Electronic component and method for manufacturing electronic component

• US 9,576,721 B2
• Filed: 03/13/2014
• Issued: 02/21/2017
• Est. Priority Date: 03/14/2013
• Status: Active Grant

• Current Assignee: Sumida Corporation
• Original Assignee: Sumida Corporation
• Inventors: Cheng, Zhigang, Sakamoto, Shinichi, Chan Mock, Fernando, Kawarai, Mitsugu
• Primary Examiner(s): Lian, Mangtin
• Application Number:
  US14/209,205
• Publication Number:
  US 20140266541A1
• Time in Patent Office: 1,076 Days
• Field of Search: 336/192, 336/83, 336/221, 336/212, 296/06
• US Class Current: 1/1
• CPC Class Codes: H01F 27/24 Magnetic cores
• 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 27/30 Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other support
• CPC Class Codes: H01F 41/0206 Manufacturing of magnetic cores by mechanical means magnetic cores per se H01F27/24
• CPC Class Codes: H01F 41/04 for manufacturing coils coils for transformer or inductances H01F27/28
• CPC Class Codes: H01F 41/061 Winding flat conductive wires or sheets
• CPC Class Codes: Y10T 29/49073 by assembling coil and core

Abstract

An electronic component includes a magnetic core member, a winding and a magnetic exterior body. The magnetic core member has a flat base and a core. The flat base has a top surface, a bottom surface, a first side surface and a second side surface opposite to the first side surface. The core is located on the top surface of the flat base. A winding has an edgewise coil and two non-wound flat wires that extend from the edgewise coil. A magnetic exterior body covers at least the core and the edgewise coil. The two non-wound flat wires continuously extend along the top surface, the first side surface, the bottom surface and the second side surface of the flat base in this order. The two non-wound flat wires located on the bottom surface work as electrodes.

Claims

1. An electronic component, comprising:

a magnetic core member that is made of a magnetic material and that has a flat base and a core, the flat base having a top surface, a bottom surface, a first side surface and a second side surface opposite to the first side surface, the core is located on the top surface of the flat base;

a winding that has an edgewise coil in which a flat wire is wound and in which the core is inserted, the winding having two non-wound flat wires that extend from the edgewise coil; and

a magnetic exterior body that covers at least the core and the edgewise coil, wherein

the two non-wound flat wires continuously extend along the top surface, the first side surface, the bottom surface and the second side surface of the flat base in this order, and

the two non-wound flat wires located on the bottom surface work as electrodes,

two ends located near the second side surface of the two non-wound wires project from the top surface, and the two ends are completely covered by a resin.

2. The electronic component according to claim 1, wherein

the two non-wound wires are connected to the bottom surface of the flat base with an adhesive.

3. The electronic component according to claim 1, wherein

the bottom surface of the flat base has two electrode grooves, and

the two non-wound wires are respectively located in the two electrode grooves.

4. The electronic component according to claim 1, wherein

the first and second side surfaces of the flat base each respectively has first and second guide grooves, and

the two non-wound wires are respectively located in the first and second guide grooves.

5. The electronic component according to claim 1, wherein

the two ends of the two non-wound wires are bent toward the first side surface of the flat base.

6. The electronic component according to claim 5, wherein

the two ends of the two non-wound wires contact the top surface of the flat base.

7. The electronic component according to claim 1, wherein

two side surfaces of the flat base respectively located between the first and second side surfaces slant downward.

8. The electronic component according to claim 1, wherein

a resin adhesive is provided on two side surfaces of the flat base respectively located between the first and second side surfaces.

9. The electronic component according to claim 1, wherein

the second side surface slants upward.

10. An electronic component, comprising:

a magnetic core member that is made of a magnetic material and that has a flat base and a core, the flat base having a top surface, a bottom surface, a first side surface and a second side surface opposite to the first side surface, the core is located on the top surface of the flat base;

a winding that has an edgewise coil in which a flat wire is wound and in which the core is inserted, the winding having first and second non-wound flat wires that respectively extend from the edgewise coil, the edgewise coil having a top and a bottom which contacts the top surface of the flat base, the first non-wound flat wire extending the top of the edgewise coil, the second non-wound flat wire extending the bottom of the edgewise coil;

first and second belt-shaped electrodes that are resectively formed along the first side surface, the bottom surface and the second side surface of the flat base; and

a magnetic exterior body that covers at least the core and the edgewise coil, wherein

the first non-wound flat wire is downwardly bent and extends toward the top surface of the flat base so that a first flat wire end of the first non-wound flat wire is located at a position between the top and bottom of the edgewise coil in a cross sectional view,

the second non-wound flat wire upwardly extends along a side of edgewise coil toward the top of the edgewise coil, and the second non-wound flat wire is bent at the top of the edgewise coil and downwardly extends toward the top surface of the flat base so that a second flat wire end of the second non-wound flat wire is located at a position between the top and bottom of the edgewise coil in the cross sectional view,

the first and second belt-shaped electrodes located on the bottom surface work as electrodes, the first and second belt-shaped electrodes respectively have first and second belt-shaped electrode ends, and the first and second belt-shaped electrode ends are respectively located at a position between the top and bottom of the edgewise coil in the cross sectional view, and

the first and second flat wire ends are electrically connected to the first and second belt-shaped electrode ends, respectively.

11. The electronic component according to claim 10, wherein

the two belt-shaped electrodes are integrally formed with the magnetic core.