METHOD FOR MAKING A HIGH CURRENT LOW PROFILE INDUCTOR
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 . An inductor comprising:
an electrical coil having an open center;
terminals for connecting the electrical coil to an electrical circuit; and
a compressed body comprised of insulated conductive particles that tightly and completely surround and magnetically shield the coil.
2 . The inductor of claim 1 wherein the coil comprises copper.
3 . The inductor of claim 2 wherein the copper is greater than approximately 99% pure.
4 . The inductor of claim 1 wherein the electrical coil comprises a plurality of L-shaped coil segments.
5 . The inductor of claim 4 wherein each of the plurality of L-shaped coil segments comprises at least one vertical leg and at least one horizontal leg.
6 . The inductor of claim 1 wherein the electrical coil is helical.
7 . The inductor of claim 1 wherein the magnetic shielding prevents electrical shorting of the terminals.
8 . The inductor of claim 1 wherein the insulated conductive particles comprise iron.
9 . The inductor of claim 1 wherein the insulated conductive particles are dry.
10 . The inductor of claim 1 wherein the inductor is substantially devoid of air spaces.
11 . The inductor of claim 1 wherein the electrical coil and the compressed body provides a closed magnetic system.
12 . The inductor of claim 1 wherein the compressed body comprises at least powdered iron, a filler, a resin and a lubricant.
13 . The inductor of claim 12 wherein the resin comprises an epoxy resin.
14 . The inductor of claim 12 wherein the lubricant comprises zinc stearate.
15 . The inductor of claim 1 wherein the compressed body is pressed with a pressure within the range of 15 to 25 tons per square inch.
16 . The inductor of claim 1 wherein the series resistance of the inductor is reduced.
17 . An inductor comprising:
an electrical coil having an open center;
terminals for connecting the electrical coil to an electrical circuit; and
a compressed body comprised entirely of insulated magnetic materials that tightly and completely surround and shield the coil.
18 . The inductor of claim 17 wherein the coil comprises copper.
19 . The inductor of claim 18 wherein the copper is greater than approximately 99% pure.
20 . The inductor of claim 17 wherein the electrical coil is helical.
21 . The inductor of claim 17 wherein the magnetic shielding prevents electrical shorting of the terminals.
22 . The inductor of claim 17 wherein the insulated magnetic materials comprise iron.
23 . The inductor of claim 17 wherein the insulated magnetic materials are dry.
24 . The inductor of claim 17 wherein the inductor is substantially devoid of air spaces.
25 . The inductor of claim 17 wherein the compressed body comprises at least powdered iron, a filler, a resin and a lubricant.
26 . The inductor of claim 25 wherein the resin comprises an epoxy resin.
27 . The inductor of claim 25 wherein the lubricant comprises zinc stearate.
28 . The inductor of claim 17 wherein the compressed body is pressed with a pressure within the range of 15 to 25 tons per square inch.
29 . The inductor of claim 17 further comprising a reduced series resistance.