Magnetic device and method of manufacturing the same

• US 9,136,050 B2
• Filed: 05/28/2013
• Issued: 09/15/2015
• Est. Priority Date: 07/23/2010
• Status: Active Grant

• Current Assignee: Cyntec Co. Ltd. (Delta Electronics Incorporated)
• Original Assignee: Cyntec Co. Ltd. (Delta Electronics Incorporated)
• Inventors: Hsieh, Roger, Lee, Cheng-Chang, Liu, Chun-Tiao, Huang, Yi-Min, Chuang, Chih-Siang
• Primary Examiner(s): NGUYEN, TUYEN T
• Application Number:
  US13/902,997
• Publication Number:
  US 20140002227A1
• Time in Patent Office: 840 Days
• Field of Search: 336/65, 336/83, 336/200, 336/232, 336/192, 336 90- 96
• US Class Current: 1/1
• CPC Class Codes: H01F 17/04 with magnetic core
• CPC Class Codes: H01F 27/00 Details of transformers or inductances, in general
• CPC Class Codes: H01F 27/022 Encapsulation
• 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 27/29 Terminals; Tapping arrangements for signal inductances
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 41/0206 Manufacturing of magnetic cores by mechanical means magnetic cores per se H01F27/24
• CPC Class Codes: H01F 41/10 Connecting leads to windings making electric connections in general H01R43/00
• CPC Class Codes: H01F 5/00 Coils superconducting coils H01F6/06; fixed inductances of the signal type H01F17/00
• CPC Class Codes: H01F 5/003 Printed circuit coils
• CPC Class Codes: H01F 7/06 Electromagnets; Actuators including electromagnets electric coils H01F5/00; devices for holding workpieces using electric force B23Q3/15; load-engaging elements for lifting articles electromagnetically B66C1/06; electromagnetic couplings F16D27/00; magnetic brakes F16D63/002; electromagnetically operated valves F16K11/24, F16K31/00; analysing materials by magnetic means G01N27/72, G01N27/80; electromagnets for winding mechanical clocks G04C1/02; electromagnetic relays H01H51/00; windings for salient poles of dynamo-electric machines H02K3/18; electromagnets for telegraphic communication H04L; for arc lamps H05B31/28
• CPC Class Codes: H05K 3/301 by means of a mounting structure H05K3/325 takes precedence
• CPC Class Codes: Y10T 29/302 Clad or other composite foil or thin metal making
• CPC Class Codes: Y10T 29/49073 by assembling coil and core
• CPC Class Codes: Y10T 29/49075 including permanent magnet or core

Abstract

A magnetic device comprises a lead frame, a first core body and a coil. The lead frame has a first portion and a second portion spaced apart from the first portion. A first core body is disposed on the lead frame, wherein the first core body comprises a first through opening and a second through opening. A coil is disposed on the first core body, wherein the coil has a first terminal and a second terminal, wherein the first portion is electrically connected with the first terminal via the first through opening, and the second portion is electrically connected with the second terminal via the second through opening, respectively.

Claims

1. A magnetic device, comprising:

a lead frame having a first portion and a second portion spaced apart from the first portion, wherein the first portion comprises a first bottom part and a first protrusion connected to the first bottom part, and the second portion comprises a second bottom part and a second protrusion connected to the second bottom part;

a first core body disposed on the lead frame, wherein the first core body comprises a first through opening and a second through opening;

a coil disposed on the first core body, wherein the coil has a first terminal and a second terminal, wherein at least a part of the first protrusion is disposed in the first through opening and is electrically connected with the first terminal, and at least a part of the second protrusion is disposed in the second through opening and is electrically connected with the second terminal; and

a molding body, encapsulating the coil, the first protrusion and the second protrusion of the lead frame.

2. The magnetic device according to claim 1, wherein the first protrusion passes through the first through opening and the second protrusion passes through the second through opening to electrically connect with the first terminal and the second terminal, respectively.

3. The magnetic device according to claim 1, wherein the top end of the first protrusion is disposed in the first through opening, and the top end of the second protrusion is disposed in the second through opening.

4. The magnetic device according to claim 1, wherein at least one portion of the first protrusion is disposed outside the first through opening, and at least one portion of the second protrusion is disposed outside the second through opening.

5. The magnetic device according to claim 1, wherein the first protrusion comprises a first foldable soldering pad, and the second protrusion comprises a second foldable soldering pad.

6. The magnetic device according to claim 1, wherein the first protrusion comprises a first bent portion for connecting with the first terminal, and the second protrusion comprises a second bent portion for connecting with the second terminal.

7. The magnetic device according to claim 1, wherein the first through opening is formed with a first outer side surface of the first core body;

and the second through opening is formed with a second outer side surface of the first core body.

8. The magnetic device according to claim 1, wherein the first through opening and the second through opening are respectively formed with two outer side surfaces of the first core body.

9. The magnetic device according to claim 1, wherein a first electrode is disposed on the bottom surface of the first bottom part of the first portion of the lead frame and a second electrode is disposed on the bottom surface of the second bottom part of the second portion of the lead frame.

10. The magnetic device according to claim 1, wherein the first portion further comprises a third protrusion, and the second portion further comprises a fourth protrusion, wherein the first protrusion, the second protrusion, the third protrusion and the fourth protrusion surround the first core body, wherein the molding body encapsulates the coil, the first protrusion, the second protrusion, third protrusion and the fourth protrusion of the lead frame.

11. The magnetic device according to claim 1, further comprising a second core body, wherein the coil is disposed between the first core body and the second core body.

12. The magnetic device according to claim 1, wherein the first core boy has a first surface which is substantially flat, wherein the coil is disposed on the first surface of the first core body.

13. The magnetic device according to claim 1, wherein the first core boy comprises a plate and a pillar having a top end and a bottom end, wherein the bottom end of the pillar is connected to the plate, wherein the coil is disposed on the plate and wound around the pillar, wherein the molding body encapsulates the coil, the first protrusion, the second protrusion and a top portion of the pillar.

14. The magnetic device according to claim 1, wherein the first through opening and the second through opening are respectively formed on a periphery of the first core body, wherein the first protrusion is not extended outside of any outer side surface of the first core body adjacent to the first through opening, and the second protrusion is not extended outside of any outer side surface of the first core body adjacent to the second through opening.

15. The magnetic device according to claim 1, wherein the entire lead frame is encapsulated by the molding body except the first bottom part and the second bottom part of the lead frame for electrically connecting with an external circuit.

16. The magnetic device according to claim 1, wherein the first core boy comprises a plate and a pillar on the plate, wherein the coil is wound on the pillar, wherein the first bottom part and the second bottom part of the lead frame are respectively embedded in a recess on the bottom surface of the plate, wherein the entire lead frame is encapsulated by the molding body except the first bottom part of the first portion of the lead frame and the second bottom part of the second portion of the lead frame for electrically connecting with an external circuit.

17. A magnetic device, comprising:

a lead frame having a first portion and a second portion spaced apart from the first portion, wherein the first portion comprises a first bottom part and a first protrusion connected to the first bottom part, and the second portion comprises a second bottom part and a second protrusion connected to the second bottom part;

a first core body disposed on the lead frame, wherein the first core body comprises a first through opening and a second through opening, wherein the first through opening and the second through opening are respectively formed on a periphery of the first core body; and

a coil disposed on the first core body, wherein the coil has a first terminal and a second terminal;

wherein at least a part of the first protrusion is disposed in the first through opening and is electrically connected with the first terminal, and at least a part of the second protrusion is disposed in the second through opening and is electrically connected with the second terminal, wherein the first protrusion is not extended outside of any outer side surface of the first core body adjacent to the first through opening.

18. The magnetic device according to claim 17, wherein the second protrusion is not extended outside of any outer side surface of the first core body adjacent to the second through opening.