Method for making a high current low profile inductor
View Patent ↗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.
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 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 resin comprising resin particles;
a mixture comprising the powdered conductive particles, the insulation material, and the resin particles;
an inductor body comprising the compressed mixture while dry of the conductive particles of conductive material, the insulation material, and the 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;
the first and second 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.