Claims
- 1. A method for making closed-shape inductors comprising:
joining together a bottom layer, a top layer and at least one intermediate layer therebetween, the bottom and top layers comprising magnetic material, and the at least one intermediate layer comprising a non-magnetic material; and dividing the joined together layers into a plurality of closed-shape cores so that each has at least one magnetic flux gap therein provided by the non-magnetic material.
- 2. The method of claim 1 wherein each closed-shape core comprises a toroidal core.
- 3. The method of claim 2 wherein the at least one magnetic flux gap is aligned along at least one radius of each toroidal core.
- 4. The method of claim 1 further comprising winding at least one conductor on each closed-shape core.
- 5. The method of claim 1 wherein dividing comprises:
dividing the joined together layers into a plurality of strips; and dividing each strip to form a plurality of closed-shape cores so that each has at least one magnetic flux gap therein provided by the non-magnetic material.
- 6. The method of claim 5 wherein each closed-shape core comprises a toroidal core; and wherein the at least one intermediate layer comprises a continuous layer of non-magnetic material so that a pair of flux gaps are provided in each toroidal core.
- 7. The method of claim 6 wherein the pair of flux gaps are aligned along opposing radii of each toroidal core.
- 8. The method of claim 5 wherein each closed-shape core comprises a toroidal core; and wherein the at least one intermediate layer comprises a laterally alternating pattern of magnetic and non-magnetic material so that a single flux gap is provided in each toroidal core.
- 9. The method of claim 8 wherein the single magnetic flux gap is aligned along a radius of each toroidal core.
- 10. The method of claim 5 wherein the at least one intermediate layer comprises a plurality of intermediate layers; and further comprising sandwiching at least one spacer layer between adjacent intermediate layers.
- 11. The method of claim 10 wherein the at least one spacer layer comprises ferrite.
- 12. The method of claim 1 wherein the at least one intermediate layer comprises a laterally alternating pattern of non-magnetic material and air gaps therein.
- 13. The method of claim 12 wherein the top and bottom layers are continuous so that at least one air gap is provided between the top and bottom portions of each closed-shape core.
- 14. The method of claim 1 further comprising rounding sharp edges of the closed-shape cores.
- 15. The method of claim 1 further comprising sintering the closed-shape cores after dividing.
- 16. The method of claim 1 wherein the at least one magnetic flux gap has a thickness of less than about 0.02 inches.
- 17. The method of claim 1 wherein the magnetic material comprises ferrite.
- 18. The method of claim 1 wherein the non-magnetic material comprises at least one of zinc ferrite, alumina, and air.
- 19. The method of claim 1 further comprising forming alignment holes in each of the bottom, at least one intermediate, and top layers for alignment.
- 20. A method for making closed-shape inductors comprising:
joining together a bottom layer, a top layer and at least one intermediate layer therebetween, the bottom and top layers comprising magnetic material, and the at least one intermediate layer comprising non-magnetic material; dividing the joined together layers into a plurality of strips; and punching each strip to form a plurality of closed-shape cores so that each has at least one magnetic flux gap therein provided by the non-magnetic material.
- 21. The method of claim 20 wherein each closed-shape core comprises a toroidal core.
- 22. The method of claim 21 wherein the at least one magnetic flux gap is aligned along at least one radius of each toroidal core.
- 23. The method of claim 20 further comprising winding at least one conductor on each closed-shape core.
- 24. The method of claim 20 wherein each closed-shape core comprises a toroidal core; and wherein the at least one intermediate layer comprises a continuous layer of non-magnetic material so that a pair of flux gaps are provided in each toroidal core.
- 25. The method of claim 24 wherein the pair of flux gaps are aligned along opposing radii of each toroidal core.
- 26. The method of claim 20 wherein each closed-shape core comprises a toroidal core; and wherein the at least one intermediate layer comprises a laterally alternating pattern of magnetic and non-magnetic material so that a single flux gap is provided in each toroidal core.
- 27. The method of claim 26 wherein the single magnetic flux gap is aligned along a radius of each toroidal core.
- 28. The method of claim 20 wherein the at least one intermediate layer comprises a plurality of intermediate layers; and further comprising sandwiching at least one spacer layer between adjacent intermediate layers.
- 29. The method of claim 28 wherein the at least one spacer layer comprises ferrite.
- 30. The method of claim 20 further comprising rounding sharp edges of the closed-shape cores.
- 31. The method of claim 20 further comprising sintering the closed-shape cores after dividing.
- 32. The method of claim 20 wherein the at least one magnetic flux gap has a thickness of less than about 0.02 inches.
- 33. The method of claim 20 wherein the magnetic material comprises ferrite.
- 34. The method of claim 20 wherein the non-magnetic material comprises at least one of zinc ferrite, alumina, and air.
- 35. The method of claim 20 further comprising forming alignment holes in each of the bottom, at least one intermediate, and top layers for alignment.
- 36. A method for making closed-shape inductors comprising:
joining together a bottom layer, a top layer and at least one intermediate layer therebetween, the bottom and top layers being substantially continuous and comprising magnetic material, and the at least one intermediate layer comprising a laterally alternating pattern of magnetic material and air gaps; and dividing the joined together layers into a plurality of closed-shape cores so that at least one air gap is provided between the top and bottom portions of each core.
- 37. The method of claim 36 wherein each closed-shape core comprises a toroidal core.
- 38. The method of claim 37 wherein the at least one air gap is aligned along at least one radius of each toroidal core.
- 39. The method of claim 36 further comprising winding at least one conductor on each closed-shape core.
- 40. The method of claim 36 further comprising rounding sharp edges of the closed-shape cores.
- 41. The method of claim 36 further comprising sintering the closed-shape cores after dividing.
- 42. The method of claim 36 wherein the magnetic material comprises ferrite.
RELATED APPLICATION
[0001] The present application is based upon provisional application Ser. No. 60/177,086, filed Jan. 20, 2000, and provisional application Ser. No. 60/208,867, filed Jun. 2, 2000, both of which are hereby incorporated herein in their entireties by reference.
Provisional Applications (2)
|
Number |
Date |
Country |
|
60177086 |
Jan 2000 |
US |
|
60208867 |
Jun 2000 |
US |