Magnetic device and method of manufacturing the same

• US 9,805,860 B2
• Filed: 01/19/2017
• Issued: 10/31/2017
• Est. Priority Date: 03/21/2013
• 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:
  US15/409,549
• Publication Number:
  US 20170133149A1
• Time in Patent Office: 285 Days
• Field of Search: 336 65, 336 83, 336107, 336192, 336200, 336220-223, 336232
• 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. An inductor, comprising:

a magnetic body, wherein a first through opening is formed on a periphery of the magnetic body; and

a first lead comprising a first conductive part and a second conductive part electrically connected to the first conductive part, wherein the first conductive part is disposed on the bottom surface of the magnetic body and a bottom surface of the first conductive part is located under said first through opening, and at least a portion of the second conductive part is disposed in the first through opening, wherein a conductive path is formed from a first terminal of a coil of the inductor to the first conductive part via the second conductive part.

2. The inductor according to claim 1, wherein there is no other conductive part that is located outside of any outer side surface of the magnetic body adjacent to the first through opening and used for soldering with the first terminal of the coil.

3. The inductor according to claim 1, wherein the first conductive part and the second conductive part of the first lead are integrally formed by metallic material, wherein the bottom surface of the first conductive part is substantially flat.

4. The inductor according to claim 1, wherein the first through opening is formed by at least two outer side surfaces of the periphery of the magnetic body, wherein said two outer side surfaces are substantially perpendicular to each other.

5. The inductor according to claim 1, wherein a second through opening is formed on a periphery of the magnetic body, further comprising a second lead comprising a third conductive part and a fourth conductive part connected to the third conductive part, wherein the third conductive part is disposed on the bottom surface of the magnetic body a bottom surface of the second conductive part is located under said second through opening, and at least a portion of the fourth conductive part is disposed in the second through opening and electrically connected to a second terminal of the coil.

6. The inductor according to claim 5, wherein the second through opening is formed by at least two outer side surfaces of the magnetic body, wherein said two outer surfaces are substantially perpendicular to each other.

7. The inductor according to claim 1, wherein the top end of the second conductive part is disposed in the first through opening.

8. An inductor, comprising:

a magnetic core, comprising a first through opening;

a coil disposed on the magnetic body;

a first lead comprising a first conductive part and a second conductive part electrically connected to the first conductive part, wherein the first conductive part is disposed on the bottom surface of the magnetic body and a bottom surface of the first conductive part is located under said first through opening, and at least a portion of the second conductive part is disposed in the first through opening, wherein a conductive path is formed from a first terminal of a coil to the first conductive part via the second conductive part; and

a molding body, wherein the coil and the second conductive part are encapsulated by the molding body.

9. The inductor according to claim 8, wherein the first conductive part and the second conductive part are integrally formed by metallic material, wherein the bottom surface of the first conductive part is substantially flat.

10. The inductor according to claim 8, wherein the molding body encapsulates the magnetic core, the coil and the second conductive part.

11. The inductor according to claim 8, wherein the magnetic core further comprises a second through opening, further comprising a second lead comprising a third conductive part and a fourth conductive part connected to the third conductive part, wherein the third conductive part is disposed on the bottom surface of the magnetic body and a bottom surface of the third conductive part is located under said second through hole, and at least a portion of the fourth conductive part is disposed in the second through opening and electrically connected to a second terminal of the coil.

12. The inductor according to claim 8, wherein the first through opening is formed on a first corner of the periphery of the magnetic body.

13. The inductor according to claim 11, wherein the second through opening is formed on a second corner of the periphery of the magnetic body.

14. The inductor according to claim 8, wherein the top end of the second conductive part is disposed in the first through opening.

15. The inductor device according to claim 11, wherein the top end of the fourth conductive part is disposed in the first through opening.

16. An inductor, comprising:

a magnetic body, wherein a first through opening is formed on a periphery of the magnetic body; and

a first lead comprising a first conductive part and a second conductive part connected to the first conductive part, wherein the first conductive part is disposed on the bottom surface of the magnetic body and a bottom surface of the first conductive part is located under said first through opening, and at least a portion of the second conductive part is disposed in the first through opening, wherein a conductive path is formed from a first terminal of a coil of the inductor to the first conductive part via the second conductive part, wherein the first through opening is formed by at least two outer side surfaces of the periphery of the magnetic body, wherein said two outer side surfaces are substantially perpendicular to each other.

17. The inductor according to claim 16, wherein the first conductive part and the second conductive part are integrally formed by metallic material, wherein the bottom surface of the first conductive part is substantially flat.

18. The inductor according to claim 16, wherein a second through opening is formed on the periphery of the magnetic body, further comprising a second lead comprising a third conductive part and a fourth conductive part connected to the third conductive part, wherein the third conductive part is disposed on the bottom surface of the magnetic body and a bottom surface of the third conductive part is located under said second through opening, and at least a portion of the fourth conductive part is disposed in the second through hole and electrically connected to a second terminal of the coil.

19. The inductor according to claim 16, wherein the first through opening is formed on a first corner of the periphery of the magnetic body.

20. The inductor according to claim 18, wherein the second through opening is formed on a second corner of the periphery of the magnetic body.