Coil component

• US 10,553,340 B2
• Filed: 11/29/2017
• Issued: 02/04/2020
• Est. Priority Date: 01/20/2017
• Status: Active Grant

• Current Assignee: Cyntec Co. Ltd. (Delta Electronics Incorporated)
• Original Assignee: Cyntec Co. Ltd. (Delta Electronics Incorporated)
• Inventors: Kuo, Min-Lian, Zhang, Dao-Chuang, Yang, QiQi, Lin, I-Feng, Chuang, Chi-Hsiang, Hsu, Chao-Hung
• Primary Examiner(s): Nguyen, Tuyen T
• Application Number:
  US15/825,460
• Publication Number:
  US 20180211756A1
• Time in Patent Office: 797 Days
• Field of Search: 336 65, 336 83, 336107, 336192, 336196, 336198, 336200, 336232
• CPC Class Codes: H01F 17/0013 with stacked layers
• CPC Class Codes: H01F 17/045 with core of cylindric geometry and coil wound along its longitudinal axis, i.e. rod or drum core
• CPC Class Codes: H01F 2017/0093 Common mode choke coil
• CPC Class Codes: H01F 27/02 Casings
• CPC Class Codes: H01F 27/2823 Wires H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/2828 Construction of conductive connections, of leads
• CPC Class Codes: H01F 27/29 Terminals; Tapping arrangements for signal inductances
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 27/306 Fastening or mounting coils or windings on core, casing or other support
• CPC Class Codes: H01F 27/327 Encapsulating or impregnating encapsulating coil and core H01F27/022
• CPC Class Codes: H01F 27/38 Auxiliary core members; Auxiliary coils or windings
• CPC Class Codes: H01F 41/066 with insulation
• CPC Class Codes: H01F 41/127 Encapsulating or impregnating encapsulating coil and core H01F41/005
• CPC Class Codes: H01G 4/005 Electrodes

Abstract

A coil component includes a core member, a coil structure, at least one terminal electrode and a soldering member. The coil structure includes an insulating layer. A first portion of the coil structure is wound around the core member. The terminal electrode is mounted onto the core member. The terminal electrode includes a clamping portion and a supporting portion. The clamping portion includes a bent part for clamping a second portion of the coil structure. The supporting portion includes a protruding part. A conductive wire of a third portion of the coil structure is revealed. A soldering member covers the protruding part to connect the supporting portion to the conductive wire to form electrical connection between the coil structure and the terminal electrode.

Claims

1. A coil component comprising:

a core member;

a coil structure including an insulating layer, a first portion of the coil structure being wound around the core member;

at least one terminal electrode mounted onto the core member and comprising a clamping portion and a supporting portion, wherein the clamping portion comprises a bent part for clamping a second portion of the coil structure, and the supporting portion comprises a protruding part, a conductive wire of a third portion of the coil structure being revealed; and

a soldering member covering the protruding part to connect the supporting portion to the conductive wire to form electrical connection between the coil structure and the terminal electrode.

2. The coil component according to claim 1, wherein the protruding part has a propping surface in contact with the third portion of the coil structure, and the propping surface confines the third portion of the coil structure in a space.

3. The coil component according to claim 2, wherein the core member is made of a magnetically permeable material, the core member comprising a winding core portion and at least one flange portion, the terminal electrode being mounted onto the flange portion.

4. The coil component according to claim 3, wherein the terminal electrode comprises a main body mounted onto a mounting surface of the flange portion, the supporting portion being connected to the main body, an intersection space being formed between the mounting surface and the propping surface for supporting the third portion of the coil structure.

5. The coil component according to claim 4, wherein the winding core portion extends along an axial direction, and the flange portion has an outer surface perpendicular to the axial direction and a lateral surface orthogonal to the outer surface, the mounting surface being the outer surface.

6. The coil component according to claim 5, wherein the flange portion has an opening at a first side, the coil structure passing through the opening and being electrically connected to the terminal electrode on the outer surface.

7. The coil component according to claim 6, further comprising a plate connected to the core member, the plate and the core member collectively constructing a magnetic path, the plate being connected to a second side of the flange portion, the second side being opposite to the first side.

8. The coil component according to claim 4, wherein the winding core portion extends along an axial direction, and the flange portion has an outer surface perpendicular to the axial direction and a lateral surface orthogonal to the outer surface, the mounting surface being the lateral surface.

9. The coil component according to claim 8, wherein the flange portion has an inner surface opposite to the outer surface and orthogonal to the lateral surface, the coil structure extending to the lateral surface along the inner surface and being electrically connect to the terminal electrode mounted onto the lateral surface.

10. The coil component according to claim 4, wherein a dihedral angle between the mounting surface and the propping surface is smaller than 180 degrees.

11. The coil component according to claim 3, further comprising a plate connected to the core member, the plate and the core member collectively constructing a magnetic path.

12. The coil component according to claim 11, wherein the terminal electrode comprises a flat connection piece to be connected to a circuit board, and the flat connection piece is mounted onto a bottom surface of the flange portion, the bottom surface being away from the plate.

13. The coil component according to claim 2, wherein the supporting portion has an auxiliary soldering surface opposite to the propping surface, the auxiliary soldering surface being covered with a solder flux, the soldering member being attached to the solder flux to cover the auxiliary soldering surface.

14. The coil component according to claim 13, wherein the solder flux and the soldering member include tin component.

15. The coil component according to claim 1, wherein the terminal electrode comprises a main body, the main body comprising a first region covered with a solder flux and a second region not covered with the solder flux, the first region being adjacent to the second region, the supporting portion being connected to the second region, the second region being located between the supporting portion and the first region.

16. The coil component according to claim 15, wherein the soldering member covers the supporting portion, and a portion of the soldering member is located at the second region.

17. The coil component according to claim 1, wherein a hole is formed within a bent part of the clamping portion for placing the second portion of the coil structure, the second portion of the coil structure including the insulating layer.

18. The coil component according to claim 1, wherein the second portion of the coil structure is connected to the third portion of the coil structure, and the third portion of the coil structure is connected to the first portion of the coil structure.

19. The coil component according to claim 1, wherein the terminal electrode comprises a main body, the main body comprising a first region covered with a solder flux, a second region not covered with the solder flux and a third region covered with the solder flux, the second region separating the first region from the third region, the clamping portion and the supporting portion being connected to the first region, the soldering member being connected to the protruding part and located at the first region.

20. The coil component according to claim 19, wherein the solder flux and the soldering member include a similar material.