Electronic component having air-core coil

• US 9,818,534 B2
• Filed: 06/09/2015
• Issued: 11/14/2017
• Est. Priority Date: 03/14/2013
• Status: Active Grant

• Current Assignee: Sumida Corporation
• Original Assignee: Sumida Corporation
• Inventors: Sakamoto, Shinichi, Malcolm, Douglas James
• Primary Examiner(s): Nguyen, Tuyen
• Application Number:
  US14/734,004
• Publication Number:
  US 20150270064A1
• Time in Patent Office: 889 Days
• Field of Search: 336 65, 336 83, 336192, 336220-223
• CPC Class Codes: H01F 17/04 with magnetic core
• 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 27/24 Magnetic cores
• 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 41/02 for manufacturing cores, coils, or magnets H01F41/14 takes precedence; for dynamo-electric machines H02K15/00
• CPC Class Codes: H01F 41/0246 Manufacturing of magnetic circuits by moulding or by pressing powder magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36
• CPC Class Codes: H01F 41/064 Winding non-flat conductive wires, e.g. rods, cables or cords
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor
• CPC Class Codes: Y10T 29/49071 by winding or coiling

Abstract

A method for manufacturing an electronic component for avoiding electromagnetic interference includes: (a) placing a T-shaped core and an air-core coil in a metal mold; (b) injecting a mixture of a composite magnetic material and a resin into the metal mold so that the T-shaped core and the air-core coil are embedded by the mixture; (c) heating the mixture at a first temperature; (d) adjusting an outer shape while removing excessive mixture; and (e) hardening the mixture. The method may further include a process of polishing an outside of the hardened mixture. The method may further include a process of applying a pressure of 0.1 to 20.0 kg/cm² to the mixture for adjusting an outer shape of the mixture by a movable punch of a press machine before the hardening process.

Claims

1. An electronic component comprising:

a T-shaped core having a post and a base;

an air-core coil that is assembled around the post of T-shaped core, the air-core coil having;

a coil member that is formed by winding a flat rectangular wire, the coil member having first and second sides opposite to each other, the coil member having a coil axis; and

first and second leads that are formed by the flat rectangular wire and that are integrally connected to the coil member, the first and second leads respectively having;

first and second bent members at the first side;

first and second ends at the second side; and

first and second bottom extensions respectively connected between the first and second bent members and the first and second ends; and

a mixture of a composite magnetic material and a resin, the mixture embedding at least part of the air-core coil, the mixture only embedding the post and a top surface of the base of the T-shaped core so that side and bottom surfaces of the base of the T-shaped core are exposed, wherein

the first and second bent members extend in a first direction parallel to the coil axis,

the first and second ends extend in a second direction parallel to the coil axis,

the first and second bottom extensions extend perpendicular to the coil axis, and the first and second bottom extensions are directly adjacent to the bottom surface of the base of the T-shaped core, and

an outer periphery of the base of the T-shaped core and an outer periphery of the mixture are coextensive in a plan view.

2. The electronic component according to claim 1, wherein

the flat rectangular wire has a rectangular cross-section including long and short sides, and

the long side is perpendicular to the coil axis, and the short side is parallel to the coil axis.

3. The electronic component according to claim 1, wherein

solder is applied at the first and second ends.

4. The electronic component according to claim 1, wherein

the first lead extends from a top of the coil member, and

the second lead extends from a bottom of the coil member.

5. The electronic component according to claim 1, wherein

the side surface of the T-shaped core having first and second side surfaces opposite to each other,

the first and second bent members extend along the first side surface of the T-shaped core, and

the first and second ends extend along the second side surface of the T-shaped core.