Low profile high current composite transformer
AssigneeVishay Dale Electronics, Inc.
InventorDarek BLOW
Life of this patent
Estimating the term…
Abstract
A low profile high current composite transformer is disclosed. Some embodiments of the transformer include a first conductive winding having a first start lead, a first finish lead, a first plurality of winding turns, and a first hollow core; a second conductive winding having a second start lead, a second finish lead, a second plurality of turns, and a second hollow core; and a soft magnetic composite compressed surrounding the first and second windings. The soft magnetic composite with distributed gap provides for a near linear saturation curve.
Claims21
-19. (canceled)
A method of forming an electromagnetic device comprising:
- forming a first conductive winding, the first conductive winding comprising a first plurality of winding turns, the first plurality of winding turns having a first end and a second end;
- forming a second conductive winding, the second conductive winding comprising a second plurality of winding turns, the second plurality of winding turns having a first end and a second end;
- forming a first lead;
- connecting the first end of the first plurality of winding turns to the first lead;
- forming a second lead;
- connecting the second end of the first plurality of winding turns to the second lead;
- forming a third lead;
- connecting the first end of the second plurality of winding turns to the third lead;
- forming a fourth lead;
- connecting the second end of the second plurality of winding turns to the fourth lead;
- and
- pressure molding a soft magnetic composite to surround at least portions of the first and second plurality of winding turns to form a single unitized body, the soft magnetic composite comprising insulated magnetic particles, the soft magnetic composite tightly pressed around at least portions of the first and second plurality of winding turns, the soft magnetic composite leaving exposed portions of the first, second, third, and fourth leads.
A method of manufacturing an electromagnetic device comprising:
- forming a first conductive winding comprising a first plurality of winding turns;
- forming a second conductive winding comprising a second plurality of winding turns;
- connecting the first conductive winding to a first lead and a second lead;
- and
- connecting the second conductive winding to a third lead and a fourth lead;
- pressure molding a soft magnetic composite to tightly surround the first plurality of winding turns and second plurality of winding turns to form a single unitized body, the soft magnetic composite leaving exposed portions of the leads.
Dependencies are inferred from the claim text.