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Method for manufacturing a magnetic element

  • US 7,392,581 B2
  • Filed: 03/02/2007
  • Issued: 07/01/2008
  • Est. Priority Date: 11/16/2004
  • Status: Active Grant
First Claim
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1. A magnetic element manufacturing method comprising the steps of:

  • die-cutting a metal member of a plate shape to form a plate member including a frame portion, a mounting terminal portion and plural terminal joint portions and having a winding number adjustment means capable of selecting a joint position of an end from the plural terminal joint portions in accordance with a winding number of a coil;

    winding a flat wire to form the coil of which ends are jointed with the terminal joint portions;

    setting the coil formed by said winding step while the terminal joint portions and the ends are in a contacting state;

    jointing the ends and the terminal joint portions to secure a positional relationship of the ends and the terminal joint portions;

    powder pressing to press the coils, the terminal joint portions and granulated powders while the coils and the terminal joint portions are coated with the granulated powders composed of a magnetic material and a thermosetting resin to thereby form a green compact in which the mounting terminal portion is in an exposed state by the pressing;

    heating the green compact formed by said powder pressing step to thermoset the granulated powders; and

    forming a terminal to form a PCB joint portion to be jointed with an external PCB by cutting the mounting terminal portion after said heating step at a middle portion of the mounting terminal portion and bending the cut mounting terminal portion.

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