Method of manufacturing an electronic component
First Claim
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1. A method of manufacturing an electronic component, comprising:
- providing a wire having first and second ends;
winding the wire into a coil having a central opening orientated about a generally vertical axis, the wire transitioning from the first wire end into an outer winding of a first row, with the wire winding continuing to wind about the generally vertical axis in turns of decreasing diameter, then transitioning to an inner winding of a second row and continuing to wind about the generally vertical axis in turns of increasing diameter to an outer winding, the wire further extending to the second wire end, wherein the first and second wire ends are connected to or form terminals for mounting the component to a circuit;
mixing a mixture of magnetic and/or non-magnetic material and binder to form a flowing mixture; and
dispersing the flowing mixture over the coil in a mold, and hardening the mixture in the mold without exposing the coil to the damaging forces of a dry press process to form the electronic component with a generally planar top surface with which the component can be picked and placed on a circuit using conventional pick-and-place equipment, wherein the mixture comprises at least about 80% iron.
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Abstract
An electronic component includes a wire winding wound around a central axis. The wire winding having first and second ends, and first and second terminals are connected to or formed by the first and second ends. The terminals provide electrical contacts for connecting the component into a circuit. The component has a wet press molded body made of a mixture of magnetic and non-magnetic material that is heated and pressed about the wire winding. The wet press molded body leaves at least a portion of the terminals exposed for mounting the component to the circuit.
156 Citations
12 Claims
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1. A method of manufacturing an electronic component, comprising:
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providing a wire having first and second ends; winding the wire into a coil having a central opening orientated about a generally vertical axis, the wire transitioning from the first wire end into an outer winding of a first row, with the wire winding continuing to wind about the generally vertical axis in turns of decreasing diameter, then transitioning to an inner winding of a second row and continuing to wind about the generally vertical axis in turns of increasing diameter to an outer winding, the wire further extending to the second wire end, wherein the first and second wire ends are connected to or form terminals for mounting the component to a circuit; mixing a mixture of magnetic and/or non-magnetic material and binder to form a flowing mixture; and dispersing the flowing mixture over the coil in a mold, and hardening the mixture in the mold without exposing the coil to the damaging forces of a dry press process to form the electronic component with a generally planar top surface with which the component can be picked and placed on a circuit using conventional pick-and-place equipment, wherein the mixture comprises at least about 80% iron. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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Specification