ELECTRONIC COMPONENT AND METHOD OF MANUFACTURING THE SAME

• US 20180182533A1
• Filed: 12/13/2017
• Published: 06/28/2018
• Est. Priority Date: 12/22/2016
• Status: Active Grant

• Current Assignee: Murata Manufacturing Co Limited
• Original Assignee: Murata Manufacturing Co Limited
• Inventors: MUNEUCHI, Keita, ISO, Eiji
• Granted Patent: US 10,692,644 B2
• Time in Patent Office: Days
• CPC Class Codes: H01F 17/04 with magnetic core
• CPC Class Codes: H01F 2017/048 with encapsulating core, e.g. made of resin and magnetic powder
• 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 27/2871 Pancake coils
• CPC Class Codes: H01F 27/29 Terminals; Tapping arrangements for signal inductances
• CPC Class Codes: H01F 27/324 Insulation between coil and core, between different winding sections, around the coil; Other insulation structures
• CPC Class Codes: H01F 27/36 Electric or magnetic shields or screens movable for varying inductance H01F21/10
• CPC Class Codes: H01F 27/366 made of ferromagnetic material
• CPC Class Codes: H01F 41/061 Winding flat conductive wires or sheets
• CPC Class Codes: H01F 41/076 Forming taps or terminals while winding, e.g. by wrapping or soldering the wire onto pins, or by directly forming terminals from the wire

Abstract

An electronic component includes at least one coil including a winding part and lead-out end parts at both ends thereof, and a magnetic molded body having a mounting surface with the coil incorporated therein. The lead-out end parts are led out toward the mounting surface such that end surfaces of the lead-out end parts are arranged on the same plane as the mounting surface.

Claims

1. An electronic component comprising:

at least one coil including a winding part and lead-out end parts at both ends of the coil; and

a magnetic molded body having a mounting surface with the coil incorporated therein, wherein

the lead-out end parts are led out toward the mounting surface such that end surfaces of the lead-out end parts are arranged on the same plane as the mounting surface.

2. The electronic component according to claim 1, comprising a plurality of the coils, wherein at least two of the coils have the respective winding parts stacked in a winding axis direction of the coils.

3. The electronic component according to claim 2, wherein an intermediate layer is disposed between the stacked coils.

4. The electronic component according to claim 3, wherein the intermediate layer comprises an insulating layer having a major surface orthogonal to the mounting surface.

5. The electronic component according to claim 3, wherein the intermediate layer comprises a magnetic flux blocking sheet having a major surface orthogonal to the mounting surface.

6. The electronic component according to claim 3, wherein the intermediate layer is sandwiched by a pair of magnetic sheets.

7. The electronic component according to claim 1, wherein the end surfaces of the lead out end parts are arranged only in the same plane as the mounting surface.

8. The electronic component according to claim 1, further comprising plural external terminals on the mounting surface and respectively contacting the end surfaces of the lead out end parts.

9. The electronic component according to claim 8, wherein the external terminals are formed only on the mounting surface.

10. A method of manufacturing an electronic component comprising at least one coil including a winding part and lead-out end parts at both ends of the coil, and a magnetic molded body having a mounting surface with the coil incorporated therein, the method comprising:

acquiring a stacked precursor, including arranging a plurality of the coils on an upper surface of a magnetic sheet such that the winding axis of the coils is orthogonal to the upper surface of the magnetic sheet and that all the lead-out end parts are led out in the same direction and stacking another magnetic sheet on the arranged coils;

pressurizing the stacked precursor in the winding axis direction of the coils to acquire a magnetic sheet stacked body having a plurality of the coils incorporated therein; and

cutting the magnetic sheet stacked body together with the lead-out end parts at both ends of the coils along a plane parallel to the winding axis direction of the coils to form a mounting surface so as to acquire a magnetic molded body with end surfaces of the lead-out end parts arranged on the same plane as the mounting surface.

11. The method of manufacturing an electronic component according to claim 10, further comprising forming external terminals connected to cut surfaces of the lead-out end parts on the mounting surface of the magnetic molded body.

12. The method of manufacturing an electronic component according to claim 10, wherein

acquiring the stacked precursor includes

arranging a plurality of the coils on an upper surface of a magnetic sheet such that the winding axis of the coils is orthogonal to the upper surface of the magnetic sheet and that all the lead-out end parts are led out in a same direction and stacking a further magnetic sheet and additional coils on the arranged coils at least once, and

further stacking an additional magnetic sheet on the additional coils, and wherein

the additional coils are arranged such that the winding parts of the additional coils are stacked in the winding axis direction of the coils above the winding parts of the coils arranged between the magnetic sheets via the stacked magnetic sheet and that the lead-out end parts of all the coils are led out in the same direction.

13. The method of manufacturing an electronic component according to claim 10, wherein

acquiring the stacked precursor includes

arranging the coils on an upper surface of a magnetic sheet such that the winding axis of the coils is orthogonal to the upper surface of the magnetic sheet and that all the lead-out end parts are led out in a same direction and stacking further magnetic sheets sandwiching an intermediate sheet and additional coils on the arranged coils at least once, and

further stacking an additional magnetic sheet on the additional coils, wherein

the further magnetic sheets sandwiching the intermediate sheet are formed by stacking a magnetic sheet, an intermediate sheet, and a magnetic sheet in this order, and wherein

the additional coils are arranged such that the winding parts of the additional coils are stacked in the winding axis direction of the coils above the winding parts of the coils arranged between the magnetic sheets via the magnetic sheet and that the lead-out end parts of all the coils are led out in the same direction.

14. The method of manufacturing an electronic component according to claim 11, wherein

acquiring the stacked precursor includes

arranging a plurality of the coils on an upper surface of a magnetic sheet such that the winding axis of the coils is orthogonal to the upper surface of the magnetic sheet and that all the lead-out end parts are led out in a same direction and stacking a further magnetic sheet and additional coils on the arranged coils at least once, and

further stacking an additional magnetic sheet on the additional coils, and wherein

the additional coils are arranged such that the winding parts of the additional coils are stacked in the winding axis direction of the coils above the winding parts of the coils arranged between the magnetic sheets via the stacked magnetic sheet and that the lead-out end parts of all the coils are led out in the same direction.

15. The method of manufacturing an electronic component according to claim 11, wherein

acquiring the stacked precursor includes

arranging the coils on an upper surface of a magnetic sheet such that the winding axis of the coils is orthogonal to the upper surface of the magnetic sheet and that all the lead-out end parts are led out in a same direction and stacking further magnetic sheets sandwiching an intermediate sheet and additional coils on the arranged coils at least once, and

further stacking an additional magnetic sheet on the additional coils, wherein

the further magnetic sheets sandwiching the intermediate sheet are formed by stacking a magnetic sheet, an intermediate sheet, and a magnetic sheet in this order, and wherein

the additional coils are arranged such that the winding parts of the additional coils are stacked in the winding axis direction of the coils above the winding parts of the coils arranged between the magnetic sheets via the magnetic sheet and that the lead-out end parts of all the coils are led out in the same direction.