Inductor core-coil assembly and manufacturing thereof

Abstract

Disclosed are a gapped magnetic core which may be coated or uncoated with an insulating layer or housed in an insulting box having a physical gap whose dimension is close to that of the gapped magnetic core and automated or semi-automated methods of applying copper wire on the gapped core or the core assembly and filling the gap with a spacer in the core or core assembly. The disclosed processes allow various combinations of core and spacer materials and gap configurations, resulting in a wide variety of core-coil assemblies which are useful as inductive components in electric and electronic circuits. Also disclosed is a core-coil assembly wherein a magnetic core with a gap directed off the conventional radial direction of a toroidally-wound core.

Dependencies are inferred from the claim text.