Surface-mount coil and method for manufacturing same

• US 6,825,746 B2
• Filed: 03/25/2003
• Issued: 11/30/2004
• Est. Priority Date: 11/26/1999
• Status: Expired due to Fees

• Current Assignee: Kazuhiko Otsuka, Satoshi Kinoshita, Tomohiko Morijiri, Tomoo Kashiwa
• Original Assignee: Kazuhiko Otsuka, Satoshi Kinoshita, Tomohiko Morijiri, Tomoo Kashiwa
• Inventors: Kinoshita, Satoshi, Kashiwa, Tomoo, Otsuka, Kazuhiko, Morijiri, Tomohiko
• Primary Examiner(s): Nguyen, Tuyen T.
• Application Number:
  US10/336,941
• Publication Number:
  US 20040021541A1
• Time in Patent Office: 616 Days
• Field of Search: 336/65, 336/83, 336/90, 336/96, 336/183, 336/185, 336/192, 336/198, 336/200, 336/208, 336/232, 296/021, 296/05--06
• US Class Current: 336/83
• 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 27/292 Surface mounted devices
• CPC Class Codes: H01F 27/327 Encapsulating or impregnating encapsulating coil and core H01F27/022
• CPC Class Codes: H01F 41/005 Impregnating or encapsulating insulating of windings H01F41/12

Abstract

A surface mountable coil is provided with a drum-shaped core including a body portion and raised portion each raised portion having a peripheral surface and an end surface, a winding wire wound around the body portion, an encapsulating member, base electrodes, and terminal electrodes. The encapsulating member exposes some portions of the base electrodes on the peripheral surfaces and substantially the whole base electrodes on the end surfaces. By exposing the portions of the base electrodes on the peripheral surfaces and whole base electrodes on the end surfaces, the contact strength between the base electrodes and the terminal electrodes can be substantially increased.

Claims

1. A surface mountable coil comprising:

a core including a body portion and two raised portions disposed at two opposite ends of the body portion, each of the raised portions having an end surface and a peripheral surface, wherein the peripheral surface has corner regions and is provided with cutaway portions at the corner regions;

a winding wire wound around the body portion;

a pair of base electrodes, each of the base electrodes being disposed on the peripheral surface and the end surface of one of the raised portions, and two ends of the winding wire being connected to the base electrodes respectively;

an encapsulating member extending from a portion of one base electrode to a portion of the other base electrode to thereby cover the region therebetween while exposing a part of the base electrode on each peripheral surface; and

a pair of terminal electrodes respectively covering the exposed base electrodes and end portions of the encapsulating member on the peripheral surfaces of the raised portions,

wherein the end portions of the encapsulating member on the peripheral surfaces have peak portions extending toward the end surfaces of the raised portions and valley portions retracting away from the end surfaces.

2. The surface mountable coil of claim 1, wherein the encapsulating member exposes the entire base electrodes on the end surfaces.

3. The surface mountable coil of claim 1, wherein the peripheral surfaces are provided with recesses.

4. The surface mountable coil of claim 1, wherein the peripheral surfaces the end surfaces are provided with recesses and protrusions.

5. The surface mountable coil of claim 1, wherein each of the base electrodes is a mesh-shaped electrode.

6. The surface mountable coil of claim 1, wherein each of the base electrodes is a perforated electrode having a plurality of openings.

7. The surface mountable coil of claim 1, further comprising a stress buffer layer disposed between each of the base electrodes and the end surface of each of the raised portions.

8. The surface mountable coil of claim 1, wherein each of the raised portions is of a polygonal shape when viewed along an axial direction of the body portion.

9. The surface mountable coil of claim 1, wherein each of the raised portions is of generally a rectangular shape when viewed along art axial direction of the body portion.

10. The surface mountable coil of claim 9, wherein at least one of the cutaway portions is of a rectangular shape pillar having a rectangular base.

11. The surface mountable coil of claim 9, wherein at least one of the cutaway portions is of a triangular prism shape having a triangular base.

12. The surface mountable coil of claim 9, wherein the rectangular shape has one or more round corners.

13. The surface mountable coil of claim 1, comprising the step of:

preparing the core provided with the winding wire and the base electrodes;

providing a mold having an elastic material on parts of an inner surface thereof, the elastic material facing portions of the base electrodes on the peripheral surfaces;

molding the encapsulating member by using the mold while maintaining the contact between the elastic material and the portions of the base electrodes on the peripheral surfaces; and

forming the terminal electrodes.