to an associated electrical circuit; and

a body of compressed dry insulated iron particles that completely contact the inside and outside surfaces of the coil, preventing electrical shorting of the external terminals and magnetically shielding the coil.