Method of making slotted core inductors and transformers

Abstract

Slot core inductors and transformers and methods for manufacturing same including using large scale flex circuitry manufacturing methods and machinery for providing two mating halves of a transformer winding. One winding is inserted into the slot of a slot core and one winding is located proximate to the exterior wall of the slot core. These respective halves are joined together using solder pads or the like to form continuous windings through the slot and around the slotted core.

1 . The method of manufacturing slotted core inductors and transformers comprising:
 forming a first flex circuit having a plurality of side-by-side spaced discrete electrical conductors by etching a copper plane supported by a flexible dielectric material;   forming a second flex circuit having a plurality of side-by-side spaced discrete electrical conductors by etching a copper plane supported by a flexible dielectric material;   covering said etched copper electrical conductors while leaving access holes that expose said copper conductors to provide solder pads;   folding said first flex circuit to form a cavity;   inserting one or more slot cores into said cavity so that a portion of said conductors extend into the slot of said core;   locating said second flex circuit over said core or cores; and   bonding together respective solder pads of both said first and second flex circuits.   
   
   
       2 . The method of manufacturing slotted core inductors and transformers comprising:
 forming a first flex circuit having a plurality of spaced discrete electrical conductors with access connectors;   forming a second flex circuit having a spaced discrete electrical conductor with access connectors;   folding said first plurality of spaced discrete electrical conductors to form a plurality of cavities;   inserting said first flex circuit into the slot of a slot so that a portion of said conductors extend the slot of said core;   locating said second flex circuit over said core or cores; and   bonding together access connectors of both the first and second flex circuits.   
   
   
       3 . The method of manufacturing slotted core inductors and transformers comprising:
 forming a first flex circuit having a plurality of spaced discrete electrical conductors with access connectors;   forming a second flex circuit having a spaced discrete electrical conductor with access connectors;   inserting said first flex circuit into the slot of said core so that a portion of said conductors extend the slot of said core;   locating said second flex circuit over said core or cores; and   bonding together access connectors of both the first and second flex circuits.   
   
   
       4 . The method of manufacturing inductors and transformers comprising:
 forming a flex circuit having a plurality of spaced discrete electrical conductors with access connectors; and   locating said flex circuit over a core to form a continuous winding around said core.   
   
   
       5 . The method of manufacturing slotted core inductors and transformers comprising:
 forming a first flex circuit having a plurality of spaced discrete electrical conductors with access connectors;   forming a second flex circuit having a spaced discrete electrical conductor with access connectors;   folding said first and second flex circuits to form a plurality of cavities;   inserting said core into said cavities so that both said first and said second flex circuit are inserted into the slot of said core so that a portion of said conductors extend the slot of said core; and   bonding together access connectors of both the first and second flex circuits.