Surface-mount inductor and production method thereof

• US 9,305,702 B2
• Filed: 08/30/2013
• Issued: 04/05/2016
• Est. Priority Date: 08/31/2012
• Status: Active Grant

• Current Assignee: Murata Manufacturing Co Limited
• Original Assignee: TOKO Incorporated (Murata Manufacturing Co Limited)
• Inventors: Sasamori, Kunio, Totsuka, Masaaki, Sakai, Chitoshi, Takahashi, Naoto, Mori, Hiroyasu
• Primary Examiner(s): Chan, Tsz
• Application Number:
  US14/015,477
• Publication Number:
  US 20140062638A1
• Time in Patent Office: 949 Days
• Field of Search: 336/175, 336/200, 336/232, 336/83, 336/233, 296/021, 296/05, 296/06
• 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 27/2847 Sheets; Strips H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 41/064 Winding non-flat conductive wires, e.g. rods, cables or cords
• CPC Class Codes: Y10T 29/49071 by winding or coiling

Abstract

[Technical Problem]

This invention provides a surface-mount inductor that is capable of positioning a coil in a predetermined position in a mold, thereby to position the coil in a predetermined position of a core and to prevent led-out ends from being buried in the core.

[Solution to the Problem]

A surface-mount inductor of the present invention comprises: a coil formed by winding a winding wire; and a core containing a magnetic powder and including the coil therein. The coil has opposite led-out ends, each of which is exposed on respective ones of opposed side surfaces of the core. Each of the led-out ends of the coil is connected to an external electrode formed on the core.

Claims

1. A surface-mount inductor comprising:

a coil formed by winding a winding wire; and

a core containing a magnetic powder and including the coil therein;

wherein the coil is formed by winding the wire such that opposite ends of the wire are positioned on an outer periphery of the coil, each opposite end of the wire being led out from the outer periphery where the wire is wound to form a first lead-out end and a second lead-out end,

the first led-out end of the coil extending in the core between two opposed side surfaces of the core is exposed on the two opposed side surfaces of the core,

the second led-out end of the coil extending in the core between the two opposed side surfaces of the core is exposed on the two opposed side surfaces of the core,

the first led-out end of the coil exposed on the surface of the core is connected to a first external electrode formed on the core, and

the second led-out end of the coil exposed on the surface of the core is connected to a second external electrode formed on the core.

2. The surface-mount inductor as defined in claim 1, wherein each of the led-out ends of the coil has elasticity.

3. A surface-mount inductor comprising:

a coil formed by winding a winding wire; and

a core containing a magnetic powder and including the coil therein;

wherein the coil is formed by winding the wire such that opposite ends of the wire are positioned on an outer periphery of the coil, each opposite end of the wire being led out from the outer periphery where the wire is wound to form a first lead-out end and a second lead-out end,

the first led-out end having a surface exposed on one end surface of the core extends to an opposed side surface of the core adjacent the end surface of the core to be exposed on the opposed side surface of the core,

the second led-out end having a surface exposed on another end surface of the core extends to an opposed side surface of a core adjacent the end surface of the core to be exposed on the opposed side surface of the core,

the first led-out end of the coil exposed on the surface of the core is connected to a first external electrode formed on the core, and

the second led-out end of the coil exposed on the surface of the core is connected to a second external electrode formed on the core.

4. The surface-mount inductor as defined in claim 3, wherein each of the led-out ends of the coil has elasticity.

5. A method of producing a surface-mount inductor, comprising:

winding a winding wire to form a coil; and

providing the coil and a magnetic powder within a core;

wherein the coil is formed by winding the wire such that opposite ends of the wire are positioned on an outer periphery of the coil, each opposite end of the wire being led out from the outer periphery where the wire is wound to form a first lead-out end and a second lead-out end,

the first led-out is processed such that said first led-out end extends between a pair of two opposed inner walls of a mold and comes into contact with the two opposed inner walls of the mold,

the second led-out end is processed such that said second led-out end extends between a pair of two opposed inner walls of the mold and comes into contact with the two opposed inner walls of the mold,

the coil is disposed in the mold and is formed via said mold,

a first external electrode and a second external electrode are formed on the core,

the first led-out end of the coil extending in the core between two opposed side surfaces of the core and exposed on the two opposed side surfaces of the core is connected to the first external electrode formed on the core, and

the second led-out end of the coil extending in the core between the two opposed side surfaces of said core and exposed on the two opposed side surfaces of the core is connected to the second external electrode formed on the core.

6. A method of producing a surface-mount inductor which comprises:

winding a winding wire to form a coil; and

providing the coil and a magnetic powder within a core;

wherein the coil is formed by winding a wire such that opposite ends of the wire are positioned on an outer periphery of the coil, each opposite end of the wire is led out from the outer periphery where the wire is wound to form a first lead-out end and a second lead-out end,

the first led-out end is processed such that said first led-out end extends between a pair of two opposed inner walls of a mold and comes into contact with both of the two opposed inner walls and another wall of the two opposed inner walls adjacent both of the opposed inner walls,

the second led-out end is processed such that said second led-out end extends between a pair of two opposed inner walls of the mold and comes into contact with both of the two opposed inner walls and the other of the other pair of two opposed inner walls adjacent both of the two opposed inner walls,

the coil is disposed in the mold and is formed via the mold,

a first external electrode and a second external electrode are formed on the core,

the first led-out end having a surface exposed on one end surface of the core and extending to an opposed side surface of the core adjacent an end surface of the core to be exposed on the opposed side surface of the core is connected to the first external electrode formed on the core, and

the second led-out end having a surface exposed on the other end surface of the core and extending to an opposed side surface of the core adjacent the end surface of the core to be exposed on the opposed side surface of the core is connected to the second external electrode formed on the core.