Method for making a high current low profile inductor

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.

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.