Magnetic core with flexible packaging

[0025]FIGS. 5(A)-(D) depict a core according to the principles of the present disclosure. Core 150 includes a body 152 (FIG. 5(B)), which may be formed in the shape of a toroid or cylinder, made by winding material, for example, of the type and in the manner described above with reference to FIGS. 1-3. In certain embodiments, the material is vitreous material or a flexible magnetic material. Body 152 includes an outer surface 154, an inner surface 156, a first side surface 158 and a second side surface 160 (not shown). Body 152 is encased within a package 162 (FIG. 5(A)), which may be formed of rubber, plastic or other suitable flexible material. Package 162 includes an outer surface 164, an inner surface 166, a first side surface 168 and a second side surface 170 (not shown). Inner surface 166 of package 162 defines a central opening 172 for receiving a wire or wires such as in the twisted pair application described above.

[0026]As shown in FIG. 5(C), in one embodiment after body 152 i

[0031]Referring now to FIGS. 6(A)-(D), a core according to the principles of the present disclosure is shown. Core 250 (FIG. 6(B)) includes a body 252 made by winding material, for example, of the type and in the manner described above with reference to FIG. 3. Body 252 includes an outer surface 254, an inner surface 256, a first side surface 258 and a second side surface 260 (not shown). Body 252 is encased within a partially rubber based package 262 (FIG. 6(A)). Package 262 includes flexible portion 253 (which in one embodiment is rubber based) and an epoxy or plastic portion 255 which adds to the strength of core 250. Flexible portion 253 acts as a hinge as is described below. Package 262 further includes an outer surface 264, an inner surface 266, a first side surface 268 and a second side surface 270 (not shown). Inner surface 266 of package 262 defines a central opening 272 for receiving a wire or wires such as in the twisted pair application described above.

[0032]As shown in FIG