Power inductor element

Abstract

The power inductance element comprises a conductor and a magnetic powder material mold. The conductor includes two bent portions and two electrode portions attached to the two bent portions, respectively. The magnetic powder material mold and the conductor form an integrated structure. The conductor is embedded in the integrated structure. The magnetic powder material mold comprises a first magnetic powder part and a second magnetic powder part. The conductor is less than one turn. The first magnetic powder portion is disposed outside the conductor. The second magnetic powder portion is disposed inside the conductor. The integrated structure comprises a first surface, a second surface opposite to the first surface, a third surface, a fourth surface opposite to the third surface, a fifth surface and a sixth surface opposite to the fifth surface.

Description

Technical Field

[0001] This invention discloses a power inductor, and more particularly a power inductor with ultra-low inductance and low AC loss. Background Technology

[0002] Inductors are widely used in various electronic devices, such as smartphones, tablets, and laptops. As the performance requirements of these devices increase, their power consumption also increases. Therefore, reducing energy losses in power integrated circuits (ICs) and inductors becomes crucial. Energy losses in power circuits are affected by operating conditions. For example, they may increase with higher load current and frequency. Furthermore, in direct-to-DC converter circuits, smaller inductors with lower inductance values ​​can be used to increase the switching frequency, thereby reducing the required mounting area and enabling device miniaturization. This technique is common in small, portable devices.

[0003] However, for smaller inductors, traditional hot-pressing processes often damage the conductors due to excessive molding pressure, potentially leading to open or short circuits. Furthermore, in traditional composite core power inductors, ferrite cores with surface coatings are typically used, creating gaps between the conductor and the core, resulting in flux leakage and increased noise. When the conductor is too wide, traditional molding processes for power inductors may cause core cracking due to insufficient adhesion between the magnetic powder particles. Additionally, the side electrodes in these inductors are located outside the core, hindering the full utilization of the core volume.

[0004] Therefore, there is a need to develop a small power inductor that can effectively reduce AC losses, make full use of the core volume, and overcome the limitations of traditional inductor design. Summary of the Invention

[0005] An embodiment of the present invention provides a power inductor. The power inductor includes a conductor and a magnetic powder material mold. The conductor includes two bent portions and two electrode portions respectively attached to the two bent portions. The magnetic powder material mold and the conductor form an integral structure. The conductor is embedded in the integral structure. The magnetic powder material mold includes a first magnetic powder portion and a second magnetic powder portion. The conductor has fewer than one turn. The first magnetic powder portion is disposed on the outer side of the conductor. The second magnetic powder portion is disposed on the inner side of the conductor. The integral structure includes a first surface and a second surface opposite to the first surface, a third surface and a fourth surface opposite to the third surface, and a fifth surface and a sixth surface opposite to the fifth surface. Attached Figure Description

[0006] Figure 1 This is a schematic diagram of a power inductor element according to an embodiment of the present invention.

[0007] Figure 2 This is for Figure 1 The power inductor element is shown in a cross-sectional view along line 2-2'.

[0008] Figure 3 This is for Figure 1 A schematic diagram of the six surfaces of a single-piece structure in a power inductor.

[0009] Figure 4 This is for Figure 1 A schematic diagram of the first and second surfaces of an integral structure in a power inductor.

[0010] Figure 5 This is for Figure 1 A schematic diagram of the fifth and sixth surfaces of a power inductor element with an integral structure.

[0011] Figure 6 This is for Figure 1 A schematic diagram of the fourth surface in a power inductor.

[0012] Figure 7 This is for Figure 1 A schematic diagram of the third surface in a power inductor.

[0013] Figure 8 This is for Figure 1 The diagram shows the dimensions of the internal space below the fifth surface in a power inductor.

[0014] Figure 9 This is for Figure 1 The diagram shows the dimensions of the internal space below the second surface in a power inductor.

[0015] Figure 10 This is for Figure 1 A schematic diagram of the two inner radius fillets of the U-shaped portion of the conductor in a power inductor.

[0016] The reference numerals in the attached figures are explained as follows:

[0017] 10: Conductor

[0018] 10a: First bend

[0019] 10b: Second bend

[0020] 10c: First electrode section

[0021] 10d: Second electrode section

[0022] 10e: U-shaped part

[0023] 11: Magnetic Powder Material Mold

[0024] 11a: First magnetic powder section

[0025] 11b: Second magnetic powder section

[0026] S1: First surface

[0027] S2: Second surface

[0028] S3: Third Surface

[0029] S4: Fourth Surface

[0030] S5: Fifth Surface

[0031] S6: Sixth Surface

[0032] S1' and S5': Surface

[0033] A: Internal space length

[0034] B: Interior space height

[0035] C: Bottom chamfer length

[0036] D: Line width

[0037] E: Width of long sidewall

[0038] F: Line thickness

[0039] G: Short sidewall width

[0040] L: Component length

[0041] W: Component width

[0042] AL: Left inner radius fillet

[0043] AR: Right inner radius fillet

[0044] R1 and R2: Radius of curvature Detailed Implementation

[0045] Figure 1 This is a schematic diagram of a power inductor 100 according to an embodiment of the present invention. Figure 2 This is a cross-sectional view along line 2-2' of the power inductor 100. The power inductor 100 overcomes the limitations of traditional wire-winding processes and composite core structures by employing specific dimensional formulas for the conductor and a one-piece molded structure made of magnetic powder material. The design of the power inductor 100 effectively utilizes the core volume and significantly reduces AC losses caused by current and voltage variations in AC circuits. The design of the power inductor 100 further optimizes the ratio of the conductor's side width to the length and width of the element, thereby maximizing the contact area between the conductor and the magnetic powder material to prevent core cracking.

[0046] exist Figure 1 and Figure 2 In this embodiment, the power inductor 100 includes a conductor 10 and a magnetic powder material mold 11. The conductor 10 may be made of copper, chosen for its excellent conductivity. However, the embodiment is not limited to copper, and other conductive materials may be used. The conductor 10 is not a conventional wire winding, but a single bent sheet designed to minimize path length and reduce impedance. The conductor 10 is embedded within the magnetic powder material mold 11, forming a monolithic structure (also referred to as a one-piece molded structure). This configuration has a higher conductor volume ratio compared to conventional designs, thereby contributing to lower inductance and higher efficiency. The conductor 10 includes a first bent portion 10a, a second bent portion 10b, a first electrode portion 10c, and a second electrode portion 10d (e.g., ...). Figure 2 (As shown). The first electrode portion 10c is attached to the first bent portion 10a. The second electrode portion 10d is attached to the second bent portion 10b. In one embodiment, the first electrode portion 10c and the second electrode portion 10d are covered (coated) with a nickel layer and a tin layer. In another embodiment, the first electrode portion 10c and the second electrode portion 10d are covered with a tin layer.

[0047] Conductor 10 further includes a U-shaped portion 10e (such as...) Figure 2 (As shown). The U-shaped portion 10e is formed by bending a portion of the conductor 10 into a U-shape. The bottom of the U-shaped portion 10e is the part closest to the bottom of the conductor 10. The two electrode portions 10c and 10d extend from the bottom of the U-shaped portion at both ends. The configuration of the conductor 10 ensures that current can flow efficiently, thereby minimizing energy loss and maximizing the efficiency of the power inductor element 100.

[0048] As previously described, the magnetic powder material mold 11 and the conductor 10 form an integral structure. The conductor 10 is embedded in the integral structure. In other words, the conductor 10 is surrounded and encapsulated within the space of the integral structure. This is quite different from conventional wire-wound inductors, where the conductor is wound on a separate magnetic core. In this embodiment, the integral structure may be made of magnetic powder material that has been compressed and heated to form a solidified material. Embedding the conductor 10 in this way allows for a more compact design and can improve the electrical performance of the inductor. The magnetic powder material mold 11 includes a first magnetic powder portion 11a and a second magnetic powder portion 11b. The first magnetic powder portion 11a and the second magnetic powder portion 11b may be designed to be made of a material with magnetic permeability. The magnetic permeability may be selected based on the required inductance of the power inductor element 100. Furthermore, the first magnetic powder portion 11a and the second magnetic powder portion 11b may also be designed to have a high magnetic saturation point, or a range of magnetic saturation may be designed as needed, thereby helping to prevent the element from saturating under high current.

[0049] In one embodiment, the first magnetic powder portion 11a and the second magnetic powder portion 11b are of the same material type to ensure that the entire power inductor element 100 has uniform magnetism. In other words, the uniform material type of the first magnetic powder portion 11a and the second magnetic powder portion 11b helps maintain consistent magnetism, thereby ensuring that the power inductor element 100 operates effectively and reliably. In another embodiment, the first magnetic powder portion 11a and the second magnetic powder portion 11b are of different material types to achieve specific magnetic and performance characteristics in the power inductor element 100. For example, the first magnetic powder portion 11a may contain a material with high permeability and low loss at high frequencies, while the second magnetic powder portion 11b may contain a material with high saturation magnetization and good temperature stability. This combination enables the power inductor element 100 to achieve high inductance efficiency and high current capability. Any reasonable technical or material modifications are within the scope of the embodiments of the present invention. The power inductor element 100 includes a conductor 10 having less than one turn, meaning that the conductor 10 does not form a complete loop. Having fewer than one turn of conductor 10 reduces the overall conductor length, which lowers DC resistance (DCR) and improves the efficiency of the power inductor 100. The design of this embodiment is particularly suitable for low-inductance applications because DC resistance is a significant factor affecting total power loss in these applications. Furthermore, refer to... Figure 1 The first magnetic powder section 11a is disposed on the outer side of the conductor 10, and the second magnetic powder section 11b is disposed on the inner side of the conductor 10. In the embodiment, the first magnetic powder section 11a and the second magnetic powder section 11b provide a magnetic circuit for the magnetic flux generated by the current flowing through the conductor 10.

[0050] Figure 3 This is a schematic diagram of the six surfaces S1 to S6 of the integrated structure in the power inductor element 100. Figure 4 This is a schematic diagram of the first surface S1 and the second surface S2 of the integrated structure in the power inductor element 100. Figure 5 This is a schematic diagram of the fifth surface S5 and the sixth surface S6 of the integrated structure in the power inductor element 100. Figure 6 This is a schematic diagram of the fourth surface S4 in the power inductor element 100. Figure 7 This is a schematic diagram of the third surface S3 in the power inductor element 100. Figure 3In the diagram, the power inductor 100 has an integral cubic structure and includes a first surface S1, a second surface S2 opposite to the first surface S1, a third surface S3, a fourth surface S4 opposite to the third surface S3, a fifth surface S5, and a sixth surface S6 opposite to the fifth surface S5. The first surface S1 is located on the left side of the power inductor 100, while the second surface S2 is located on the right side, opposite to the first surface S1. The first surface S1 and the second surface S2 are visible surfaces of the first magnetic powder portion 11a and the electrode portions 10c / 10d. The fifth surface S5 is located on the front side of the power inductor 100, while the sixth surface S6 is located on the back side, opposite to the fifth surface S5. The fifth surface S5 and the sixth surface S6 are visible surfaces of the first magnetic powder portion 11a and the electrode portions 10c and 10d. Figure 6 In this context, the fourth surface S4 can be defined by the viewing angle observed from the top of the power inductor element 100, representing the top surface of the element. Figure 7 In this embodiment, the third surface S3 can be defined by the viewing angle from the bottom of the power inductor element 100, representing the bottom surface of the element. The third surface S3 is the visible surface of the second magnetic powder portion 11b, electrode portions 10c and 10d. In this embodiment, the third surface S3 can also be considered as a mounting surface. The mounting surface provides a stable base for the power inductor element 100 and allows for electrical connections. For example, the mounting surface of the power inductor element 100 can be the third surface S3, which is used to attach the power inductor element 100 to a circuit board or other surface. Furthermore, in the power inductor element 100, the two bent portions 10a and 10b contact the first surface S1 and the second surface S2 of the integral structure, respectively. The two electrode portions 10c and 10d contact the third surface S3 of the integral structure.

[0051] Figure 8 This is a dimensional diagram of the internal space below the fifth surface S5 in the power inductor element 100. Figure 9 This is a dimensional diagram of the internal space below the second surface S2 in the power inductor element 100. Figure 8 and Figure 9 In the diagram, "A" represents the internal space length, "B" represents the internal space height, "C" represents the bottom chamfer length, "D" represents the line width, "E" represents the long sidewall width, "F" represents the line thickness, "G" represents the short sidewall width, "L" represents the component length, and "W" represents the component width. Figure 8In the diagram, the internal space length A is the horizontal distance between the two electrode portions 10c and 10d of the conductor 10. The internal space height B is the vertical distance between the top surface of the second magnetic powder portion 11b contacting the conductor 10 and the two electrode portions 10c and 10d of the conductor 10. The bottom chamfer length C is the horizontal distance between the edge of the electrode portion 10d and the outer edge of the integral structure on the same side, representing the length of the electrode portion 10d of the power inductor element 100. Furthermore, the bottom chamfer length C can be calculated using C = D + E. The linewidth D is defined as the width of the conductor 10. The long sidewall width E is the distance between the short side surface S1' of the conductor 10 and the first surface S1 of the integral structure of the power inductor element 100. Figure 9 In this design, the line thickness F is defined as the horizontal width of the conductor 10 when the integral structure of the power inductor 100 is viewed from the second surface S2. The short sidewall width G is the distance between the long side surface S5' of the conductor 10 and the fifth surface S5 of the integral structure of the power inductor 100. The element length L is defined as the distance between the first surface S1 and the second surface S2 of the integral structure of the power inductor 100. The element width W is defined as the distance between the fifth surface S5 and the sixth surface S6 of the integral structure of the power inductor 100. In the power inductor 100, the ratio of the long sidewall width E to the element length L ranges from 5% to 15%. This design increases the contact area between the conductor and the magnetic powder material, helping to prevent cracking of the magnetic core (magnetic powder portion 11a or 11b). If the long sidewall width E is insufficient, the magnetic core may crack during the thermoforming process. In other words, by ensuring the appropriate thickness of the sidewalls for surfaces S5 and S6, this design prevents the magnetic core from cracking or breaking during the thermoforming process. This is crucial for the design of the power inductor element 100, as it utilizes a high conductor-to-volume ratio, increasing the core's stress resistance during molding. In one embodiment, using a 1005 dimension (1.0 mm × 0.5 mm), a long sidewall width E of 0.075 mm, and an element length L of 1.0 ± 0.2 mm, an E / L ratio (the ratio of the long sidewall width E to the element length L) ranging from 6.25% to 9.37% can be applied. Therefore, by maintaining the E / L ratio within a specified range (5% to 15%), core cracking during the thermoforming process can be effectively prevented.

[0052] In the power inductor 100, the ratio of the short sidewall width G to the element width W ranges from 10% to 30%. Similarly, this design increases the contact area between the conductor and the magnetic powder material, helping to prevent cracking of the core (magnetic powder portion 11a or 11b). If the short sidewall width G is insufficient, the core may crack during the thermoforming process. In other words, for surfaces S1 and S2, by designing an appropriate thickness for the sidewalls, cracking or breakage of the core during the thermoforming process can be prevented. This is crucial for the design of the power inductor 100, as it utilizes a high conductor-to-volume ratio to increase the core's stress resistance during molding. In one embodiment, using a 1005 dimension (1.0 mm × 0.5 mm), a short sidewall width G of 0.075 mm, and an element width W of 0.5 ± 0.2 mm, a G / W ratio (the ratio of the short sidewall width G to the element width W) ranging from 10.7% to 25% can be applied. By maintaining the G / W ratio within a specified range (10% to 30%), cracking of the magnetic core during the hot pressing process can be effectively prevented.

[0053] Furthermore, in the power inductor element 100, the relationship between the internal space length A and the internal space height B satisfies the following condition:

[0054] -2.5 mm < (2 × B – A) < 2.5 mm

[0055] This condition ensures efficient utilization of the core volume and achieves the desired inductance value. If the dimensions of the internal space length A and internal space height B are outside this specified range, it may affect the inductance of the final product, thereby affecting its performance. By maintaining the relationship between the internal space length A and internal space height B within a given range, the design of the embodiment can optimize the magnetic flux and ensure that the volume of the second magnetic powder section 11b is utilized as efficiently as possible, thus helping to achieve the desired inductance characteristics while maintaining the compactness of the power inductor element 100.

[0056] Figure 10This is a schematic diagram of the two inner radius fillets AL and AR of the U-shaped portion 10e of the conductor in the power inductor element 100. In the power inductor element 100, the two fillets are located at the inner connection where the inner surface of the U-shaped portion 10e intersects with the vertical side. These two fillets are smooth curves, and are therefore essentially rounded rather than acute angles, represented in the diagram as the left inner radius fillet AL and the right inner radius fillet AR. The two fillets AL and AR are designed to maximize the utilization of the core volume. It should be understood that if acute angles were used, they would leave unused space within the core, thus reducing space utilization. Therefore, fillets are used in this embodiment to allow for more efficient magnetic flux flow. In this embodiment, the radius of curvature R1 of the left inner radius fillet AL is equal to the radius of curvature R2 of the right inner radius fillet AR. Furthermore, the radii of curvature R1 of the left inner radius fillet AL and the radii of curvature R2 of the right inner radius fillet AR are both greater than 15 micrometers.

[0057] In the above embodiment, the radius of curvature R1 of the left inner radius fillet AL and the radius of curvature R2 of the right inner radius fillet AR are both greater than 15 micrometers. This limitation is because the copper wire (conductor 10) is embedded into the magnetic powder material mold 11 by a stamping process. The stamping tool cannot create perfectly sharp corners. Therefore, in this embodiment, the lower limit of the radius of curvature of the inner radius fillet is set to 15 micrometers to accommodate these manufacturing conditions. Furthermore, this design of the right inner radius fillet AR and the left inner radius fillet AL also increases the utilization rate of the magnetic core volume and allows for more efficient flow of magnetic flux. In the power inductor element 100, the cross-sectional area ratio of conductor 10 to the third surface S3 ranges from 35% to 60%. The volume ratio of conductor 10 to the integral structure ranges from 20% to 50%. For example, for the 1N5 type, the conductor cross-sectional area ratio is 48.65%, and for the 1N0 type, the conductor cross-sectional area ratio is 44.2%. For type 1N5, the conductor volume ratio is 32.7%, and for type 1N0, the conductor volume ratio is 25.2%.

[0058] Furthermore, an insulating layer may be introduced into the power inductor element 100. The insulating layer may be formed on the surface of the conductor 10. The conductor 10 is electrically insulated from the first magnetic powder portion 11a. The conductor 10 is electrically insulated from the second magnetic powder portion 11b. In other words, the insulating layer is an optional element designed to provide electrical isolation between the conductor 10 and the magnetic powder material mold 11. The insulating layer can be made of various materials, such as polymers or ceramics, depending on the specific requirements of its application. The primary function of the insulating layer is to prevent any electrical contact between the conductor 10 and the magnetic material, thereby ensuring that current flows only through the conductor 10. Introducing the insulating layer can minimize energy loss and improve the overall efficiency of the power inductor element 100. Furthermore, the insulating layer can reduce noise and electromagnetic interference (EMI).

[0059] In the power inductor 100, the manufacturing process comprises a series of steps. First, a cold pressing process is used to form a U-shaped magnetic core (e.g., a first magnetic powder section 11a), referred to as a U-shaped powder section or U-shaped section. The U-shaped magnetic core is the basic structure of the power inductor 100. Then, a pre-formed conductor 10 (typically made of copper) is inserted into the U-shaped magnetic core. The conductor 10 is designed to have fewer than one turn, meaning it forms an incomplete one-turn loop. After the conductor 10 is in place, an I-shaped section (e.g., a second magnetic powder section 11b), also referred to as an I-shaped powder section, is inserted to fill the space in the conductor 10. This design creates a closed magnetic circuit. Finally, the entire assembly undergoes a hot pressing process. The hot pressing process compresses and heats the materials, fusing them into a solidified structure, thereby forming a compact and robust power inductor 100.

[0060] As previously stated, the power inductor 100 can significantly reduce AC losses. It should be understood that AC losses in an inductor are caused by factors such as the skin effect and proximity effect, which increase with frequency and load current. However, the design of the power inductor 100 can effectively utilize the core volume and reduce AC losses caused by various factors. First, the integral structure of the power inductor 100 eliminates the gap between the conductor and the magnetic powder material mold, thereby reducing leakage flux. Second, the specific dimensions of the conductor (including width, height, and corner radius) are designed to minimize factors contributing to AC losses, such as the skin effect and proximity effect. For example, the conductor 10 in the power inductor 100 can be designed with a rectangular cross-section instead of a circle or square to minimize the skin effect and proximity effect. Any reasonable component design is within the scope of this embodiment.

[0061] In summary, embodiments of the present invention disclose a power inductor. The power inductor is designed to overcome the limitations of conventional wire-wound processes and composite core structures. By employing specific dimensional formulas for the conductor and a one-piece molded structure made from magnetic powder material, the core volume can be effectively utilized, and AC losses caused by current and voltage variations in AC circuits can be significantly reduced. The power inductor further optimizes the ratio of the conductor's side width to the length and width of the element, thereby maximizing the contact area between the conductor and the magnetic powder material to prevent core cracking. Therefore, the power inductor of the embodiments is particularly suitable for electronic devices requiring high efficiency and compact size, such as smartphones, tablets, and laptops.

[0062] The above description is only a preferred embodiment of the present invention. All equivalent changes and modifications made in accordance with the claims of the present invention should be included within the scope of the present invention.

Claims

1. A power inductor element, comprising: A conductor, comprising: Two curved sections; and Two electrode portions are respectively attached to the two curved portions; and A magnetic powder material mold, integrally formed with the conductor, wherein the conductor is embedded in the integral structure, the magnetic powder material mold comprising: First magnetic powder section; and First, the second magnetic powder section; The conductor has fewer than one turn, the first magnetic powder portion is disposed on the outer side of the conductor, the second magnetic powder portion is disposed on the inner side of the conductor, and the integral structure includes a first surface and a second surface opposite to the first surface, a third surface and a fourth surface opposite to the third surface, and a fifth surface and a sixth surface opposite to the fifth surface.

2. The power inductor element as claimed in claim 1, wherein the two bent portions are in contact with the first surface and the second surface of the integral structure, respectively, and the two electrode portions are in contact with the third surface of the integral structure.

3. The power inductor element as claimed in claim 1, wherein the length of an element of the integral structure is a distance between the first surface and the second surface, the width of a long sidewall of the integral structure is a distance between a short side surface of the conductor and the first surface, and the ratio of the width of the long sidewall to the length of the element is in the range of 5% to 15%.

4. The power inductor element as claimed in claim 3, wherein the ratio of the width of the long sidewall to the length of the element ranges from 6.25% to 9.37%.

5. The power inductor element as claimed in claim 4, wherein the width of the long sidewall is about 0.075 mm and the length of the element is about 1.0 mm.

6. The power inductor element as claimed in claim 1, wherein the width of an element of the integral structure is a distance between the fifth surface and the sixth surface, the width of a short sidewall of the integral structure is a distance between a long side surface of the conductor and the fifth surface, and the ratio of the width of the short sidewall to the width of the element is in the range of 10% to 30%.

7. The power inductor element of claim 6, wherein the ratio of the short sidewall width to the element width ranges from 10.7% to 25%.

8. The power inductor element of claim 7, wherein the width of the short sidewall is about 0.075 mm and the width of the element is about 0.5 mm.

9. The power inductor element as claimed in claim 1, wherein the height of an internal space of the conductor is a vertical distance between a top surface of the second magnetic powder portion contacting the conductor and the two electrode portions of the conductor, the length of an internal space of the conductor is a horizontal distance between the two electrode portions, and a relationship between the height of the internal space and the length of the internal space satisfies: -2.5 mm < (2 × BA) < 2.5 mm Where A is the length of the internal space and B is the height of the internal space.

10. The power inductor element of claim 1, wherein the conductor further comprises: A U-shaped part; The base of the U-shaped portion serves as the two electrode portions, and the U-shaped portion includes a left inner radius fillet and a right inner radius fillet, and the radius of curvature of the left inner radius fillet is equal to the radius of curvature of the right inner radius fillet.

11. The power inductor element of claim 10, wherein the radius of curvature of the left inner radius fillet and the radius of curvature of the right inner radius fillet are greater than 15 micrometers.

12. The power inductor element as claimed in claim 1, wherein the two electrode portions are covered by a nickel layer and a tin layer.

13. The power inductor element as claimed in claim 1, wherein the two electrode portions are covered by a tin layer.

14. The power inductor element as claimed in claim 1, further comprising: An insulating layer is formed on one surface of the conductor; When the conductor is disposed in the integral structure, the conductor is electrically insulated from the first magnetic powder section and from the second magnetic powder section.

15. The power inductor element of claim 1, wherein the ratio of the cross-sectional area of ​​the conductor to the third surface is in the range of 35% to 60%, and the ratio of the volume of the conductor to the integral structure is in the range of 20% to 50%.

16. The power inductor element of claim 1, wherein the conductor comprises a copper material.

17. The power inductor element as claimed in claim 1, wherein the first magnetic powder portion and the second magnetic powder portion are of the same material type.

18. The power inductor element as claimed in claim 1, wherein the first magnetic powder portion and the second magnetic powder portion are two different material types.

19. The power inductor element as claimed in claim 1, wherein the first magnetic powder portion is a U-shaped powder portion and the second magnetic powder portion is an I-shaped powder portion.

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