Optimal inductor
AssigneeComsys AB
InventorsÓscar H. BJARNASEN, Tord CEDELL
Life of this patent
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Abstract
A coil may include a metal wire wound circular around a center axis. The wire may have an electrically insulating layer insulating each turn of the wire in the winding from neighbouring turns. The shape of the complete winding, building up the coil, may be toroidal having an elliptic cross section in a plane perpendicular to a wire winding direction. And the wound coil may have a metal volume to total volume at a level so that the thermal heat conduction of the coil is above 0.8 W/m*K. A method for producing such a coil may involve applying the insulating layer to the wire. The wire may be wound around the center axis. The winding may be compressed to a toroidal shape.
Claims15
A method of producing a coil including a metal wire wound circular around a center axis, wherein the wire has an electrically insulating layer insulating each turn of the wire in the winding from neighbouring turns, wherein the shape of the complete winding, building up the coil, is toroidal having an elliptic cross section in a plane perpendicular to a wire winding direction, and wherein the wound coil has a metal volume to total volume at a level so that the thermal heat conduction of the coil is above 0.8 W/m*K;
- the method comprising:
- applying the insulating layer to the wire;
- winding the wire around the center axis;
- and
- compressing the winding to a toroidal shape.
A method of producing an inductor including a coil embedded in a core;
- wherein the coil includes a metal wire wound circular around a center axis, wherein the wire has an electrically insulating layer insulating each turn of the wire in the winding from neighbouring turns, wherein the shape of the complete winding, building up the coil, is toroidal having an elliptic cross section in a plane perpendicular to a wire winding direction, and wherein the wound coil has a metal volume to total volume at a level so that the thermal heat conduction of the coil is above 0.8 W/m*K;
- and
- wherein the core is made of a soft magnetic composite material made of metallic particles and a binder material, wherein the coil has an electrically insulating layer covering its surface area, and wherein core particles are magnetically aligned with the H-field of the coil;
- the method comprising:
- placing the soft magnetic composite material made of metallic particles and the binder material in a mould;
- and
- arranging a magnetic field in the mould during a moulding and/or a hardening phase of the soft magnetic composite material, magnetically aligning the metallic particles with the H-field.
Dependencies are inferred from the claim text.