Method for making a multi-thickness electro-magnetic device
Electro-magnetic devices are provided, having conductive elements and leads of multiple thicknesses. Templates are provided for making electro-magnetic devices, formed by an extrusion process, a skiving process, a swaging process, 3D printing, or a machining process. The multi-thickness electro-magnetic devices may comprise a conductive element having an increased thickness area, and one or more leads having at least one decreased thickness area, having a thickness less than the increased thickness area. An electro-magnetic device may be provided comprising a conductive element having an increased thickness encased in a body formed from a core material, and leads or lead portions connected to the conductive element having a decreased thickness.
1. A method for making a multi-thickness electro-magnetic device comprising the steps of:
providing a conductive material;
forming the conductive material into a multi-thickness sheet by performing an extrusion process, a skiving process, or a flattening process, the multi-thickness sheet comprising a first portion having a first thickness, a second portion having a second thickness, and a third portion have a third thickness; and
forming a multi-thickness template by:
forming the first portion of the multi-thickness sheet into a conductive element,
forming the second portion of the multi-thickness sheet into a first lead portion, and
forming the third portion of the multi-thickness sheet into a second lead portion;
wherein the first thickness is greater than the second thickness, and
wherein the first thickness is greater than the third thickness.
2. The method of claim 1 , wherein at least a portion of the multi-thickness template is formed by stamping the multi-thickness sheet.
3. The method of claim 1 , wherein the conductive element has a serpentine shape, a rectangular shape, an I-shape, an H-shape, or a barbell shape.
4. The method of claim 1 , wherein the conductive element, the first lead portion, and the second lead portion are formed from a continuous, non-wound piece of conductive material.
5. The method of claim 1 , wherein no portion of the conductive element crosses over or under another portion of the conductive element.
6. The method of claim 1 , wherein the first lead portion has a thickness that is uniform along substantially an entire length of the first lead portion, and the second lead portion has a thickness that is uniform along substantially an entire length of the second lead portion.
7. The method of claim 1 , wherein the first lead portion has a first width adjacent the conductive element and a second width at an end of the first lead portion, and wherein the second width is different than the first width.
8. The method of claim 1 , wherein the second lead portion has a first width adjacent the conductive element and a second width at an end of the second lead portion, and wherein the second width is greater than the first width.
9. A method for making an electro-magnetic device comprising the steps of:
providing a conductive material;
forming the conductive material into a multi-thickness sheet, the multi-thickness sheet comprising a first portion for forming a conductive element having a first thickness, a second portion for forming a first lead portion having a second thickness, and a third portion for forming a second lead portion having a third thickness, wherein the first thickness is greater than the second thickness, and wherein the first thickness is greater than the third thickness;
forming a multi-thickness template by:
forming the first portion of the multi-thickness sheet into the conductive element,
forming the second portion of the multi-thickness sheet into the first lead portion, and
forming the third portion of the multi-thickness sheet into the second lead portion; and
pressing a core material around the conductive element and at least a portion of the first lead portion and at least a portion of the second lead portion to form a body.
10. The method of claim 9 , further comprising the steps of trimming the first lead portion and trimming the second lead portion.
11. The method of claim 10 , further comprising the steps of positioning at least a portion of the first lead portion along an outer surface of the body and extending at least a portion of the first lead portion along a bottom surface of the body, and further comprising the steps of positioning at least a portion of the second lead portion along an outer surface of the body and extending at least a portion of the second lead portion along a bottom surface of the body.
12. The method of claim 9 , wherein the step of forming the conductive material into a multi-thickness sheet comprises performing an extrusion process.
13. The method of claim 9 , wherein the step of forming the conductive material into a multi-thickness sheet comprises performing a skiving process.
14. The method of claim 9 , wherein the step of forming the conductive material into a multi-thickness sheet comprises performing a flattening process.
15. The method of claim 9 , wherein the step of forming the multi-thickness template comprises stamping the multi-thickness sheet to form the conductive element, the first lead portion, and the second lead portion.
16. The method of claim 9 , wherein the conductive element has a serpentine shape, a rectangular shape, an I-shape, an H-shape, or a barbell shape.
17. The method of claim 9 , wherein the conductive element, first lead portion, and second lead portion are formed from a continuous, non-wound piece of conductive material.
18. The method of claim 9 , wherein no portion of the conductive element crosses over or under another portion of the conductive element.
19. The method of claim 9 , further comprising the step of plating the multi-thickness sheet or the multi-thickness template with a layer of nickel or a layer of tin.