INTEGRALLY-FORMED INDUCTOR

• US 20160055954A1
• Filed: 08/20/2015
• Published: 02/25/2016
• Est. Priority Date: 08/21/2014
• Status: Active Grant

• Current Assignee: Cyntec Co. Ltd. (Delta Electronics Incorporated)
• Original Assignee: Cyntec Co. Ltd. (Delta Electronics Incorporated)
• Inventors: HUANG, YI-MIN, CHUANG, CHIH-SIANG, CHANG, YUNG-CHENG
• Granted Patent: US 10,546,684 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: H01F 17/06 with core substantially closed in itself, e.g. toroid
• CPC Class Codes: H01F 2017/065 Core mounted around conductor to absorb noise, e.g. EMI filter
• CPC Class Codes: H01F 27/292 Surface mounted devices

Abstract

An inductive component is disclosed, the inductive component comprising: a metal structure, the metal structure comprising a conductor wire and a lead frame, wherein the lead frame and the conductor wire are integrally formed, wherein the lead frame comprises a first part and a second part space spaced apart from the first part, wherein a contiguous metal path is formed from the first part of the lead frame to the second part of the lead frame via the conductor wire; a magnetic body encapsulating the conductor wire, and a first portion of the first part and a second portion of the second part of the lead frame adjacent to the conductor wire.

Claims

1. An inductive component, comprising:

a metal structure, the metal structure comprising a conductor wire and a lead frame, wherein the lead frame and the conductor wire are integrally formed, wherein the lead frame comprises a first part and a second part spaced apart from the first part, wherein a contiguous metal path is formed from the first part of the lead frame to the second part of the lead frame via the conductor wire; and

a magnetic body encapsulating the conductor wire, and a first portion of the first part and a second portion of the second part of the lead frame adjacent to the conductor wire.

2. The inductive component according to claim 1, wherein the inductive component is a choke.

3. The inductive component according to claim 1, wherein the conductor wire is a straight wire.

4. The inductive component according to claim 1, wherein the conductor wire is an arc-type coil or curved-line coil.

5. The inductive component according to claim 1, wherein the conductor wire is a spiral coil.

6. The inductive component according to claim 1, wherein the magnetic body is integrally formed to encapsulate the conductor wire, the first portion of the first part and the second portion of the second part of the lead frame.

7. The inductive component according to claim 1, wherein the width of the first portion of the first part of the lead frame is larger than that of the conductive wire for strengthen the mechanical strength between the conductor wire and the first part of the lead frame.

8. The inductive component according to claim 1, wherein the width of the second portion of the second part of the lead frame is larger than that of the conductive wire for strengthen the mechanical strength between the conductor wire and the second part of the lead frame.

9. The inductive component according to the claim 1, wherein the conductor wire is a line-type coil and the width of the line-type coil is 60 μ

m˜

70 μ

m.

10. The inductive component according to the claim 1, wherein each of the first portion of the first part of the lead frame and the second portion of the second part of the lead frame has a shape in one of the followings:

round, rectangle and trapezoid.

11. The inductive component according to the claim 1, wherein each of the first portion and the second portion has a round-corner in the front surface adjacent to the conductor wire.

12. The inductive component according to the claim 1, wherein the third portion extending from the first portion of the first part and the fourth portion extending from the second portion of the second part extend outside of the magnetic body and are bent onto two recesses on said two opposite surfaces of the magnetic body for making two electrodes, respectively.

13. The inductive component according to the claim 11, wherein an outer surface of each electrode aligns with a corresponding surface of the magnetic body on which the electrode is disposed.

14. A method to form an inductive component, comprising:

integrally forming a metal structure, the metal structure comprising a conductor wire and a lead frame, wherein the lead frame comprising a first part and a second part space spaced apart from the first part, wherein a contiguous metal path is formed from the first part of the lead frame to the second part of the lead frame via the conductor wire; and

a magnetic body encapsulating the conductor wire, and a first portion of the first part and a second portion of the second part of the lead frame adjacent to the conductor wire.

15. The method according to claim 14, further comprising extending the first portion of the first part of the lead frame onto a first surface of the magnetic body to form a first electrode and extending the second portion of the second part of the lead frame onto a second surface opposite to the first surface of the magnetic body to form a second electrode.

16. The method according to claim 14, wherein the inductive component is a choke.

17. The method according to claim 14, wherein the conductor wire is a line-type coil.

18. The method according to the claim 16, wherein the width of line-type coil is 60 nm˜

70 nm.

19. The method according to the claim 14, wherein the shape of each of the first portion of the first part and the second portion of the second part of the lead frame is round, rectangle or trapezoid.

20. The method according to claim 14, wherein the width of the second portion of the second part of the lead frame is larger than that of the conductive wire for strengthen the mechanical strength between the conductor wire and the second part of the lead frame.