Method of Generating Novel Air Gap Layouts for Laminated Magnetic Core Miniature Thin Film Inductors and Transformers with a Continuous Function

A computer-implemented method of generating at least one miniature laminated magnetic core layer with at least one partial air gap:

• Inputting by the computer through a graphical user interface at least one air gap radius, density value, and exclusion area;
• Generating by a computer an area of the magnetic core layer having a series of air gaps as determined by the air gap radius, density value, and the exclusion area inputs as limited to the area radius input;
• Determining by the computer the mechanical tolerances of the magnetic core layer having the generated are of air gaps;
• Displaying by the computer the mechanical tolerances of the magnetic core layer with computer-generated air gap series;
• and
• Selecting an air gap grouping generated by the computer for implementation into a core according to the determined mechanical tolerances of the magnetic core layer of core.

A computer implemented method of generating at least one miniature laminated magnetic core layer with at least one partial air gap:

• Inputting by the computer through a graphical user interface an initial radius, an initial coordinate angle, an end radius, and an end coordinate angle for at least one first cut;
• Inputting by the computer through a graphical user interface an initial radius, an initial coordinate angle, an end radius, and an end coordinate angle for a number of second cuts matching the number of the first cuts inputted;
• Inputting by the computer through a graphical user interface at least one limited core layer area radius, density value, and exclusion radius;
• Generating by a computer an area of the magnetic core layer having a series of air gaps as determined by the density input and the exclusion input as limited to the area radius input;
• Generating by a computer at least one non-grouped air gap pattern for the magnetic core layer, each of the non-grouped air gaps, having a first edge defined by the initial radius, the initial coordinate angle, the end radius, and the end coordinate angle for a first cut and having a second edge defined by the initial radius, the initial coordinate angle, the end radius, and the end coordinate angle for the second cut;
• Determining by the computer an inductance over current curve for a core having the given core layer with all generated air gaps for each generated air gap pattern;
• Determining by the computer the mechanical tolerances of the magnetic core layer having the generated area of air gaps;
• Displaying by the computer the inductance over current curve for the given core with computer-generated air gap;
• and
• Selecting an air gap layout generated by the computer for implementation into a core according to the determined inductance over current curve for the given core given the mechanical tolerances of the generated magnetic core.