A high current, low profile inductor includes a conductor coil surrounded by magnetic material to form an inductor body. The inductor coil is formed from a flat plate which is cut into a sine-shaped configuration and then is folded in accordion fashion to create a helical coil.
1. A high current low profile (IHLP) inductor comprising:
a conductive coil having an open center, an outside surface, and first and second coil ends;
a dry powdered magnetic conductive material comprising a plurality of powdered conductive particles;
an insulation material surrounding the powdered conductive particles and providing insulation to the powdered conductive particles;
a dry resin comprising dry resin particles;
a mixture comprising the dry powdered conductive particles, the insulation material, and the dry resin particles thoroughly mixed together;
an inductor body comprising the compressed mixture of the conductive particles of conductive material, the insulation material, and the dry resin particles;
the inductor body surrounding the conductive coil and contacting the conductive coil both inside the open center and on the outside surface of the conductive coil while at the same time preventing the conductive particles of conductive material from shorting out against the coil, and causing the conductive particles to shield the coil;
the first and second coil ends being outside the inductor body.
2. A high current low profile (IHLP) inductor according to claim 1 wherein the powdered conductive particles comprise powdered iron.
3. A high current low profile (IHLP) inductor according to claim 2 wherein the mixture further comprises a lubricant to facilitate the mixture to move into contact with the open center of the coil and the outside surface of the conductive coil.
4. A high current low profile (IHLP) inductor according to claim 3 wherein the mixture further comprises a filler therein.
5. A high current low profile (IHLP) inductor according to claim 1 wherein the first and second coil ends are integral with the coil.
6. A high current low profile (LHLP) inductor according to claim 1 wherein the insulation material and the resin cause the conductive particles of conductive material to have high resistance exceeding 3 mega ohms.