Magnetic device and method of manufacturing the same

Abstract

The present invention discloses a magnetic device, including a body and a coil disposed within the body, wherein a first end of a wire forming the coil includes a first portion and a second portion, wherein the first portion is exposed outside the body to form an electrode, and wherein the second portion is deformed to increase the distance between the first end of the wire and the coil to prevent short circuit.

Description

Technical Field

[0001] This invention relates to a magnetic device, and more particularly to an inductor. Background Technology

[0002] Existing magnetic devices, such as inductors made using T-shaped magnetic cores, include a bottom base and a support on the bottom base, wherein a coil made of wire is wound around the support of the T-shaped magnetic core, wherein the T-shaped magnetic core is pressed to form the inductor body, and the bottom base is lower than the support of the T-shaped magnetic core.

[0003] However, when the T-shaped core is pressed, it may cause a short circuit between the end of the wire and the winding of the coil.

[0004] Therefore, the industry needs a better solution to address these issues. Summary of the Invention

[0005] One object of the present invention is to increase the distance between the end of the wire and the coil within the body of the magnetic device to prevent short circuits between the coil and the end of the wire.

[0006] One object of the present invention is to increase the welding strength of the electrodes of the magnetic device.

[0007] An embodiment of the present invention discloses a magnetic device, comprising: a body; and a coil formed of a wire and disposed within the body, wherein a first end of the wire includes a first portion and a second portion, wherein the first portion of the first end is exposed from the body to form a first electrode, wherein the second portion of the first end extends from a top of the coil to an end point of the first portion of the first end, wherein the second portion of the first end includes an outer surface having a curve convex outward relative to a vertical line passing through the end point.

[0008] In one embodiment, the maximum distance between the curve and the vertical line is greater than or equal to half the thickness of the conductor.

[0009] In one embodiment, the magnetic device is an inductor, wherein the body includes a magnetic body, and the coil is disposed in the magnetic body.

[0010] In one embodiment, the magnetic body includes a T-shaped magnetic core, the T-shaped magnetic core including a base and a support on the base, wherein a through hole is formed at a corner of the base, and wherein at least a portion of the first end is disposed within the through hole.

[0011] In one embodiment, a first electrode of the magnetic device includes at least one first metal layer disposed on a lower surface of the body and electrically connected to the first end of the wire, and at least one second metal layer disposed on a side surface of the body and electrically connected to the at least one first metal layer, wherein the coil has a plurality of windings, and the height of the first electrode disposed on the side surface of the body is greater than zero and not greater than a height from an upper surface of the plurality of windings to a lower surface of the plurality of windings.

[0012] In one embodiment, the first electrode disposed on the side surface of the body does not cross the lower surface of the coil.

[0013] In one embodiment, the base includes a surface that forms an angle of 20 to 60 degrees with a horizontal plane, wherein the first portion of the first end of the conductor is placed on the surface.

[0014] In one embodiment, the magnetic body includes a T-shaped magnetic core, wherein the T-shaped magnetic core includes a base and a support located on the base, wherein the base and the support are made of different magnetic materials.

[0015] In one embodiment, a second end of the conductor includes a first portion and a second portion, wherein the first portion of the second end is exposed from the body to form a second electrode of the magnetic device, wherein the second portion of the second end extends from a top of the coil to an end point of the first portion of the second end, wherein the second portion of the second end includes an outer surface having a curve that convexes outward relative to a vertical line passing through the end point.

[0016] In one embodiment, the conductor is a flat wire.

[0017] An embodiment of the present invention discloses a magnetic device comprising: a T-shaped magnetic core including a base and a support on the base; and a coil formed by a wire, wherein at least a portion of the support is disposed in a hollow space of the coil, wherein a first end of the wire includes a first portion and a second portion, wherein the first portion of the first end is exposed from the body to form a first electrode, and the second portion of the first end extends from a top of the coil to an end point of the first portion of the first end, wherein the base includes a surface forming an angle of 20 degrees to 60 degrees with a horizontal plane, wherein the first portion of the first end of the wire is placed on the surface.

[0018] In one embodiment, the magnetic body includes a T-shaped magnetic core, wherein the T-shaped magnetic core includes a base and a support located on the base, wherein the base and the support are made of different magnetic materials.

[0019] An embodiment of the present invention discloses a method for forming a magnetic device, the method comprising: forming a U-shaped magnetic core; disposing a coil in the U-shaped magnetic core, wherein the coil is formed by a conductor, wherein a first end of the conductor includes a first portion and a second portion, wherein the first portion and the second portion of the first end of the conductor form an angle between 110 degrees and 150 degrees; disposing a T-shaped magnetic core on the coil, wherein the T-shaped magnetic core includes a base and a support on the base, wherein a through hole is formed at a corner of the base, wherein at least a portion of the first end is disposed in the through hole; and applying pressure to the T-shaped magnetic core and the first portion of the first end of the conductor to form the magnetic device.

[0020] In one embodiment, the magnetic device is an inductor, the body includes a magnetic body, and the coil is disposed in the magnetic body.

[0021] In one embodiment, the base includes a surface that forms an angle of 20 to 60 degrees with a horizontal plane, wherein the first portion of the first end of the conductor is placed on the surface.

[0022] In one embodiment, the base and the support are made of different magnetic materials.

[0023] In one embodiment, the T-shaped magnetic core is in an uncured state when pressure is applied to a portion of the first end of the T-shaped magnetic core and the first portion of the wire.

[0024] An embodiment of the present invention discloses a magnetic device, comprising: a body; and a coil disposed in the body, wherein the coil is formed by a wire and has a plurality of windings, and at least a portion of a first end of the wire is exposed from the body, wherein a first electrode of the magnetic device comprises at least a first metal layer disposed on a lower surface of the body and electrically connected to the first end of the wire; and at least a second metal layer disposed on a side surface of the body and electrically connected to the at least first metal layer, wherein the height of the first electrode disposed on the side surface of the body is greater than zero and not greater than the height from an upper surface of the plurality of windings to a lower surface of the plurality of windings.

[0025] In one embodiment, the first electrode disposed on the side surface of the body does not cross the lower surface of the coil.

[0026] In one embodiment, the first electrode disposed on the side surface of the body does not cross the lower surface of the coil.

[0027] In one embodiment, the coil is a pre-wound coil.

[0028] To make the above and other features and advantages of the present invention more apparent and understandable, specific embodiments are described below in conjunction with the accompanying drawings. Attached Figure Description

[0029] The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

[0030] Figure 1A A side view of a magnetic device according to an embodiment of the present invention is shown.

[0031] Figure 1B A side view of a magnetic device according to an embodiment of the present invention is shown.

[0032] Figure 1C A bottom view of a magnetic device according to an embodiment of the present invention is shown.

[0033] Figure 1D A schematic diagram illustrating a method for forming a magnetic device according to an embodiment of the present invention is shown.

[0034] Figure 2A This invention illustrates an embodiment of a U-shaped magnetic core for forming a magnetic device;

[0035] Figure 2B This invention illustrates a T-shaped magnetic core for forming a magnetic device according to an embodiment of the invention;

[0036] Figure 2C Another T-shaped magnetic core for forming a magnetic device, according to an embodiment of the present invention;

[0037] Figure 2D A coil for forming a magnetic device is shown as an embodiment of the present invention.

[0038] Figure 2E A coil, illustrating one embodiment of the present invention, is placed in a U-shaped magnetic core to form a magnetic device;

[0039] Figure 2F A schematic diagram showing a magnetic device according to an embodiment of the present invention is provided with a T-shaped magnetic core on a coil and the support of the T-shaped magnetic core is located in the hollow space of the coil.

[0040] Figure 2GThis diagram illustrates a magnetic device formed by pressing a T-shaped magnetic core according to an embodiment of the present invention.

[0041] Figure 2H An insulating layer is coated on the body of the magnetic device illustrating an embodiment of the present invention.

[0042] Figure 2I This diagram illustrates an embodiment of the present invention, showing the use of a laser to strip enameled copper wire to form an electrode on the bottom surface of the body.

[0043] Figure 2J A schematic diagram showing an embodiment of the present invention is provided, illustrating the formation of an electrode on one side surface of the body.

[0044] Figure 2K This diagram illustrates an embodiment of the present invention where copper / nickel / tin is electroplated onto the substrate to form an electrode.

[0045] Figures 3A-3C Various types of coils used to form a magnetic device in one embodiment of the present invention are shown respectively.

[0046] Figure 3D-3E Each embodiment of the present invention is shown as having two coils for forming a magnetic device;

[0047] Figure 4A A top view of a magnetic device according to an embodiment of the present invention is shown.

[0048] Figure 4B An enlarged cross-sectional view of a magnetic device according to an embodiment of the present invention is shown.

[0049] Figure 4C The rate of increase of ACR at different frequencies was compared based on the electrode height set on one side surface of the body.

[0050] Explanation of reference numerals: 100 - Magnetic device; 101 - Coil; 101a - Upper surface; 101b - Lower surface; 101TP - Top; 102U - First portion of the first end; 102LC - Second portion of the first end; 102LS - Curve; 102b - Start point of the first portion of the first end; 102c - End point of the first portion of the first end; 130 - Body; 130a - Upper surface; 130b - Lower surface; 130U - U-shaped magnetic core; 130c - Through hole; 130d - Through hole; 130T - T-shaped magnetic core; 130e - Base surface; VL1 - Vertical line; VL2 - Vertical line; H - Height; t - Height; 103b - Start point of the first portion of the first end; 103c - End point of the first portion of the first end ; 103U - First part of the second end; 103LC - Second part of the second end; 101BP - Bottom; 103LS - Curve; 120a - First metal layer; 120c - First metal layer; 120b - Second metal layer; 131 - Side surface; 150 - Mold; 160 - Insulation layer; L1 - Length; LT - Total length; θ - Angle; HP1 - Horizontal plane; 170 - Electroplated metal layer; 104U - First part; 104L - Second part; 105U - First part; 105L - Second part; 200 - Magnetic device; 111 - Coil; 111W1 - Winding; 111W2 - Winding; 111a - Upper surface; 111b - Lower surface; 112 - First end; 113 - Second end; B - Distance; C - Distance. Detailed Implementation

[0051] Figure 1AA cross-sectional view of a magnetic device 100 according to an embodiment of the present invention is shown. The magnetic device 100 includes a body 130 having an upper surface 130a and a lower surface 130b; and a coil 101 formed of a wire and disposed in the body 130. The coil 101 includes a plurality of windings and has an upper surface 101a and a lower surface 101b. A first end of the wire includes a first portion 102U and a second portion 102LC. The first portion 102U has a starting point 102b and an ending point 102c. At least a portion of the first portion 102U... Exposed from the body 130 to form a first electrode, wherein the second portion 102LC of the first end extends from a top 101TP of the coil 101 to an end point 102c of the first portion 102LC of the first end, wherein the second portion 102LC of the first end includes an outer surface having a curve 102LS convex outward relative to a vertical line VL1 passing through the end point 102c, wherein the coil 101 has a plurality of windings, and an upper surface 101a of the plurality of windings of the coil 101 to a lower surface 101b of the plurality of windings of the coil 101 has a height H.

[0052] In one embodiment, such as Figure 1B As shown, a second end of the conductor includes a first portion 103U having a starting point 103b and an ending point 103c and a second portion 103LC, wherein at least a portion of the first portion 103U of the second end is exposed from the body 130 to form a second electrode, and the second portion 103LC of the second end extends from the bottom 101BP of the coil 101 to the ending point 103c of the first portion 103U of the second end of the conductor, wherein the second portion 103LC of the second end includes an outer surface having a curve 103LS that convexes outward relative to a vertical line VL2 passing through the ending point 103c of the first portion 103U of the second end.

[0053] In one embodiment, the body 130 includes a magnetic body in which the coil 101 is disposed.

[0054] In one embodiment, the magnetic device 100 is an inductor.

[0055] In one embodiment, at least one first metal layer 120a is disposed on the lower surface of the body 130 and electrically connected to the first portion 102U of the first end of the wire.

[0056] In one embodiment, such as Figure 1A As shown, the maximum distance T1 between the curve 102LS and the vertical line VL1 is greater than or equal to half of the conductor thickness T.

[0057] In one embodiment, such as Figure 1C As shown, a laser is used to strip the first portion 102U of the first end of a conductor, such as an enameled copper wire. At least one first metal layer 120a may be disposed on the lower surface 130b of the body 130 and electrically connected to the first portion 102U of the first end to form a first electrode on the body 130. Similarly, a laser can be used to strip the first portion 103U of the second end of a conductor, such as an enameled copper wire. At least one first metal layer 120c may be disposed on the lower surface 130b of the body 130 and electrically connected to the first portion 103U of the second end to form a second electrode on the body 130. At least one second metal layer 120b may be disposed on one side surface 131 of the body 130 and electrically connected to at least one first metal layer 120a.

[0058] In one embodiment, such as Figure 1A As shown, coil 101 has multiple windings, each winding having an upper surface 101a and a lower surface 101b. An electrode of magnetic device 100 includes at least one first metal layer 120a disposed on the lower surface 130b of body 130 and electrically connected to a first end 112U of a wire, and at least one second metal layer 120b. The second metal layer 120b is disposed on a side surface 131 of body 130 and electrically connected to the at least one first metal layer 120a. A portion of the electrode disposed on the side surface 131 of body 130 has a first height t, such as... Figure 1C As shown, the first height t is greater than zero and not greater than the second height H from the upper surface 101a to the lower surface 101b of the plurality of windings, as... Figure 1A As shown.

[0059] In one embodiment, such as Figure 1C As shown, at least one first metal layer 102a is formed on the lower surface 130b of the body 130. The at least one first metal layer 102a is electrically connected to the first portion 102U of the wire to form the first electrode of the magnetic device 100. The length L1 of the first portion 102U at the first end of the wire is 47.5 to 52.5% of the total length LT of the lower surface 130b of the body 130, and the length L1 is the length from the starting point 102b to the ending point 102c.

[0060] In one embodiment, at least one first metal layer 120a and at least one second metal layer 120b are made of the same material.

[0061] In one embodiment, at least one first metal layer 120a and at least one second metal layer 120b may be made of different materials.

[0062] In one embodiment, the conductor forming the plurality of windings is an insulated conductor.

[0063] In one embodiment, the conductor is a flat wire.

[0064] In one embodiment, the conductor is a circular wire.

[0065] In one embodiment, the magnetic body includes a T-shaped magnetic core, the T-shaped magnetic core including a base and a support, wherein the base and the support are made of different magnetic materials.

[0066] In one embodiment, such as Figure 1D As shown, this invention discloses a method for manufacturing a magnetic device, the method comprising: step S201: forming a U-shaped magnetic core; step S202: setting a coil in the U-shaped magnetic core; step S203: setting a T-shaped magnetic core on the coil, wherein the T-shaped magnetic core includes a base and a support post disposed on the base, the support post being disposed within a hollow space of the coil, wherein the base is located above the support post; step S204: applying pressure to a first portion of the T-shaped magnetic core and the end of the conductor to form the magnetic device.

[0067] In one embodiment, such as Figure 2A As shown, the U-shaped magnetic core 130U is formed by filling a mold 150 with mixed magnetic powder, and the mixed magnetic powder can be pressed to form the U-shaped magnetic core 130U.

[0068] In one embodiment, such as Figure 2B As shown, the T-shaped magnetic core 130T includes a base 130s and a support 130p on the base. A first through hole 130c is formed at one corner of the base, in which a first portion 102U of the first end of a wire can be disposed. Similarly, a through hole 130d is formed at the other corner of the base, in which a first portion 103U of the second end of a wire can be disposed.

[0069] In one embodiment, such as Figure 2C As shown, the base of the T-shaped magnetic core 130T includes a surface 130e, wherein the surface 130e forms an angle θ of 20 to 60 degrees with a horizontal plane 160, and the first portion 102U of the end of the conductor is placed on the surface 130e.

[0070] In one embodiment, when the T-shaped magnetic core 130T and the first portion 102U of the first end portion of the wire are hot-pressed to form the body 130 of the magnetic device 100, the T-shaped magnetic core 130T is in an uncured state.

[0071] In one embodiment, such as Figure 2DAs shown, coil 101 is composed of wires, wherein the first end of the wires includes a first portion 102U and a second portion 102L, wherein the first portion 102U and a horizontal plane HP1 form an angle θ between 20 degrees and 60 degrees, or the first portion 102U and the second portion 102L form an angle between 110 degrees and 150 degrees. Similarly, the second end of the wires includes a first portion 103U and a second portion 103L, wherein the first portion 103U and the second portion 103L of the second end of the wires form an angle between 110 degrees and 150 degrees.

[0072] In one embodiment, such as Figure 2E As shown, coil 101 is placed in U-shaped magnetic core 130U.

[0073] In one embodiment, such as Figure 2F As shown, the T-shaped magnetic core 130T is mounted on the coil 101.

[0074] The support of the T-shaped magnetic core 130T is placed in a hollow space of the coil to form a magnetic device according to an embodiment of the present invention, wherein a first portion 102U of the first end of the conductor is disposed in a through hole 130c in the T-shaped magnetic core 130T. Similarly, a first portion 103U of the first second end of the conductor is disposed in a through hole 130d in the T-shaped magnetic core 130T.

[0075] In one embodiment, such as Figure 2G As shown, a hot-pressed T-shaped magnetic core 130T and a first portion 102U of the first end of a wire are used to form a magnetic device.

[0076] Unlike traditional inductor manufacturing methods, this invention places the coil and the uncured T-shaped magnetic core upside down, with the base located above the support. When the first part of the conductor end and the T-shaped magnetic core are pressed together to form the body of the magnetic device, the second part of the conductor end can be pushed away from the coil, thereby increasing the distance between the conductor end and the coil winding to prevent short circuits between the coil winding and the end.

[0077] In one embodiment, such as Figure 2H As shown, the body 130 of the magnetic device is coated with an insulating layer 160. In one embodiment, the insulating layer 160 may be an insulating adhesive layer.

[0078] In one embodiment, such as Figure 2IAs shown, a laser can be used to strip the insulation layer of a first portion 102U of the first end of a conductor, such as an enameled copper wire, wherein at least one first metal layer 120a can be disposed on the lower surface 130b of the body 130 and electrically connected to the first portion 102U of the first end of the conductor, for forming a first electrode on the body 130. Similarly, a laser can be used to strip the insulation layer of a first portion 103U of the second end of a conductor, such as an enameled copper wire, wherein at least one metal layer 120c can be disposed on the lower surface 130b of the body 130 and electrically connected to the first portion 103U of the second end, for forming a second electrode on the body 130.

[0079] In one embodiment, such as Figure 2J As shown, at least one second metal layer 120b is formed on the side surface 131 of the body 130, and at least one second metal layer 120b is electrically connected to the first portion 102U of the first end of the wire.

[0080] In one embodiment, such as Figure 2K As shown, an electroplated metal layer 170, such as a Cu / Ni / Sn layer, can be electroplated on the electrode.

[0081] In one embodiment, the method further includes forming at least one first metal layer on a lower surface and a side surface of the body 130, wherein the at least one first metal layer is electrically connected to a first portion of the wire to form an electrode of the magnetic device, wherein the height t of the first metal layer disposed on the side surface of the body 130 is 31.3% to 35.3% of the total height of the side surface of the body, such as... Figure 1C As shown.

[0082] In one embodiment, the method further includes forming at least one first metal layer on the lower surface of the body, wherein the at least one first metal layer is electrically connected to a first portion of a wire to form an electrode of a magnetic device, wherein the length L1 of the first portion exposed from the body is 1 / 6 to 1 / 2 of the total length LT of the lower surface of the body 130, such as... Figure 1C As shown.

[0083] In one embodiment, the method further includes forming at least one first metal layer on the lower surface of the body, wherein the at least one first metal layer is electrically connected to a first portion of a wire to form an electrode of a magnetic device, wherein the length L1 of the first portion exposed from the body is 47.5 to 52.5% of the total length LT of the lower surface of the body 130, such as... Figure 1C As shown.

[0084] In one embodiment, the magnetic body includes a T-shaped magnetic core, the T-shaped magnetic core including a base and a pillar, wherein the base and the pillar are made of different magnetic materials.

[0085] In one embodiment, a method for forming a magnetic device is disclosed, the method comprising: forming a U-shaped magnetic core; arranging a coil in the U-shaped magnetic core, wherein the coil is composed of a conductor, wherein an end of the conductor includes a first portion and a second portion, wherein the first portion and the second portion of the end form an angle between 110 degrees and 150 degrees; arranging a T-shaped magnetic core on the coil, wherein the T-shaped magnetic core includes a base and a support post located on the base, a through hole is formed at a corner of the base, wherein the first portion of the end of the conductor is disposed within the through hole; and applying pressure to the T-shaped magnetic core and the first portion of the end of the conductor to form the magnetic device.

[0086] In one embodiment, such as Figures 3A-3C As shown, each of them illustrates a coil that can be used to form a magnetic device, wherein the first end of the conductor includes a first portion 102U and a second portion 102L, and the second end of the conductor includes a first portion 103U and a second portion 103L.

[0087] In one embodiment, such as Figure 3D-3E As shown, each of the two coils of a type for forming a magnetic device according to an embodiment of the present invention is illustrated, wherein a first end of a first conductor includes a first portion 102U and a second portion 102L, a second end of a first conductor includes a first portion 103U and a second portion 103L, a third end of a second conductor includes a first portion 104U and a second portion 104L, and a fourth end of a second conductor includes a first portion 105U and a second portion 105L.

[0088] Figure 4A A top view of a magnetic device according to an embodiment of the present invention is depicted. Figure 4B An enlarged cross-sectional view of a magnetic device according to an embodiment of the present invention is depicted.

[0089] Please refer to Figure 4A and Figure 4BThe magnetic device 200 includes a body 130 having an upper surface 130a and a lower surface 130b; and a coil 111 formed of wire and having a plurality of windings 111W1, 111W2, wherein the plurality of windings 111W1, 111W2 are disposed within the body 130 and have an upper surface 111a and a lower surface 111b, wherein at least a portion of the first end 112 of the wire is exposed from the body 130, and wherein the first electrode of the magnetic device 200 includes a electrode disposed on the lower surface 110a of the body 130. At least one first metal layer 120a and at least one second metal layer 120b are electrically connected to the first end 112 of the conductor on the body 130. The at least one second metal layer 120b is disposed on one side surface 131 of the body 130 and electrically connected to the at least one first metal layer 120a. The height t of the first electrode disposed on the side surface 131 of the body 130 is greater than zero and not greater than the height H of the upper surface 111a to the lower surface 111b of the plurality of windings 111W1, 111W.

[0090] In one embodiment, the conductor forming the multiple windings is enameled wire.

[0091] In one embodiment, the conductor forming the multiple windings is enameled copper wire.

[0092] In one embodiment, the conductor is a flat wire.

[0093] In one embodiment, the conductor is a circular wire.

[0094] In one embodiment, the second electrode of the magnetic device 200 includes at least one third metal layer disposed on the lower surface 130b of the body 130 and electrically connected to the second end 113 of the wire, wherein at least one fourth metal layer is disposed on one side surface of the body 130 and electrically connected to the at least one third metal layer, wherein the height of the second electrode disposed on the side surface of the body 130 is greater than zero and not greater than the height H of the plurality of windings 111W1, 111W from the upper surface 111a to the lower surface 111b of the plurality of windings 111W1, 111W.

[0095] In one embodiment, the present invention can increase the SMD welding strength of the electrodes of a magnetic device.

[0096] Figure 4C The performance of the ACR rise rate at different frequencies was compared based on the first height t of the electrode disposed on the side surface 131 of the body 130, wherein the ACR rise rate increases as the first height t increases. Figure 4CAs shown, the ACR rise rate is low when the first height t is zero, and high when the first height t is equal to B plus the height H of the coil, where B represents the distance between the electrode on the side surface 131 of the body 130 and the lower surface 111b of the coil.

[0097] When the first height t of the electrode set on the side surface 131 of the body 130 is greater than zero and not greater than the second height H of the coil, the SMD (Surface-mounted Device) welding strength of the magnetic device electrode can be improved while keeping the ACR rise of the magnetic device within a good range.

[0098] In one embodiment, such as Figure 4B As shown, the electrodes provided on the side surface 131 of the body 130 do not cross the lower surface 111b of the coil.

[0099] Although the present invention has been described with reference to the above embodiments, it will be apparent to those skilled in the art that modifications can be made to the described embodiments without departing from the spirit of the invention. Therefore, the scope of the invention will be defined by the claims, not by the detailed description above.

Claims

1. A magnetic device, characterized by, include: one body; as well as A coil comprising a plurality of windings stacked in a vertical direction and disposed within a body formed of a flat wire, wherein the plurality of windings stacked in the vertical direction form a hollow space, and a first end of the flat wire includes a first portion and a second portion, wherein the first portion of the first end is exposed from the body to form a first electrode, wherein the second portion of the first end extends from a top of the coil to an end point of the first portion of the first end, wherein the second portion of the first end includes an outer surface, wherein a vertical line passing through the end point passes through the second portion of the first end and intersects the outer surface at a first intersection point, the outer surface having a curve convex outward relative to the vertical line passing through the end point, and the curve being a smooth curve extending from the end point to the first intersection point, wherein the first intersection point is located below the upper surface of the coil, and the segment of the vertical line extending from the end point to the first intersection point does not have any portion located outside the boundary of the first end of the flat wire.

2. The magnetic device of claim 1, wherein, The maximum horizontal distance between the curve and the vertical line is less than the thickness of the flat line.

3. The magnetic device as described in claim 1, characterized in that, The magnetic device is an inductor, wherein the body includes a magnetic body, and the coil is disposed in the magnetic body.

4. The magnetic device as described in claim 3, characterized in that, The magnetic body includes a T-shaped magnetic core, the T-shaped magnetic core includes a base and a support on the base, wherein a through hole is formed at a corner of the base, and wherein at least a portion of the first end is disposed in the through hole.

5. The magnetic device as claimed in claim 1, characterized in that, A first electrode of the magnetic device includes at least one first metal layer disposed on a lower surface of the body and electrically connected to the first end of the flat wire, and at least one second metal layer disposed on a side surface of the body and electrically connected to the at least one first metal layer, wherein the coil has a plurality of windings, and the height of the first electrode disposed on the side surface of the body is greater than zero and not greater than a height from an upper surface of the plurality of windings to a lower surface of the plurality of windings.

6. The magnetic device as described in claim 5, characterized in that, The first electrode, disposed on the side surface of the body, does not cross the lower surface of the coil.

7. The magnetic device as described in claim 4, characterized in that, The base includes a surface that forms an angle of 20 to 60 degrees with a horizontal plane, wherein the first portion of the first end of the flat line is placed on the surface.

8. The magnetic device as described in claim 3, characterized in that, The magnetic body includes a T-shaped magnetic core, wherein the T-shaped magnetic core includes a base and a support located on the base, wherein the base and the support are made of different magnetic materials.

9. The magnetic device as claimed in claim 1, characterized in that, A second end of the flat wire includes a first portion and a second portion, wherein the first portion of the second end is exposed from the body to form a second electrode of the magnetic device, wherein the second portion of the second end extends from a top of the coil to an end point of the first portion of the second end, wherein the second portion of the second end includes an outer surface having a curve that convexes outward relative to a vertical line passing through the end point.

10. A method for forming a magnetic device, characterized in that, The method includes: Form a U-shaped magnetic core; A coil is disposed in the U-shaped magnetic core, wherein the coil is formed by a wire, wherein a first end of the wire includes a first portion and a second portion, wherein the first portion and the second portion of the first end form an angle between 110 degrees and 150 degrees. A T-shaped magnetic core is disposed on the coil, wherein the T-shaped magnetic core includes a base and a support on the base, at least a portion of the support is disposed in a hollow space of the coil, and a through hole is formed at a corner of the base, wherein at least a portion of the first end is disposed within the through hole; and The T-shaped magnetic core and a first portion of the first end are pressed to form the magnetic device, wherein the first portion of the first end is exposed from the body of the magnetic device to form a first electrode, and a second portion of the first end extends from a top of the coil to an end point of the first portion of the first end, wherein the second portion of the first end includes an outer surface, wherein a vertical line passing through the end point passes through the second portion of the first end and intersects the outer surface at a first intersection point, the outer surface having a curve that convexes outward relative to the vertical line passing through the end point, and the curve being a smooth curve extending from the end point to the first intersection point.

11. The method as described in claim 10, characterized in that, The magnetic device is an inductor, the body includes a magnetic body, and the coil is disposed in the magnetic body.

12. The method as described in claim 10, characterized in that, The base includes a surface that forms an angle of 20 to 60 degrees with a horizontal plane, wherein a first portion of the first end is placed on the surface.

13. The method as described in claim 10, characterized in that, The base and the support are made of different magnetic materials.

14. The method as described in claim 10, characterized in that, When the T-shaped magnetic core is pressed, the T-shaped magnetic core is in an uncured state.

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