MAGNETIC DEVICE AND METHOD OF MANUFACTURING THE SAME

• US 20140002227A1
• Filed: 05/28/2013
• Published: 01/02/2014
• Est. Priority Date: 07/23/2010
• Status: Active Grant

• Current Assignee: Cyntec Co. Ltd. (Delta Electronics Incorporated)
• Original Assignee: Cyntec Co. Ltd. (Delta Electronics Incorporated)
• Inventors: Hsieh, Roger, Lee, Cheng-Chang, Liu, Chun-Tiao, Huang, Yi-Min, Chuang, Chih-Siang
• Granted Patent: US 9,136,050 B2
• Time in Patent Office: Days
• US Class Current: 336/200
• CPC Class Codes: H01F 17/04 with magnetic core
• CPC Class Codes: H01F 27/00 Details of transformers or inductances, in general
• CPC Class Codes: H01F 27/022 Encapsulation
• CPC Class Codes: H01F 27/255 made from particles H01F27/26 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 41/0206 Manufacturing of magnetic cores by mechanical means magnetic cores per se H01F27/24
• CPC Class Codes: H01F 41/10 Connecting leads to windings making electric connections in general H01R43/00
• CPC Class Codes: H01F 5/00 Coils superconducting coils H01F6/06; fixed inductances of the signal type H01F17/00
• CPC Class Codes: H01F 5/003 Printed circuit coils
• CPC Class Codes: H01F 7/06 Electromagnets; Actuators including electromagnets electric coils H01F5/00; devices for holding workpieces using electric force B23Q3/15; load-engaging elements for lifting articles electromagnetically B66C1/06; electromagnetic couplings F16D27/00; magnetic brakes F16D63/002; electromagnetically operated valves F16K11/24, F16K31/00; analysing materials by magnetic means G01N27/72, G01N27/80; electromagnets for winding mechanical clocks G04C1/02; electromagnetic relays H01H51/00; windings for salient poles of dynamo-electric machines H02K3/18; electromagnets for telegraphic communication H04L; for arc lamps H05B31/28
• CPC Class Codes: H05K 3/301 by means of a mounting structure H05K3/325 takes precedence
• CPC Class Codes: Y10T 29/302 Clad or other composite foil or thin metal making
• CPC Class Codes: Y10T 29/49073 by assembling coil and core
• CPC Class Codes: Y10T 29/49075 including permanent magnet or core

Abstract

A magnetic device comprises a lead frame, a first core body and a coil. The lead frame has a first portion and a second portion spaced apart from the first portion. A first core body is disposed on the lead frame, wherein the first core body comprises a first through opening and a second through opening. A coil is disposed on the first core body, wherein the coil has a first terminal and a second terminal, wherein the first portion is electrically connected with the first terminal via the first through opening, and the second portion is electrically connected with the second terminal via the second through opening, respectively.

Claims

1. A magnetic device, comprising:

a lead frame having a first portion and a second portion spaced apart from the first portion;

a first core body disposed on the lead frame, wherein the first core body comprises a first through opening and a second through opening; and

a coil disposed on the first core body, wherein the coil has a first terminal and a second terminal, wherein the first portion is electrically connected with the first terminal via the first through opening, and the second portion is electrically connected with the second terminal via the second through opening, respectively.

2. The magnetic device according to claim 1, wherein the first portion comprises a first protrusion and the second portion comprises a second protrusion, wherein the first protrusion is connected with the first terminal through the first through opening, and the second protrusion is connected with the second terminal through the second through opening, respectively.

3. The magnetic device according to claim 1, wherein a first conductive pillar is disposed in the first through opening to connect the first portion with the first terminal, and a second conductive pillar is disposed in the second through opening to connect the second portion with the second terminal, respectively.

4. The magnetic device according to claim 2, wherein the top end of the first protrusion is disposed in the first through opening, and the top end of the second protrusion is disposed in the second through opening.

5. The magnetic device according to claim 2, wherein at least one portion of the first protrusion is disposed outside the first through opening, and at least one portion of the second protrusion is disposed outside the second through opening.

6. The magnetic device according to claim 1, further comprising a molding body encapsulating the coil.

7. The magnetic device according to claim 2, wherein the first protrusion comprises a first foldable soldering pad, and the second protrusion comprises a second foldable soldering pad.

8. The magnetic device according to claim 1, wherein the first protrusion comprises a first bent portion for connecting with the first terminal, and the second protrusion comprises a second bent portion for connecting with the second terminal.

9. The magnetic device according to claim 1, wherein the first through opening is formed with one side of the first through opening aligned with a first edge of the first core body;

and the second through opening is formed with one side of the second through opening aligned with a second edge of the first core body.

10. The magnetic device according to claim 1, wherein the first through opening is formed with two sides of the first through opening aligned with a first two edges of the first core body;

and the second through opening is formed with two sides of the second through opening aligned with a second two edges of the first core body.

11. The magnetic device according to claim 1, wherein a first electrode is disposed on the bottom surface of the first portion and a second electrode is disposed on the bottom surface of the second portion.

12. The magnetic device according to claim 2, wherein the first portion further comprises a third protrusion, and the second portion further comprises a fourth protrusion, wherein the first protrusion, the second protrusion, the third protrusion and the fourth protrusion surround the first core body.

13. The magnetic device according to claim 1, further comprising a second core body, wherein the coil is disposed between the first core body and the second core body.

14. The magnetic device according to claim 1, wherein the first core boy has a first surface which is substantially flat, wherein the coil is disposed on the first surface of the first core body.

15. The magnetic device according to claim 1, wherein the first core boy comprises a plate and a pillar having a top end and a bottom end, wherein the bottom end of the pillar is connected to the plate, wherein the coil is disposed on the plate and winded around the pillar.

16. A method for forming a magnetic device, the method comprising the steps of:

a forming a lead frame having a first portion and a second portion spaced apart from the first portion;

disposing a first core body on the lead frame, wherein the first core body comprises a first through opening and a second through opening; and

disposing a coil on the first core body, wherein the coil has a first terminal and a second terminal, wherein the first portion is electrically connected with the first terminal via the first through opening, and the second portion is electrically connected with the second terminal via the second through opening, respectively.

17. The method structure according to claim 16, wherein the lead frame is formed by electroplating or etching.

18. The method according to claim 16, further comprising:

forming a molding body to encapsulate the coil.

19. The method according to claim 16, wherein the first portion comprises a first protrusion and the second portion comprises a second protrusion, wherein the first protrusion is connected with the first terminal through the first through opening, and the second protrusion is connected with the second terminal through the second through opening, respectively.

20. The method according to claim 16, wherein a first conductive pillar is disposed in the first through opening to connect the first portion with the first terminal, and a second conductive pillar is disposed in the second through opening to connect the second portion with the second terminal, respectively.