Plate member, magnetic element using the same, and magnetic element manufacturing method

• US 20060103262A1
• Filed: 11/16/2005
• Published: 05/18/2006
• Est. Priority Date: 11/16/2004
• Status: Active Grant

• Current Assignee: Sumida Corporation
• Original Assignee: Sumida Corporation
• Inventors: Sano, Kan, Yamada, Satoru
• Granted Patent: US 7,327,212 B2
• Time in Patent Office: Days
• US Class Current: 310/263
• CPC Class Codes: H01F 2017/046 helical coil made of flat wire, e.g. with smaller extension of wire cross section in the direction of the longitudinal axis
• CPC Class Codes: H01F 27/027 specially adapted for combination of signal type inductors or transformers with electronic circuits, e.g. mounting on printed circuit boards
• CPC Class Codes: H01F 27/255 made from particles H01F27/26 takes precedence
• CPC Class Codes: H01F 27/2847 Sheets; Strips H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 41/005 Impregnating or encapsulating insulating of windings H01F41/12
• CPC Class Codes: Y10T 29/49021 Magnetic recording reproducing transducer [e.g., tape head, core, etc.]
• CPC Class Codes: Y10T 29/49032 Fabricating head structure or component thereof
• CPC Class Codes: Y10T 29/4905 Employing workholding means
• CPC Class Codes: Y10T 29/49071 by winding or coiling
• CPC Class Codes: Y10T 29/49073 by assembling coil and core
• CPC Class Codes: Y10T 29/49146 with encapsulating, e.g., potting, etc.
• CPC Class Codes: Y10T 29/49171 with encapsulating
• CPC Class Codes: Y10T 29/4922 with molding of insulation
• CPC Class Codes: Y10T 29/49222 forming array of contacts or terminals

Abstract

A plate member includes a frame portion (51) provided in a state of coupling both one end portion and other end portion and mounting terminal portions (44) protruding from the one end portion and the other end portion of said frame portion (51) to approach each other, from which a PCB joint portions (46) to be a mounting portion to a PCB are formed by cutting and bending when manufacturing a magnetic element. Further, a winding number adjustment means (41), which is capable of selecting joint portions with ends of a coil and adjusting the winding number of the coil in accordance with the selection, protrudes from the one end portion and the other end portion to approach each other farther as compared to the mounting terminal portions (44).

Claims

1. A plate member comprising:

a frame portion provided in a state of coupling both one end portion and other end portion;

mounting terminal portions protruding from the one end portion and the other end portion of said frame portion to approach each other, from which a PCB joint portion to be a mounting portion to a PCB are formed by cutting and bending when manufacturing a magnetic element; and

a winding number adjustment means protruding from an end portion and an other end portion to approach each other farther as compared to said mounting terminal portions and capable of selecting joint portions with ends of a coil, said winding number adjustment means adjusting the winding number of the coil in accordance with the selection.

2. The plate member according to claim 1:

wherein said winding number adjustment means includes plural inner terminal portions and at least one of the plural inner terminal portions is provided with an extending portion extending in a direction orthogonal to a flat surface on which a flat plate portion of said frame portion exists; and

wherein the inner terminal portion provided with the extending portion is disposed at a different position from those of the other inner terminal portions in view of a normal direction of the flat plate portion of said frame portion due to the existence of the extending portion.

3. The plate member according to claim 2;

wherein there exist four inner terminal portions and the four inner terminal portions are provided at intervals of an angle of 90 degrees when viewing from the normal direction of the flat plate portion of said frame portion as a plan view.

4. A magnetic element comprising:

a plate member comprising a frame portion provided in a state of coupling both one end portion and other end portion;

mounting terminal portions protruding from the one end portion and the other end portion of said frame portion to approach each other, from which a PCB joint portion to be a mounting portion to a PCB are formed by cutting and bending when manufacturing a magnetic element; and

a winding number adjustment means protruding from an end portion and an other end portion to approach each other farther as compared to said mounting terminal portions and capable of selecting joint portions with ends of a coil, said winding number adjustment means adjusting the winding number of the coil in accordance with the selection;

a core composed of a magnetic material and a thermosetting resin and including therein a winding number adjustment means, out of said plate member; and

a coil included inside said core and ends thereof are jointed with the winding number adjustment means,

wherein a mounting terminal portion follows an end surface of said core and is provided from the end surface to a mounting portion of said core to be mounted to a PCB, and

wherein the winding number adjustment means includes plural inner terminal portions and is enabled to adjust a winding number of the coil by selecting any one of the plural inner terminal portions.

5. The magnetic element as claimed in claim 4

wherein said winding number adjustment means of said plate member includes plural inner terminal portions and at least one of the plural inner terminal portions is provided with an extending portion extending in a direction orthogonal to a flat surface on which a flat plate portion of said frame portion exists;

and

wherein the inner terminal portion provided with the extending portion is disposed at a different position from those of the other inner terminal portions in view of a normal direction of the flat plate portion of said frame portion due to the existence of the extending portion.

6. The magnetic element according to claim 5,

wherein there exist four inner terminal portions and the four inner terminal portions are provided at intervals of an angle of 90 degrees when viewing from the normal direction of the flat plate portion of said frame portion as a plan view.

7. The magnetic element according to claim 4:

wherein said coil is composed of a flat wire; and

wherein the two ends existing in the coil are connected to such sides of the inner terminal portion that face each other, respectively.

8. The magnetic element according to claim 5:

wherein said coil is composed of a flat wire, and

wherein the two ends existing in the coil are connected to such sides of the inner terminal portion that face each other, respectively.

9. The magnetic element according to claim 6:

wherein said coil is composed of a flat wire; and

wherein the two ends existing in the coil are connected to such sides of the inner terminal portion that face each other, respectively.

10. A magnetic element manufacturing method comprising the steps of:

die-cutting a metal member of a plate shape to form a plate member including a frame portion, a mounting terminal portion and plural terminal joint portions and having a winding number adjustment means capable of selecting a joint position of an end from the plural terminal joint portions in accordance with the winding number of the coil;

winding a flat wire to form the coil of which ends are jointed with the terminal joint portions;

setting the coil formed by said winding step while the terminal joint portions and the ends are in a contacting state;

jointing the ends and the terminal joint portions to secure a positional relationship of the ends and the terminal joint portions;

powder pressing to press the coils, the terminal joint portions and granulated powders while the coils and the terminal joint portions are coated with the granulated powders composed of a magnetic material and a thermosetting resin to thereby form a green compact in which the mounting terminal portion is in an exposed state by the pressing;

heating the green compact formed by said powder pressing step to thermoset the granulated powders; and

forming a terminal to form a PCB joint portion to be jointed with an external PCB by cutting the mounting terminal portion after said heating step at a middle portion of the mounting terminal portion and bending the cut mounting terminal portion.