Multi-layer parallel plane inductor with field control pockets

A method of manufacturing a high current multi-layer parallel plane inductor comprising a plurality of electrically conductive continuous layers folded back and forth and separated from each other by a separation gap height to form a compact series inductor, each one of the plurality of electrically conductive continuous layers having a layer height;

• and one or more coil control pockets, each one of the one or more coil control pockets formed from at least one layer pocket hole in each one of the plurality of electrically conductive continuous layers, the at least one layer pocket hole in each one of the plurality of electrically conductive continuous layers having a layer first edge notch or a layer second edge notch for selectively directing an alternating current supplied to each of the at least one layer pocket hole in each one of the plurality of electrically conductive continuous layers to generate a magnetic field in each of the one or more coil control pockets, the magnetic field controlled by a configuration of the at least one layer pocket hole in each one of the plurality of electrically conductive continuous layers forming each one of the one or more coil control pockets, the method comprising:
• forming an inductor preform having the plurality of electrically conductive continuous layers in a linear configuration from an electrically conductive solid block stock;
• forming the at least one layer pocket hole for each layer;
• forming the layer first edge notch and the layer second edge notch for each layer pocket hole of the at least one layer pocket hole, wherein each layer first edge notch extends perpendicularly from a first edge of the plurality of electrically conductive continuous layers to the layer pocket hole and each second edge notch extends perpendicularly from a second edge of the plurality of electrically conductive continuous layers to the layer pocket hole;
• and
• folding back and forth the inductor preform along a plurality of transverse fold regions defined perpendicularly between the first edge and the second edge to produce the high current multi-layer parallel plane inductor, wherein the plurality of transverse fold regions are disposed between each layer of the plurality of electrically conductive continuous layers,
• wherein the layer pocket holes for alternating ones of the plurality of electrically conductive continuous layers have reversed the layer first edge notches and the layer second edge notches, such that each consecutive layer pocket hole of the one or more coil control pockets alternates between having the layer first edge notch and the layer second edge notch.

A method of generating a sinusoidal-like magnetic field with a high current multi-layer parallel plane inductor comprising a plurality of electrically conductive continuous layers folded back and forth and separated from each other by a separation gap height to form a compact series inductor, each one of the plurality of electrically conductive continuous layers having a layer height;

• and
• one or more coil control pockets, each one of the one or more coil control pockets formed from at least one layer pocket hole in each one of the plurality of electrically conductive continuous layers,
• wherein a diameter of at least one layer pocket hole is different than the diameter of at least one of a remainder of the layer pocket holes, the at least one layer pocket hole in each one of the plurality of electrically conductive continuous layers having a layer first edge notch or a layer second edge notch for selectively directing an alternating current supplied to each of the at least one layer pocket hole in each one of the plurality of electrically conductive continuous layers,
• wherein the layer first edge notch extends perpendicularly from a first edge of each of the plurality of electrically conductive continuous layers to the at least one layer pocket hole and the layer second edge notch extends perpendicularly from a second edge of each of the plurality of electrically conductive continuous layers to the at least one layer pocket hole, the alternating current selectively directed to generate a magnetic field in each of the one or more coil control pockets, the magnetic field controlled by a configuration of the at least one layer pocket hole in each one of the plurality of electrically conductive continuous layers forming each one of the one or more coil control pockets,
• wherein the layer pocket holes for alternating ones of the plurality of electrically conductive continuous layers have reversed the layer first edge notches and the layer second edge notches, such that each consecutive layer pocket hole of the one or more coil control pockets alternates between having the layer first edge notch and the layer second edge notch.