Coil electrical component and method of manufacturing the same

• US 9,082,541 B2
• Filed: 01/06/2012
• Issued: 07/14/2015
• Est. Priority Date: 04/13/2011
• Status: Expired due to Fees

• Current Assignee: MagiQ Technologies, Incorporated
• Original Assignee: MagiQ Technologies, Incorporated
• Inventors: Lo, Peng-Chen, Tan, Lung Ching
• Primary Examiner(s): YI, STELLA KIM
• Application Number:
  US13/345,653
• Publication Number:
  US 20120262265A1
• Time in Patent Office: 1,285 Days
• Field of Search: 264/272.19, 264/611, 264/614, 264/618, 264/619, 264/621, 264/272.2, 264/272.21, 264615-617, 264/104, 264/272.11, 264/272.12
• US Class Current: 1/1
• CPC Class Codes: H01F 2017/048 with encapsulating core, e.g. made of resin and magnetic powder
• CPC Class Codes: H01F 27/022 Encapsulation
• CPC Class Codes: H01F 27/255 made from particles H01F27/26 takes precedence
• CPC Class Codes: H01F 41/026 protecting methods against environmental influences, e.g. oxygen, by surface treatment magnetic particles with skin H01F1/061, H01F1/09, H01F1/24, H01F1/33 and G11B5/706
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

Abstract

A coil electrical component and a method of manufacturing the same. Magnetic material powder and adhesive powder are mixed in a predetermined proportion to form a solid mixture. The solid mixture and an object, such as a coil or a core material surrounded by the coil, are filled in a mold having a predetermined shape. The solid mixture in the mold is heated such that the magnetic material powder is adhered by the adhesive powder and covers the object, so as to form the coil electrical component. The coil electrical component corresponds in shape to the mold. Therefore, the coil electrical component has stable quality, and can be manufactured with less time and lower cost.

Claims

1. A method of manufacturing a coil electrical component, the method comprising:

(1) mixing magnetic material powder and adhesive powder in a predetermined proportion to form a solid mixture;

(2) disposing an object and the solid mixture in a mold having a predetermined shape, wherein the object is covered by the solid mixture, and a pressure below 50 kg/cm² is applied to the mold; and

(3) heating the solid mixture in the mold such that the magnetic material powder is adhered by the adhesive powder and covers the object, so as to form the coil electrical component corresponding in shape to the mold.

2. The method of claim 1, further comprising mixing the solid mixture with insulation material powder.

3. The method of claim 1, further comprising, before the execution of step (3), shaking the mold.

4. The method of claim 1, wherein step (3) further comprises pressing the mold when heating the solid mixture such that the mold is uniformly filled with the solid mixture.

5. The method of claim 1, wherein the object is a coil or a core material surrounded by the coil.

6. The method of claim 5, wherein the mold is provided with a hole, and the coil has one end stretched out from the hole.

7. The method of claim 1, wherein the predetermined proportion is 70:

30 to 95;

5 by weight.

8. The method of claim 1, further comprising mixing the solid mixture with adhesive gel.