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US 7,882,614 B2Granted
Method for providing a power inductor
AssigneeMarvell World Trade Ltd.
InventorSehat Sutardja
Life of this patent
Estimating the term…
Abstract
A method for providing a power inductor comprises forming a first magnetic core material having first and second ends and an inner cavity that extends from the first end to the second end; forming a first notch in the first magnetic core material that projects inwardly towards the inner cavity from one of the first and second ends; and passing a first conductor through the inner cavity that is received by the first notch.
Claims35
A method for providing a power inductor, comprising:
- forming a first magnetic core material having first and second ends and an inner cavity that extends from said first end to said second end in a first direction;
- forming a first notch in said first magnetic core material that projects inwardly towards said inner cavity from one of said first and second ends in said first direction;
- passing a first conductor through said inner cavity in said first direction, the first conductor being retained by said first notch;
- and
- forming a second notch in said first magnetic core material that projects inwardly towards said inner cavity from the other of said first and second ends in said first direction, wherein said first conductor is also retained by said second notch.
2 more elements
A method for providing a power inductor, comprising:
- forming a first magnetic core material having first and second ends and an inner cavity that extends from said first end to said second end;
- forming a first notch in said first magnetic core material that projects inwardly towards said inner cavity from one of said first and second ends;
- passing a first conductor through said inner cavity that is received by said first notch;
- and
- forming 2n+1 additional notches in said first magnetic core material that project inwardly towards said inner cavity, wherein said first conductor is also received by said 2n+1 additional notches and said first conductor passes through said inner cavity n+1 times.
2 more elements
A method for providing a power inductor, comprising:
- forming a first magnetic core material having first and second ends and an inner cavity that extends from said first end to said second end;
- forming a first notch in said first magnetic core material that projects inwardly towards said inner cavity from one of said first and second ends;
- passing a first conductor through said inner cavity that is received by said first notch;
- and
- forming a slotted air gap in said first magnetic core material that extends from said first end to said second end.
2 more elements
A method for providing a power inductor, comprising:
- forming a first magnetic core material having first and second ends and an inner cavity that extends from said first end to said second end;
- forming a first notch in said first magnetic core material that projects inwardly towards said inner cavity from one of said first and second ends;
- passing a first conductor through said inner cavity that is received by said first notch;
- forming a slotted air gap in said first magnetic core material that extends from said first end to said second end;
- and
- arranging an eddy current reducing material adjacent to at least one of an inner opening of said slotted air gap in said inner cavity between said slotted air gap and said first conductor and an outer opening of said slotted air gap, wherein said eddy current reducing material has a permeability that is lower than said first magnetic core material.
3 more elements
A method for providing a power inductor, comprising:
- forming a first magnetic core material having first and second ends and an inner cavity that extends from said first end to said second end in a first direction;
- forming a first notch in said first magnetic core material that projects inwardly towards said inner cavity from one of said first and second ends in said first direction;
- passing a first conductor through said inner cavity in said first direction, the first conductor being retained by said first notch;
- forming a second notch in said first magnetic core material that projects inwardly from one of said first and second ends in said first direction;
- and
- passing a second conductor through said inner cavity in said first direction, the second conductor being retained by said second notch.
3 more elements
A method for providing a power inductor, comprising:
- forming a first magnetic core material having first and second ends and an inner cavity that extends from said first end to said second end;
- forming a first notch in said first magnetic core material that projects inwardly towards said inner cavity from one of said first and second ends;
- passing a first conductor through said inner cavity that is received by said first notch;
- forming a second notch in said first magnetic core material that projects inwardly from one of said first and second ends;
- passing a second conductor through said inner cavity that is received by said second notch;
- and
- creating a projection of said first magnetic core material that extends outwardly from a first side of said first magnetic core material between said first and second conductors.
4 more elements
A method for providing a power inductor, comprising:
- forming a first magnetic core material having first and second ends and an inner cavity that extends from said first end to said second end in a first direction;
- forming a first notch in said first magnetic core material that projects inwardly towards said inner cavity from one of said first and second ends in said first direction;
- passing a first conductor through said inner cavity in said first direction, the first conductor being retained by said first notch;
- and
- arranging an insulating material on an outer surface of said first conductor.
2 more elements
A method for providing a power inductor, comprising:
- forming a first magnetic core material having first and second ends and an inner cavity that extends from said first end to said second end in a first direction;
- forming a first notch in said first magnetic core material that projects inwardly towards said inner cavity from one of said first and second ends in said first direction;
- passing a first conductor through said inner cavity in said first direction, the first conductor being retained by said first notch, wherein a cross-sectional shape of said first magnetic core material is one of square, circular, rectangular, elliptical, and oval.
A method for providing a power inductor, comprising:
- forming a first magnetic core material having first and second ends and an inner cavity that extends from said first end to said second end in a first direction;
- forming a first notch in said first magnetic core material that projects inwardly towards said inner cavity from one of said first and second ends in said first direction;
- passing a first conductor through said inner cavity in said first direction, the first conductor being retained by said first notch;
- and
- locating a first end of said first conductor and a second end of said first conductor along an outer side of said first magnetic core material.
2 more elements
A method for providing a power inductor, comprising:
- forming a first magnetic core material having first and second ends and an inner cavity that extends from said first end to said second end in a first direction;
- forming a first notch in said first magnetic core material that projects inwardly towards said inner cavity from one of said first and second ends in said first direction;
- passing a first conductor through said inner cavity in said first direction, the first conductor being retained by said first notch;
- and
- projecting first and second ends of said first conductor outwardly from said first magnetic core material.
2 more elements
A method for providing a power inductor, comprising:
- forming a first magnetic core material having first and second ends and an inner cavity that extends from said first end to said second end;
- forming a first notch in said first magnetic core material that projects inwardly towards said inner cavity from one of said first and second ends;
- passing a first conductor through said inner cavity that is received by said first notch;
- projecting first and second ends of said first conductor outwardly from said first magnetic core material;
- and
- surface mounting and first and second ends of said first conductor on a printed circuit board in a gull wing configuration.
3 more elements
A method for providing a power inductor, comprising:
- forming a first magnetic core material having first and second ends and an inner cavity that extends from said first end to said second end;
- forming a first notch in said first magnetic core material that projects inwardly towards said inner cavity from one of said first and second ends;
- passing a first conductor through said inner cavity that is received by said first notch;
- projecting first and second ends of said first conductor outwardly from said first magnetic core material;
- and
- locating said at least one of said first and second ends of said first conductor in plated-through holes of a printed circuit board.
3 more elements
A method for providing a power inductor, comprising:
- forming a first magnetic core material having first and second ends and an inner cavity that extends from said first end to said second end;
- forming a first notch in said first magnetic core material that projects inwardly towards said inner cavity from one of said first and second ends;
- passing a first conductor through said inner cavity that is received by said first notch;
- forming a slotted air gap in said first magnetic core material that extends from said first end to said second end;
- and locating a second magnetic core material at least one of in and adjacent to said slotted air gap, wherein said first magnetic core material comprises a ferrite bead core material.
2 more elements
A method for providing a power inductor, comprising:
- forming a first magnetic core material having first and second ends and an inner cavity that extends from said first end to said second end;
- forming a first notch in said first magnetic core material that projects inwardly towards said inner cavity from one of said first and second ends;
- passing a first conductor through said inner cavity that is received by said first notch;
- and
- forming said first notch in said first magnetic core material during molding and before sintering.
2 more elements
A method for providing a power inductor, comprising:
- forming a first magnetic core material having first and second lengthwise ends and an inner cavity that extends from said first lengthwise end to said second lengthwise end;
- forming a first notch in said first magnetic core material that projects inwardly towards said inner cavity from one of said first and second lengthwise ends;
- passing a first conductor through said inner cavity from said first lengthwise end to said second lengthwise end that is received by said first notch;
- and
- forming a second notch in said first magnetic core material that projects inwardly towards said inner cavity from the other of said first and second ends, wherein said first conductor is also received by said second notch.
2 more elements
Dependencies are inferred from the claim text.