Transformer and inductor modules having directly bonded terminals and heat-sink fins

A method of manufacturing a module having at least one solid magnetic core, said at least one solid magnetic core having an electrically insulating top surface and an electrically insulating bottom surface, said module comprising at least one of a transformer module and an inductor module and said module having at least a first and a second electrical output for connecting said module to circuitry external to said module, said method comprising the steps of:

• obtaining said at least one solid magnetic core;
• obtaining an electrically conductive base plate that is dimensioned to cover said bottom surface of said at least one solid magnetic core, said base plate being manufactured of a material having sufficient electrical conductivity to allow said base plate to serve as a termination in a power converter;
• obtaining an electrically conductive top plate that is dimensioned to cover said top surface of said at least one solid magnetic core, said base plate being manufactured of a material having sufficient electrical conductivity to allow said base plate to serve as a termination in a power converter;
• bonding said bottom surface of said at least one solid magnetic core directly to said conductive base plate;
• bonding said conductive top plate directly to said top surface of at least one solid magnetic core;
• connecting the at least a first output to said conductive base plate;
• and
• connecting the at least a second output to said conductive top plate;
• wherein at least one of said steps of obtaining said conductive base plate and obtaining said conductive top plate further comprises obtaining a conductive plate manufactured of a material that is both electrically conductive and thermally conductive and has at least one surface dimensioned to serve as a heat conductive path to a heat sink;
• and
• wherein said resulting module may utilize said conductive base plate as a first termination and may utilize said conductive top plate as a second termination and may utilize at least one surface of one of said conductive base plate and said conductive top plate as a heat conductive path to a heat sink.