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US 9,859,043 B2Granted
Magnetic components and methods of manufacturing the same
AssigneeCooper Technologies Company
InventorsYipeng Yan, Robert James Bogert
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Abstract
Magnetic component assemblies including moldable magnetic materials formed into magnetic bodies, at least one conductive coil, and termination features are disclosed that are advantageously utilized in providing surface mount magnetic components such as inductors and transformers.
Claims31
An electromagnetic component assembly comprising:
- at least one prefabricated conductive coil including an outer layer of bonding agent that is one of heat activated and chemically activated;
- and
- a laminated magnetic body having distributed gap properties throughout, the laminated magnetic body formed around the at least one coil,
- wherein the bonding agent couples the at least one coil to the laminated magnetic body,
- wherein the laminated magnetic body comprises a plurality of stacked prefabricated layers of magnetic material pressed in surface contact with one another,
- wherein each of the prefabricated layers of magnetic material comprises magnetic powder particles and a polymeric binder shaped into a thin sheet,
- wherein the at least one prefabricated coil comprises a freestanding element formed apart from all of the prefabricated layers of magnetic material,
- wherein two of the stacked prefabricated layers of magnetic material are positioned on opposing sides of the at least one prefabricated coil and sandwich the at least one prefabricated coil in between, and
- wherein the at least one coil and laminated magnetic body define a direct current power inductor for powering an electronic device.
6 more elements
An electromagnetic component assembly comprising:
- at least one prefabricated coil having a winding portion defining more than complete turn;
- and
- a laminated magnetic body having distributed gap properties throughout, the laminated magnetic body formed around the at least one coil and comprising a plurality of stacked prefabricated layers of magnetic material each being pressed in surface contact with at least one other of the plurality of stacked prefabricated layers of magnetic material,
- wherein each of the prefabricated layers of magnetic material comprises magnetic powder particles and a polymeric binder shaped into a thin sheet,
- wherein the at least one prefabricated coil comprises a freestanding conductive element formed apart from all of the prefabricated layers of magnetic material,
- wherein two of the stacked prefabricated layers of magnetic material are positioned on opposing sides of the at least one prefabricated coil and sandwich the at least one prefabricated coil in between, and
- wherein the at least one coil and laminated magnetic body define a direct current power inductor for powering an electronic device.
4 more elements
Dependencies are inferred from the claim text.