Patent ID: 8484829

Claim:
A method of manufacturing a chip inductor configured as a power management device for an electrical system of an electronic device, the chip inductor including a coil winding and a core structure therefor, the method comprising: providing at least one prefabricated coil winding having a number of turns; providing a plurality of flexible dielectric sheet layers, wherein the at least one prefabricated coil winding is fabricated independently of any of the plurality of flexible dielectric sheet layers, and wherein each of the flexible dielectric sheet layers include a core opening; assembling the at least one prefabricated coil winding with the plurality of flexible dielectric sheet layers by stacking the plurality of flexible dielectric sheet layers while the flexible dielectric sheet layers are in a solidified state; laminating the plurality of flexible dielectric sheets around the at least one prefabricated coil winding to form a dielectric body having a low profile chip configuration, wherein the core opening exposes the at least one prefabricated coil winding; and providing surface mount circuit terminations on an exterior of the dielectric body, the surface mount circuit terminations attachable to a circuit board of the electronic device and completing an electrical path from the circuit board through the least one prefabricated coil winding when mounted to the circuit board; and applying a magnetic core material in the core opening.