Patent ID: 8327524

Claim:
A method for producing an inductive component having at least one coil and a magnetic soft core, comprising: (a) providing a mold, the at least one coil, an alloy powder, and a casting resin formulation; (b) arranging the at least one coil in the mold; (c1) either: (c1a) soft discharging the alloy powder into the mold, and soft discharging the casting resin formulation into the mold; or (c1b) mixing the alloy powder and the casting resin formulation to produce a mixed casting resin formulation, and soft discharging the mixed casting resin formulation into the mold; (c2) aligning particles of the alloy powder during or after placement of the alloy powder of the mixed casting resin formulation into the mold by creating a magnetic field created by an electrical current that is directed through the at least one coil when the coil is in the mold; and (d) curing the casting resin formulation or the mixed casting resin formulation without removing the at least one coil from the mold, so that the coil becomes part of the cured inductive component.