COIL COMPONENT AND METHOD FOR MANUFACTURING THE SAME

• US 20170084383A1
• Filed: 03/17/2016
• Published: 03/23/2017
• Est. Priority Date: 09/21/2015
• Status: Active Grant

• Current Assignee: Samsung Electro-Mechanics Co., Ltd. (Samsung Group)
• Original Assignee: Samsung Electro-Mechanics Co., Ltd. (Samsung Group)
• Inventors: Kim, Hyung Ho, Kim, Jae Kwang, Shin, Sang Ho
• Granted Patent: US 10,026,543 B2
• Time in Patent Office: Days
• CPC Class Codes: H01F 17/04 with magnetic core
• 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 41/10 Connecting leads to windings making electric connections in general H01R43/00

Abstract

A coil component includes a core including a winding portion and a flange portion extending from a first end of the winding portion, a coil wound around the winding portion, a lead formed at the flange portion, and a cover coupled to the flange portion and covering at least a portion of the coil.

Claims

1. A coil component, comprising:

a core including a winding portion and a flange portion extending from a first end of the winding portion;

a coil wound around the winding portion;

a lead formed at the flange portion; and

a cover coupled to the flange portion and covering at least a portion of the coil.

2. The coil component of claim 1, wherein the cover covers one side portion of the coil.

3. The coil component of claim 1, wherein the cover covers one side portion and an upper portion of the coil.

4. The coil component of claim 3, wherein the portion of the cover covering the upper portion of the coil includes an opening.

5. The coil component of claim 4, wherein the opening is adhered to a second end opposite the first end of the winding portion.

6. The coil component of claim 5, wherein an area of the opening is greater than that of a longitudinal cross section of the winding portion.

7. The coil component of claim 6, wherein a center of the opening is spaced apart from a center of the winding portion.

8. The coil component of claim 1, wherein at least a portion of the lead is embedded in the flange portion.

9. The coil component of claim 1, wherein the lead is bent to one side of the coil.

10. The coil component of claim 3, wherein the lead is bent to cover the portion of the cover covering the upper portion of the coil.

11. The coil component of claim 1, wherein the coil has at least one drawing portion and the drawing portion is connected to the lead.

12. The coil component of claim 1, wherein the core includes magnetic powder particles and a thermosetting resin.

13. The coil component of claim 1, wherein the thermosetting resin is epoxy or polyimide.

14. The coil component of claim 1, wherein the winding portion is disposed to be perpendicular with respect to the flange portion.

15. A method for manufacturing a coil component, comprising steps of:

preparing a lead frame including a lead;

forming a core including a winding portion and a flange portion extending from one end part of the winding portion;

winding a coil around the winding portion;

coupling a cover covering at least a portion of the coil to the flange portion; and

cutting the lead from the lead frame.

16. The method of claim 15, wherein in the step of forming the core, at least a part of the lead is embedded in the flange portion.

17. The method of claim 15, wherein the core and the cover are each formed by filling a mold with magnetic powder particles and then pressing and molding the magnetic powder particles.

18. The method of claim 15, further comprising:

after the step of winding the coil around the winding portion, a step of connecting at least one drawing portion of the coil to the lead by welding.

19. The method of claim 15, further comprising:

cutting the lead from the lead frame and then bending the lead to cover the cover covering an upper portion of the coil,

wherein the cover covers one side portion and the upper portion of the coil.