Abstract: The method may include joining together a bottom layer, a top layer and at least one intermediate layer therebetween, with the bottom and top layers including a non-magnetic material, and the at least one intermediate layer including a non-magnetic material. The method may also include dividing the joined together layers into a plurality of closed-shape cores each having at least one magnetic flux gap therein provided by the non-magnetic material. The closed-shape cores may be toroidal, for example. The method may also include winding at least one conductor on each closed-shape core to form the inductors. In some embodiments the joined together layers may be divided into a plurality of strips. The method may also include punching each strip to form a plurality of closed shape cores, with toroidal core having at least one magnetic flux gap therein provided by the non-magnetic material.

Abstract: A toroidal inductor includes a toroidal core including magnetic material and having at least one magnetic flux gap therein, and at least one conductor wound on the core. The magnetic flux gap may include a non-magnetic material having a substantially uniform thickness between respective adjacent magnetic material portions. In some embodiments, the non-magnetic material may have a shrinkage factor during sintering substantially equal to a shrinkage factor of the magnetic material. For example, the magnetic material may include ferrite, and the non-magnetic material may include alumina or zinc ferrite. In some embodiments, the flux gap may be provided by an air gap. The substantially uniform thickness of the at least one magnetic flux gap is readily and accurately produced in accordance with associated manufacturing aspects of the invention.