INDUCTOR ASSEMBLIES AND METHODS FOR FORMING THE SAME

A dual coil inductor assembly includes an inner coil assembly including an inner coil and first and second terminals, and an outer coil assembly including an outer coil and third and fourth terminals. The inner coil includes an inner metal foil, and an inner electrical insulator sheet spirally co-wound with the inner metal foil. The outer coil includes an outer metal foil, and an outer electrical insulator sheet spirally co-wound with the outer metal foil. The inner coil is disposed within an outer coil air core of the outer coil so that the outer coil circumferentially surrounds the inner coil. The first and second terminals are electrically connected to the inner metal foil at respective first and second locations spaced apart along the inner metal foil. The third and fourth terminals are electrically connected to the outer metal foil at respective third and fourth locations spaced apart along the outer metal foil.