MAGNETIC ELEMENT

• US 20130027161A1
• Filed: 04/19/2012
• Published: 01/31/2013
• Est. Priority Date: 07/25/2011
• Status: Active Grant

• Current Assignee: Sumida Corporation
• Original Assignee: Sumida Corporation
• Inventors: URANO, Yuichiro
• Granted Patent: US 8,471,665 B2
• Time in Patent Office: Days
• US Class Current: 336/83
• CPC Class Codes: H01F 17/04 with magnetic core
• CPC Class Codes: H01F 27/292 Surface mounted devices

Abstract

A magnetic element including: a first magnetic core including a coil which is wound by a predetermined number of turns; a second magnetic core which includes the coil in the inside thereof and which is combined along the outer circumference of the first magnetic core; and a metal terminal which connects the coil and a mounting substrate, wherein the metal terminal includes a fixing portion for fixing the second magnetic core in a state of combining the first magnetic core and the second magnetic core.

Claims

1. A magnetic element comprising:

a first magnetic core including a coil which is wound by a predetermined number of turns;

a second magnetic core which includes said coil in the inside thereof and which is combined along the outer circumference of said first magnetic core; and

a metal terminal which connects said coil and a mounting substrate, wherein

said metal terminal includes;

a fixing portion for fixing said second magnetic core in a state of combining said first magnetic core and said second magnetic core.

2. The magnetic element according to claim 1, wherein

said metal terminal, further, includes:

a mount portion connected to the mounting substrate, and

a solder fillet forming portion which is formed along an outer wall of said first magnetic core and said second magnetic core and which induces formation of solder fillet with respect to said mounting substrate.

3. The magnetic element according to claim 2, wherein

said first magnetic core includes a winding axis around which said coil is wound, and a first flange portion and a second flange portion which are provided at both ends of said winding axis respectively and whose diameters are unequal to each other;

said second magnetic core is formed in a ring shape surrounding said first magnetic core and is disposed at said first flange portion in a state in which said winding axis which said first magnetic core includes is inserted therein; and

said mount portion of said metal terminal is bonded to said first flange portion of said first magnetic core and said fixing portion of said metal terminal is formed up to the height of a cutaway portion of said second magnetic core.

4. The magnetic element according to claim 1, wherein the front end of said fixing portion is hooked to the cutaway portion of said second magnetic core which is combined with said first magnetic core and said fixing portion maintains the position when combining said second magnetic core with respect to said first magnetic core.

5. The magnetic element according to claim 2, wherein said metal terminal includes a binding portion to which both ends of said coil are bound.

6. The magnetic element according to claim 2, wherein

said metal terminal includes a binding portion to which both ends of said coil are bound, and

there is formed an air gap of 0.5 mm or more between the root of said binding portion and the root of said solder fillet forming portion.

7. The magnetic element according to claim 3, wherein at an outer wall of said second magnetic core, there is formed a concave portion immediately under said cutaway portion toward the center of said second magnetic core.

8. The magnetic element according to claim 1, wherein

said coil is an air-core coil,

said first magnetic core houses said coil and is formed in a box shape whose one surface is opened,

said second magnetic core is formed as a lid portion for sealing said opened one surface of said first magnetic core, and

a terminal end extended from said coil which is housed in said first magnetic core is bound to said metal terminal formed with a binding portion for fixing both ends of said coil.

9. The magnetic element according to claim 7, wherein there is formed an air gap between the concave portion of said second magnetic core &

the outer edge of said first flange portion and said metal terminal.

10. A metal terminal including a fixing portion, a solder fillet forming portion, a mount portion, a binding portion and a claw portion, wherein

said solder fillet forming portion is formed perpendicularly to said mount portion;

said fixing portion is formed on an upper end surface of said solder fillet forming portion;

said claw portion is formed at a front end of said fixing portion;

said fixing portion is formed up to a predetermined height;

said solder fillet forming portion is formed by a predetermined length; and

the width of said solder fillet portion forming portion is at least larger than the width of said fixing portion.