Abstract: A low-profile coupled inductor includes a magnetic core and first and second windings. The magnetic core includes first and second end flanges, a winding form element, a first outer plate, and a first leakage post. The winding form element is disposed between and connects the first and second end flanges in a first direction. The first outer plate is disposed over and faces the first and second end flanges in a second direction. The first leakage post is disposed between the winding form element and the first outer plate in the second direction. The first winding is wound around the winding form element, between the first end flange and the first leakage post, and the second winding is wound around the winding form element, between the first leakage post and the second end flange. Each of the windings is wound around a common axis extending in the first direction.

Abstract: A low-profile coupled inductor includes a magnetic core and first and second windings. The magnetic core includes first and second end flanges, a winding form element, a first outer plate, and a first leakage post. The winding form element is disposed between and connects the first and second end flanges in a first direction. The first outer plate is disposed over and faces the first and second end flanges in a second direction. The first leakage post is disposed between the winding form element and the first outer plate in the second direction. The first winding is wound around the winding form element, between the first end flange and the first leakage post, and the second winding is wound around the winding form element, between the first leakage post and the second end flange. Each of the windings is wound around a common axis extending in the first direction.

Abstract: A method of forming a radially anisotropic toroidal magnetic core includes providing apparatus having a first magnet for providing a radial magnetic field extending across a cavity from an axial spindle to a surrounding second magnetic element, placing a substrate in the cavity, the substrate having a hole fitting around the head of the spindle; and sputter-depositing a film of ferromagnetic material onto the substrate. In an embodiment, the spindle is magnetically coupled to a first pole of the first magnet, the second magnetic element is coupled to a second pole of the first magnet, and a thermally conductive, nonmagnetic, insert separates the spindle and the second magnetic element.

Abstract: A coupled inductor array has length, width, and height. The coupled inductor array includes a monolithic magnetic core formed of a magnetic material having a distributed gap, and a plurality of windings embedded in the monolithic magnetic core. Each winding forms a respective winding loop of one or more turns around a respective winding axis, and each winding axis extends in the height direction. Areas of the monolithic magnetic core enclosed by the winding loops are greater than areas of the monolithic magnetic core outside of the winding loops, as seen when the coupled inductor array is viewed cross-sectionally in the height direction. One possible application of the coupled inductor array is in a multi-phase switching power converter.