Patent ID: 6449829
Filing Date: 2002-09-17
Classification: B29C,B29K,H01F,Y10T

Abstract:
A method for making a high current low profile inductor comprising:taking an elongated plate conductor having a first end, a second end, opposite side edges, opposite flat surfaces, and a longitudinal plate axis; cutting a plurality of slots in each of said opposite side edges of said plate conductor so as to form said plate conductor into a plurality of cross segments extending transversely with respect to said plate axis and a plurality of connecting segments extending approximately axially with respect to said plate axis, said connecting segments connecting said cross segments together into a continuous conductor which extends in a sine shaped path; said cross segments each having opposite flat surfaces formed from said opposite surfaces of said plate conductor; bending said connecting segments transversely with respect to said plate axis so as to form said plate conductor into a plurality of accordion folds, each of which comprise one of said cross segments and a portion of one of said connecting segments, whereby said cross segments and said connecting segments form a continuous conductor coil formed into an approximate helical shape and having first and second opposite ends; said bending step being done so as to place said opposite flat surfaces of said cross segments in planes parallel to one another and perpendicular to said longitudinal plate axis.