Patent ID: 8910373

Claim:
A method of manufacturing an electromagnetic component, the method comprising: providing a plurality of substantially planar and flexible magnetic powder sheets, wherein each of the plurality of substantially planar and flexible magnetic powder sheets is capable of being laminated to another one of the plurality of substantially planar and flexible magnetic powder sheets; providing at least one preformed multiple turn conductive winding including a flexible wire conductor that is wound in multiple turns about an open center area and further including first and second leads, wherein the at least one preformed multiple turn conductive winding is separately fabricated from all of the plurality of substantially planar and flexible magnetic powder sheets; stacking the plurality of substantially planar and flexible magnetic powder sheets; locating the at least one preformed multiple turn conductive winding between at least two of the plurality of substantially planar and flexible magnetic powder sheets in the stack; pressure laminating the substantially planar and flexible magnetic powder sheets around the at least one preformed multiple turn conductive winding to define a magnetic core containing the at least one preformed multiple turn conductive winding, wherein at least one of the plurality of substantially planar and flexible magnetic powder sheets is pressed directly to and around the at least one preformed multiple turn conductive winding, and wherein at least two of the plurality of substantially planar and flexible magnetic powder sheets are disposed adjacent to the at least one preformed multiple turn conductive winding without a physical gap being formed adjacent the at least one preformed multiple turn conductive winding; providing first and second terminals on at least one of the plurality of substantially planar and flexible magnetic powder sheets; and connecting the first and second terminals to the respective first and second leads.