Magnetic element

• US 8,471,665 B2
• Filed: 04/19/2012
• Issued: 06/25/2013
• Est. Priority Date: 07/25/2011
• Status: Active Grant

• Current Assignee: Sumida Corporation
• Original Assignee: Sumida Corporation
• Inventors: Urano, Yuichiro
• Primary Examiner(s): Musleh, Mohamad
• Assistant Examiner(s): LIAN, MANG TIN BIK
• Application Number:
  US13/450,824
• Publication Number:
  US 20130027161A1
• Time in Patent Office: 432 Days
• Field of Search: 336/192, 336/83, 336/212, 336/221, 336/178
• US Class Current: 336/192
• CPC Class Codes: H01F 17/04 with magnetic core
• CPC Class Codes: H01F 27/292 Surface mounted devices

Abstract

A magnetic element including: a first magnetic core including a coil which is wound by a predetermined number of turns; a second magnetic core which includes the coil in the inside thereof and which is combined along the outer circumference of the first magnetic core; and a metal terminal which connects the coil and a mounting substrate, wherein the metal terminal includes a fixing portion for fixing the second magnetic core in a state of combining the first magnetic core and the second magnetic core.

Claims

1. A magnetic element comprising:

a first magnetic core including a coil which is wound by a predetermined number of turns;

a second magnetic core which circumferentially surrounds said first magnetic core and which is combined with said first magnetic core, said second magnetic core having a cutaway portion; and

a metal terminal which connects said coil and a mounting substrate, wherein said metal terminal includes;

a fixing portion which secures said second magnetic core to said first magnetic core;

a mount portion which is connectable to said mounting substrate, said mount portion having first and second sides;

a solder fillet forming portion extending from said first side of said mount portion along an outer wall of said second magnetic core; and

a binding portion to which an end of said coil is bound, said binding portion extending from said second side of said mount portion along said outer wall of said second magnetic core,

wherein a first air gap of 0.5 mm or more is located between a root of said binding portion and a root of said solder fillet forming portion;

a concave portion is formed on said outer wall of said second magnetic core immediately under said cutaway portion toward a center of said second magnetic core, and said concave portion is located next to said solder fillet forming portion.

2. The magnetic element according to claim 1, wherein

said first magnetic core includes a winding axis around which said coil is wound, and a first flange portion and a second flange portion which are provided at both ends of said winding axis respectively and whose diameters are unequal to each other;

said second magnetic core is formed in a ring shape surrounding said first magnetic core and is disposed at said first flange portion in a state in which said winding axis is inside said second magnetic core, and said cutaway portion is adjacent to said second flange portion; and

said mount portion of said metal terminal is bonded to said first flange portion of said first magnetic core and said fixing portion of said metal terminal engages said cutaway portion of said second magnetic core.

3. The magnetic element according to claim 1, wherein a tip of said fixing portion is hooked to a cutaway portion of said second magnetic core and said fixing portion maintains relative positioning when said second magnetic core is combined with said first magnetic core.

4. The magnetic element according to claim 1, wherein a second air gap is formed between the concave portion of said second magnetic core and said solder fillet forming portion, and

a third gap is formed between an outer edge of said first flange portion and said solder fillet form portion.

5. A magnetic element, comprising:

an air-core coil;

a first magnetic core having a box shape with an open top, the air-core coil being provided inside the first magnetic core;

a second magnetic core fit within the open top of the first magnetic core; and

a metal terminal connected to the air-core coil, the metal terminal including;

a mount portion under the first magnetic core relative to the second magnetic core;

a solder fillet forming portion having a first plate shape of a first width and that perpendicularly extends from the mount portion along a side of the first magnetic core;

a fixing portion having a second plate shape of a second width that is narrower than the first width, and that extends from the solder fillet forming portion further along the side of the first magnetic core, the fixing portion having a tip that engages a cutaway of the second magnetic core to secure the second magnetic core to the first magnetic core, and

a binding portion to which an end of the air-core coil is attached, the binding portion having a recess between the tip and the solder fillet forming portion for binding the end of the air-coil.