INDUCTOR WITH PREFORMED END AND METHOD AND ASSEMBLY FOR MAKING THE SAME

Abstract

An inductor and a method and assembly for making the same are provided. The inductor includes a preformed conducting coil comprising a medial portion between the first and second terminal conductors, and an inductor body comprising a magnetic material surrounding at least the medial portion of the preformed conducting coil. At least a portion of each of the first and second terminal conductors of the preformed conducting coil is exposed outside the inductor body.The method for making the inductor includes providing a one-piece conducting coil having a substantially curved medial portion and first and second terminal conductors, and molding a magnetic material around at least the medial portion of the formed conducting coil to form an inductor body, wherein at least a portion of the first and second terminal conductors of the formed one-piece conducting coil is exposed outside the inductor body.

Claims

CLAIMS 1. An inductor, characterized in that it comprises: a preformed conducting coil comprising a medial portion between the first and second terminal conductors; and an inductor body comprising a magnetic material molded around the preformed conducting coil; wherein at least a portion of each of the first and second terminal conductors of the preformed conducting coil is exposed outside the inductor body.

2. The inductor according to claim 1, characterized in that the magnetic material is molded around the middle portion and portions of the first and second terminal conductors of the conducting coil.

3. The inductor according to claim 1, characterized in that the medial portion comprises a circular shape, a semi-circular shape or an oblong shape.

4. The inductor according to claim 1, characterized in that the conducting coil is of omeqa shape.

5. The inductor according to claim 1, characterized in that the inductor body is package-shaped and has a bottom side, a top side, a right side, a left side, a front side, and a rear side. > your NCNN 6. The inductor according to claim 5, characterized in that the portion of each of the first and second terminal conductors exposed outside the inductor body is positioned along the bottom side of the inductor body.

7. The inductor according to claim 5, characterized in that each of the first and second terminal conductors further comprises: a bottom portion having an exposed portion positioned along the bottom side of the inductor body; and a side portion terminating along a respective right and left side of the inductor body.

8. The inductor according to claim 7, characterized in that each of the right and left sides of the inductor body comprises a cut-out portion where the side portion of one respective of the first and second terminal conductors is positioned and a maximum width of the conducting coil between the respective side portion of the first and second terminal conductors is substantially the same as the maximum width of the inductor body.

9. The inductor in accordance with the > your NCNNCC « 38 « 7, characterized in that the lateral portion of each of the first and second terminal conductors are preformed to be substantially perpendicular to the bottom portion.

10. The inductor according to claim 0, characterized in that each of the first and second conductors is substantially L-shaped or U-shaped, wherein a first portion of the L or U is positioned along the bottom side of the inductor body and a second portion of the L or U is positioned along a respective right and left side of the inductor body.

11. The inductor according to claim 1, characterized in that each of the first and second terminal conductors of the conducting coil has a cross-sectional area that is flatter and wider than the cross-sectional area of ​​the middle portion of the conducting coil.

12. The inductor according to claim 1, characterized in that the magnetic material is a powdered magnetic material.

13. The inductor according to claim 1, characterized in that the magnetic material is powdered iron particles.

14. A method for making an inductor, characterized in that it comprises: providing a formed conducting coil having a medial portion and first and second terminal conductors; and molding a magnetic material around at least the medial portion of the formed conducting coil to form an inductor body, wherein at least a portion of the first and second terminal conductors of the formed conducting coil are exposed outside the inductor body.

15. The method according to claim 14, characterized in that the formed inductor body is substantially in the form of a package having a bottom side, a top side, a right side, a left side, a front side and a rear side, and the first and second terminal conductors are exposed along the bottom side and one respective right side and left side of the inductor body.

16. The method according to claim 15, characterized in that the molding of the magnetic material further comprises: positioning the formed conducting coil in a mold assembly; introducing the magnetic material into the mold assembly; and pressing the magnetic material around the conducting coil.

17. The method conforming to 16, characterized in that the positioning of the formed conductive coil in the mold assembly further comprises: seating the first and second terminal conductors of the formed conductive coil in the first and second shelves formed within a wall of a seating channel of the mold assembly, wherein the first and second shelves have a shape that is complementary to the first and second terminal conductors such that the first and second terminal conductors function as a part of the wall of the mold assembly during molding.

18. The method according to claim 17, characterized in that the first and second terminal conductors are L-shaped or U-shaped.

19. The method according to claim 18, characterized in that the first and second shelves further each comprise a reduced wall forming a complementary cutout on each of the right and left sides of the inductor body and a portion of each of the first and second terminal conductors are positioned in a respective cutout.

20. An assembly for forming an inductor having a preformed conducting coil comprising a medial portion between the first and second terminal conductors, the assembly characterized in that it comprises: > your NCNNCC « 41 « a mold section having a seating channel defined therethrough and a wall surrounding the seating channel, the wall comprising first and second shelves configured to receive the first and second terminal conductors of the preformed conducting coil;and at least one punch configured to press the magnetic particles around the conducting coil when the conducting coil is positioned within the mold section, wherein the first and second shelves have a shape that is complementary to the first and second terminal conductors of the conducting coil such that the first and second terminal conductors are capable of contacting the wall of the mold section when the magnetic particles are pressed around the conducting coil.

21. The inductor according to claim 1, characterized in that the magnetic material surrounds the entirety of at least the middle portion of the conducting coil without any gaps.

22. The inductor according to claim 1, characterized in that the preformed conducting coil is formed as a planar member without any of the coil turns stacked.

23. The inductor according to claim 4, characterized in that each of the first and second terminal conductors of the preformed conducting coil is exposed outside the inductor body along a common plane.

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