ELECTRODE STRUCTURE AND THE CORRESPONDING ELECTRICAL COMPONENT USING THE SAME AND THE FABRICATION METHOD THEREOF

• US 20160012962A1
• Filed: 07/06/2015
• Published: 01/14/2016
• Est. Priority Date: 07/10/2014
• Status: Active Grant

• Current Assignee: Cyntec Co. Ltd. (Delta Electronics Incorporated)
• Original Assignee: Cyntec Co. Ltd. (Delta Electronics Incorporated)
• Inventors: LEE, Chi-Hsun, HSIEH, Hsieh-Shen, CHEN, Sen-Huei
• Granted Patent: US 9,831,023 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• 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 2017/048 with encapsulating core, e.g. made of resin and magnetic powder
• CPC Class Codes: H01F 27/022 Encapsulation
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 3/10 Composite arrangements of magnetic circuits
• CPC Class Codes: H01L 24/00 Arrangements for connecting or disconnecting semiconductor or solid-state bodies; Methods or apparatus related thereto
• CPC Class Codes: H01L 28/10 Inductors

Abstract

An electrical component is disclosed, wherein the electrical component comprises: a body; a conductive element disposed in the body, wherein at least one portion of a terminal part of the conductive element is exposed outside of the body; a metal foil having an adhesive material on the bottom surface thereof, the metal foil being adhered on the body through the adhesive material and covering a first portion of the terminal part of the conductive element, wherein a second portion of the terminal part of the conductive element is not covered by the metal foil; and a metal layer, overlaying on the metal foil and covering the second portion of the terminal part of the conductive element, wherein the metal layer is electrically connected to the second portion of the terminal part of the conductive element for electrically connecting with an external circuit.

Claims

1. An electrical component, comprising:

a body;

a conductive element disposed in the body, wherein at least one portion of a terminal part of the conductive element is exposed outside of the body;

a metal foil having an adhesive material on the bottom surface thereof, the metal foil being adhered on the body through the adhesive material and covering a first portion of the terminal part of the conductive element, wherein a second portion of the terminal part of the conductive element is not covered by the metal foil; and

a metal layer, overlaying on the metal foil and covering the second portion of the terminal part of the conductive element, wherein the metal layer is electrically connected to the second portion of the terminal part of the conductive element for electrically connecting with an external circuit.

2. The electrical component according to claim 1, wherein the electrical component is an inductor or a choke, wherein the body is a magnetic body and the conductive element is a conductive wire.

3. The electrical component according to claim 1, wherein the metal foil is coated with conductive adhesive material on the bottom surface thereof.

4. The electrical component according to claim 1, wherein the metal foil is a resin coated copper foil.

5. The electrical component according to claim 1, wherein the metal foil is made of Cu.

6. The electrical component according to claim 1, wherein the metal layer is made of Sn or Ni.

7. The electrical component according to claim 1, wherein the metal layer is made by electroplating.

8. The electrical component according to claim 1, wherein the metal foil is adhered on the first portion and a third portion of the terminal part of the conductive element, wherein the second portion is located between the first portion and the third portion.

9. The electrical component according to claim 1, wherein a third portion of the terminal part of the conductive element is not covered by the metal foil, wherein the first portion of the terminal part of the conductive element is located between the second portion and the third portion of the terminal part of the conductive element.

10. The electrical component according to claim 1, wherein a recess is formed on the top surface of the body, wherein the terminal part of the conductive element is disposed in the recess.

11. The electrical component according to claim 1, wherein the electrical component is an inductor and the conductive element is a coil, and the coil is disposed in the body with the terminal part of the coil disposed in a recess on a surface of the body.

12. The electrical component according to claim 1, wherein the electrical component is an inductor and the conductive element is a coil, wherein the body is a magnetic body and the coil is disposed in the magnetic body with the terminal part of the coil disposed in a recess on the bottom surface of the body, wherein the magnetic body comprises a T-core having a pillar, wherein the coil surrounds the pillar and the terminal part of the coil disposed in the recess on the bottom surface of the magnetic body via a side surface of the T-core.

13. A method to make an electrical component, comprising:

proving a body, wherein a conductive element disposed in the body, wherein at least one portion of a first terminal part of the conductive element is exposed outside of the body; and

disposing a first metal layer on the body by using a PVD process, wherein the first metal layer covers the at least one portion of the first terminal part of the conductive element.

14. The method according to claim 13, wherein at least one portion of a second terminal part of the conductive element is exposed outside of the body, the method further comprising disposing a second metal layer on the body by using the PVD process, wherein the second metal layer covers the at least one portion of the second terminal part of the conductive element.

15. The method according to claim 13, wherein the electrical component is an inductor, wherein the body is a magnetic body and the conductive element is a coil, wherein the coil is disposed in the magnetic body with the terminal part of the coil disposed in a recess on a surface of the body.

16. The method according to claim 13, wherein the electrical component is an inductor, wherein the body is a magnetic body and the conductive element is a coil, wherein coil is disposed in the magnetic body with the terminal part of the coil disposed in a recess on the bottom surface of the body, wherein the magnetic body comprises a T-core having a pillar, wherein the coil surrounds the pillar and the terminal part of the coil disposed in the recess on the bottom surface of the magnetic body via a side surface of the T-core.

17. An electrical component, comprising:

a body;

a conductor wire disposed in the body, wherein a first axial surface of a first end of the conductor wire and a second axial surface of a second end of the conductor wire are exposed outside of the body, wherein the first axial surface and the second axial surface are exposed on a same surface or two opposite surfaces of the body;

a first electrode structure disposed on the body and electrically connected to the first axial surface of the first end of the conductor wire; and

a second electrode structure disposed on the body and electrically connected to the second axial surface of the second end of the conductor wire.

18. The electrical component according to claim 17, further comprising a protecting layer covering the outer surfaces of the body without covering the first axial surface of the first end of the conductor wire and the second axial surface of the second end of the conductor wire.

19. The electrical component according to claim 17, wherein the electrical component is an inductor, wherein the body is a magnetic body and the conductive wire is a coil, wherein the coil is disposed in the magnetic body.

20. The electrical component according to claim 17, wherein the electrical component is an inductor and the conductive wire is a coil, wherein the body is a magnetic body and the coil is disposed in the magnetic body with the terminal part of the coil disposed in a recess on the bottom surface of the body, wherein the magnetic body comprises a T-core having a pillar, wherein the coil surrounds the pillar and the terminal part of the coil disposed in the recess on the bottom surface of the magnetic body via a side surface of the T-core.