Inductor with high current coil having low direct current resistance

Abstract

An inductor and a method for manufacturing the same are presented. The inductor includes a coil formed of a conductor and having a serpentine shape. The coil can have an "S" shape. The coil has two leads extending from opposite ends of the coil. An inductor body surrounds the coil and portions of the leads. The leads can be wrapped around the body to create contact points on an exterior of the inductor.

Description

[0001] This application is a divisional application of the Chinese Patent Application No. 201780066826.X filed on August 30, 2017, entitled "Inductor with High Current Coil Having Low DC Resistance", the entire contents of which are incorporated herein by reference.

[0002] INTERACTION WITH RELATED APPLICATIONS

[0003] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 382,182, filed August 31, 2016, the entire contents of which are incorporated by reference as if fully set forth herein. TECHNICAL FIELD

[0004] The present application relates to the field of electronic components, and more particularly, to inductors and methods for manufacturing inductors. BACKGROUND

[0005] Inductors are generally passive, two-terminal electrical components that resist changes in current through them. Inductors include a conductor, such as a wire, that is wound into a coil. When current flows through the coil, energy is temporarily stored in the magnetic field within the coil. According to Faraday's law of electromagnetic induction, when the current through an inductor changes, a time-varying magnetic field induces a voltage within the conductor. As a result of operating based on magnetic fields, inductors can generate electric and magnetic fields that can interfere with, disrupt, and / or degrade the performance of other electronic components. In addition, other electric, magnetic, or electrostatic fields from electrical components on a circuit board can interfere with, disrupt, and / or degrade the performance of inductors.

[0006] Some known inductors are generally formed with a core of magnetic material, with a conductor inside, sometimes formed as a wound coil. Examples of known inductors include U.S. Patent Nos. 6,198,375 ("Inductor coil structure") and 6,204,744 ("High current, low profile inductor"), the entire contents of which are incorporated herein by reference. It is common to attempt to improve the design and improve the economics of building inductors. Thus, there is a need for a simple and cost-effective way to produce consistent inductors, including those with inductances below 1 uH, while improving DC resistance. SUMMARY

[0007] An inductor and a method for manufacturing the same are disclosed herein. The inductor can include a coil formed from a conductor. The coil can have two leads extending from opposite ends of the coil. A body surrounds the coil and portions of the first and second leads. The leads can be wrapped around the body to create contact points on an outer surface of the inductor, such as surface mount terminals.

[0008] A method for manufacturing the inductor is also presented. A conductor (e.g., a sheet or strip of metal or a wire) can be formed into the shape of the coil and the two leads from opposite ends of the coil. The coil can be formed into a particular shape, such as a serpentine or meandering shape, and preferably can be formed with an "S" shape. The conductor can be folded, bent, and / or stamped to form the shape of the coil and the two leads. A body of the inductor surrounds the coil and can be pressed around the coil with the leads extending from the body. The leads can then be bent to wrap around the body to form contact points at one outer surface of the body.

[0009] In one aspect, the present invention presents a flat inductor coil with leads in a shape that is formed as a unitary piece by stamping a piece of metal (e.g., copper). It is contemplated that other conductive materials known in the art, such as other materials used for coils in inductors, can be used without departing from the teachings of the present invention. An insulator can also be used around portions of or between the coil and / or leads if desired for a particular application. The lead portions are aligned along a generally straight path and can have a width. The coil can include portions that extend beyond the width of the leads, preferably bent or positioned away from the center of the coil, where the portions are connected by a connecting portion that extends at an angle through the center of the coil. The coil and leads can initially lie in a plane during manufacture (e.g., when formed from a flat piece of metal). The leads can ultimately be bent around and under an inductor body that surrounds the coil. In one embodiment of the completed inductor, all components of the coil can preferably lie in a plane. The inductor body is pressed around the coil and houses the coil.

[0010] The coil extending between and connecting the leads has a shape. In a preferred embodiment, the coil joins the opposite leads (or lead portions) and generally includes a first curved portion and a second curved portion. The curved portions are preferably bent away from and / or around the center of the coil and thus can be considered "outwardly" curved. Each curved portion of the coil can extend along a portion of a circumference of a circular path that is curved around the center of the central portion. Each curved portion has a first end extending from one of the leads and a second end opposite the first end. The central portion or connecting portion extends at an angle across the center of the central portion between the second ends of each of the first and second curved portions. This results in a serpentine coil that can have an "S" shape when viewed from above or below.

[0011] A plurality of coil layers can be provided. An insulator can be positioned between the plurality of coil layers. The coil according to the present application can be formed as a flat, circular or oval metal sheet.

[0012] In one aspect of the present application, the coil and the leads of the present application are preferably formed as a flat, complete unit, for example by stamping. That is, there is no interruption or break in the coil from one lead to the opposite lead. The leads and the coil are formed simultaneously by stamping during the manufacturing process. The coil does not have to be joined to the leads, for example by soldering. In other embodiments, the leads are formed separately and joined to the coil. BRIEF DESCRIPTION OF DRAWINGS

[0013] Figure 1 An isometric view of an inductor according to the present application is shown in partial transparency;

[0014] Figure 2 An end view of the inductor of Figure 1 is shown from the lead end;

[0015] Figure 3 An end view of the inductor of Figure 1 is shown from the non-lead end;

[0016] Figure 4A A view from the top of the inductor of Figure 1 is shown in partial transparency;

[0017] Figure 4B A side view of the inductor of Figure 1 is shown from the lead edge;

[0018] Figure 4C A side view of the inductor of Figure 1 is shown from the non-lead edge;

[0019] Figure 5 A method of manufacturing an inductor according to one embodiment of the present application is schematically shown;

[0020] Figure 6 A lead frame formed in the method of Figure 5 is shown during the stamping step;

[0021] Figure 7 A top perspective view of the lead frame formed in the method of Figure 5 is shown during the stamping step;

[0022] Figure 8 A component formed in the method of Figure 5 is shown during the pressing step;

[0023] Figure 9a top perspective view of the part formed in the pressing step in the method of Figure 5

[0024] Figure 10 a top perspective view of the part formed in the pressing step in the method of Figure 5

[0025] Figure 11A a top perspective view of the part formed in the pressing step in the method of Figure 5

[0026] Figure 11B a side perspective view of the part formed in the pressing step in the method of Figure 5

[0027] Figure 12 a leadframe having an embodiment of an inductor coil according to the present invention;

[0028] Figure 13 a top view of a leadframe and inductor coil of Figure 12

[0029] Figure 14 a leadframe having an embodiment of an inductor coil according to the present invention;

[0030] Figure 15 a top view of a leadframe having an embodiment of an inductor coil according to the present invention;

[0031] Figure 16 another embodiment of a leadframe and coil according to the present invention;

[0032] Figure 17 a perspective view of an assembled inductor according to one embodiment of the present invention;

[0033] Figure 18A and 18B an assembled inductor according to the present invention;

[0034] Figure 19 an inductor, shown with the second body transparent and the core and body removed;

[0035] Figure 20 a top view of the coil from an assembled inductor, with other parts of the inductor 3100 removed;

[0036] Figure 21 a bottom view of the coil from an assembled inductor, with other parts of the inductor 3100 removed;

[0037] Figures 22A-22B ​​​​​A body from an assembled inductor is shown, with other parts of the inductor removed;

[0038] Figure 23 A coil of an inductor is shown with connections by welding and / or soldering.

[0039] Figure 24 An isometric view of a coil of one example of an inductor is shown;

[0040] Figure 25 A side view of a coil of one example of an inductor is shown;

[0041] Figure 26 A side view of one example of a body is shown, with inductor leads formed around the sides of the core;

[0042] Figure 27 A side view of one example of a core is shown, with the body made transparent to see the internal coil, with inductor leads formed around the sides of the core;

[0043] Figure 28 An isometric view of one example of a body is shown, with inductor leads formed around the sides of the core;

[0044] Figure 29 An isometric view of one example of a body is shown, with the core made transparent to see the internal coil, with inductor leads formed around the sides of the core;

[0045] Figure 30 A bottom perspective view of one example of a body is shown, with leads formed;

[0046] Figure 31 An isometric view of one example of a conductor is shown, with multiple coils formed;

[0047] Figure 32 An isometric view of one example of a conductor is shown, with coils and components attached;

[0048] Figure 33 A method for manufacturing an example of an inductor is shown, according to one embodiment;

[0049] Figure 34A An isometric view of one example of a folded conductor is shown;

[0050] Figure 34B A front perspective view of one example of a folded conductor is shown;

[0051] Figure 34C A front perspective view of one example of a folded conductor is shown, with an insulator;

[0052] Figure 35 shows an isometric view of an example inductor coil made from folded conductor;

[0053] Figure 36 shows an isometric view of an example inductor coil made from folded conductor;

[0054] Figure 37 shows an isometric view of an example inductor coil made from folded conductor with leads formed;

[0055] Figure 38 is an isometric view of a body of an example, where the core has been made transparent to see the internal coil, inductor leads formed around the sides of the core;

[0056] Figure 39 is a bottom perspective view of a body of an example, where the core has been made transparent to see the internal coil, inductor leads formed around the sides of the core;

[0057] Figure 40 shows an isometric view of an example coil made from folded conductor with leads formed;

[0058] Figure 41 is an isometric view of a body of an example, where the core has been made transparent to see the internal coil, inductor leads formed around the sides of the core;

[0059] Figure 42 is a top perspective view of a body of an example, where the core has been made transparent to see the internal coil, inductor leads formed around the sides of the core;

[0060] Figure 43 shows an isometric view of an example coil made from folded conductor with leads formed;

[0061] Figure 44 is an isometric view of a body of an example, where the core has been made transparent to see the internal coil, inductor leads formed around the sides of the core;

[0062] Figure 45 is a top perspective view of a body of an example, where the core has been made transparent to see the internal coil, inductor leads formed around the sides of the core;

[0063] Figures 46A-46D shows an example method of manufacturing an inductor according to an embodiment;

[0064] Figures 47A-47D shows an example method of manufacturing a component for an inductor according to an embodiment;

[0065] Figure 48 An example method of manufacturing an inductor according to one embodiment is shown;

[0066] Figures 49A-49D An example method of manufacturing a component for an inductor according to one embodiment is shown;

[0067] Figures 50A-50F An example method of manufacturing an inductor according to one embodiment is shown; and

[0068] Figures 51A-51H An example method of manufacturing an inductor according to one embodiment is shown. DETAILED DESCRIPTION

[0069] In the following detailed description certain terminology is used to describe particular features and aspects of the application. The terminology used is for the purpose of description only and is not intended to be limiting. The words "right," "left," "top," and "bottom" designate directions in the drawings to which reference is made. The words "comprises," "comprising," "includes," "including" and "has" and their conjugates, mean "including but not limited to." The singular forms "a", "an" and "the" include plural references unless the context clearly dictates otherwise. The term "at least one" followed by a list of two or more items, such as "A, B, or C," means any of the items can be present, and multiple items of the list can be present. It is further noted that the use of "about" in connection with a given value means that the value is within a reasonable yet articulable range around the stated value. The use of the term "about" will be apparent in the context in which it is used. It is noted that some of the drawings can be shown in partial transparency for explanation, illustration and demonstration purposes only, and not to indicate that the elements themselves would be transparent in their final manufactured form.

[0070] Figure 1 An example of an inductor 3100 according to one embodiment described herein is shown, which includes a shaped coil 3150 formed from a conductor (e.g., a metal plate, sheet or strip). The shaped coil 3150 can be shaped into a unique configuration that provides increased efficiency and performance in a small volume, and which is simple to manufacture. The coil 3150 and leads 3140a and 3140b are preferably initially formed by stamping a conductive sheet (e.g., a copper sheet), which can be flat, and which results in a flat coil, as for example Figure 6The surface of the coil 3150 can be somewhat or slightly rounded, arcuate, or curved, and the side edges can be rounded or curved, depending on the method used to form the coil 3150, and can be known. Acceptable metals for forming the coil and leads can be copper, aluminum, platinum, or other metals known in the art for use as inductor coils. As used herein, "flat" means "generally flat," i.e., within normal manufacturing tolerances. It can be known that the flat surface of the coil 3150 can be somewhat or slightly rounded, arcuate, curved, or corrugated, and the side edges can be somewhat or slightly rounded, arcuate, curved, or corrugated, depending on the method used to form the coil 3150, and still be considered "flat."

[0071] After stamping, a residual copper strip, referred to as a carrier strip or frame portion, remains, at least one strip having a progressive aperture at the opposite end of the lead. The aperture can be used for alignment with manufacturing equipment. The stamped copper coil, leads, and frame portion can collectively be referred to as a "lead frame." An example is shown in Figure 6-1 1. Initially, for example during manufacture, the shaped coil and leads can lie in the same plane. Each lead 3140a and 3140b will eventually be bent around the inductor body, with the lead contact portion 3130 bent under the bottom of the inductor body. The leads 3140a and 3140b and the coil 3150 are preferably formed as an integral piece without soldering.

[0072] In the embodiments shown in Figure 1 , 4A , 5, and 6, the coil 3150 comprises a serpentine or meandering coil, which when viewed from the top as oriented in the associated figures, is disposed as an "S" shaped coil or "S-coil." The coil 3150 has a central portion 3151 that diagonally traverses a middle of the coil. A first curved portion CI has a first end 3152 extending from one of the leads 3140b and a second end 3153 bent around a center of the coil 3150. A second curved portion C2 has a first end 3155 extending from the other of the leads 3140a and a second end 3154 bent around the center of the coil 3150 in an opposite direction from the first curved portion CI. Each curved portion forms an arc around a portion of the center of the coil 3150. The curved portions can each extend along a circumferential path of the central circle.

[0073] The coil 3150 can have a central portion 3151 that can be formed as a flat straight strip, which extends from the second end 3153 of the first curved portion CI and across the center of the coil 3150 to the second end 3154 of the second curved portion C2. The central portion 3151 completes the "S" shape.

[0074] This S-coil, or "S" shape, illustrates a preferred embodiment. Other configurations are also contemplated, including arc-shaped, Z-coil, or N-coil configurations, as will be discussed in the following sections. A coil configuration will be considered a "winding" coil: it extends along a meandering path between the leads, with a portion of the coil crossing the central wire or central portion of the coil or inductor body. For example, and without limitation, S-coils, Z-coils, N-coils, and other coil shapes whose trajectories from one lead to another have meandering paths are considered "winding" coils. A winding coil can be distinguished from a "winding" coil formed by conductors that wrap around the central portion of the inductor core but do not have a portion crossing or traversing the central portion or central wire of the inductor core.

[0075] like Figure 4A and 7 As shown, the meandering coil 3150 of the present invention may have a first path P1 extending in a first direction from one side of the inductor toward the opposite side, for example, from the side of the inductor including lead 3140b toward the opposite side of the inductor including lead 3140a. In a preferred embodiment, the first path P1 is a curved path or arcuate path that bends away from the central portion of the coil.

[0076] The second path P2 continues from the first path P1 and crosses the center line L of the coil in the second direction. A Extension. In a preferred embodiment, the second path P2 passes through the center of the coil and the central line L. A The second path P2 can be a path that slopes diagonally back from the side where the first path P1 ends toward the side where the first path P1 begins, for example, from the side of the inductor including lead 3140a toward the opposite side of the inductor including lead 3140b. The second path P2 can be a path that is substantially straight for most of its length.

[0077] The third path P3 continues from the second path P2 and extends upward from one side of the inductor toward the opposite side, for example, from the side of the inductor including lead 3140b toward the opposite side of the inductor including lead 3140a. In a preferred embodiment, the third path P3 is a curved or arcuate path that bends away from the central portion of the coil. In a preferred embodiment, the first and third directions are substantially the same, but bend in opposite directions, and both are different from the second direction. The combination of paths P1, P2, and P3 is preferably an uninterrupted, continuous, meandering path formed by the same conductor.

[0078] The first and third paths P1 and P3 can form a route along a curved path, a straight path, or a combination of curved and straight paths. For example, as... Figure 16As shown in one alternative embodiment, the "N"-shaped coil can pass through the center line L along a first path P1 that is generally straight from the first side of the inductor to the opposite side. A Returning to the second path P2, which extends diagonally toward the first side, and the third path P3, which is roughly straight from the first side of the inductor to the opposite side, a line is formed along most of the length of those paths.

[0079] In configurations of coils with "S", "N", or "Z" shapes, spaces or gaps are provided between the portions of the coil, such as between the curved portion C1 and the central portion 3151, and between the curved portion C2 and the central portion 3151. In embodiments with an "S" shape, the spaces or gaps have a generally semi-circular shape, such as... Figure 4A , 7 As shown in 25 and 39. In, as Figure 16 In the illustrated "N"-shaped embodiment, the space or gap has a generally triangular shape. In the "Z"-shaped coil, the space or gap also has a generally triangular shape.

[0080] The shape of coil 3150 is designed to optimize the path length to fit within the available space of the inductor, while minimizing resistance and maximizing inductance. This shape can be designed to increase the ratio of the space used to the available space within the inductor body. In one embodiment of the invention, coil 3150 is preferably flat and substantially oriented in a plane.

[0081] The “S” shape optimizes inductance and resistance values ​​compared to other non-coil conductor configurations. The 1212 package with an S-coil (approximately 0.12" x 0.12" x 0.04") produces an inductance value in the range of 0.05uH at 2.2mΩ. The 4040 package with an S-coil (approximately 0.4" x 0.4" x 0.158") produces an inductance value in the range of 0.15uH at 0.55mΩ. The 1616 package with an S-coil produces an inductance value of 0.075uH, and the 6767 package with an S-coil produces an inductance value of 0.22uH.

[0082] according to Figure 1 The embodiment shown in example -4, which partially transparently displays the inductor body to view the interior, includes an inductor body 3100 according to the invention, which is partially transparently formed around, pressed onto, or otherwise accommodates the coil and at least some of the leads. The inductor body includes a first body portion 3110 and a second body portion 3120. (As shown in example -4) Figures 1-4CAs shown, the first body portion 3110 and the second body portion 3120 sandwich, press around, or otherwise house portions of the shaped coil 3150 and the leads 3140a and 3140b to form the completed inductor 3100. From Figure 2 and Figure 3 As viewed from the side, the inductor 3100 can be seen with the first body portion 3110 at the bottom and the second body portion 3120 at the top.

[0083] In the example embodiment shown as partially transparent Figure 2 and Figure 3 The first body portion 3110 and the second body portion 3120 are shown as separate or discrete portions used to form the completed inductor 3100, but a single, unitary, overall body can be used. In alternative embodiments, any number of body portions can be used. The body can be formed of a ferrous material. The body can include, for example, iron, a metal alloy or ferrite, combinations thereof, or other materials known in the inductor art and used to form such bodies. As will be further discussed, the first body portion 3110 and the second body portion 3120 can include powdered iron or similar materials. Other acceptable materials known in the inductor art can be used to form the body or body portions, such as known magnetic materials. For example, magnetic molding materials can be used for the body, including powdered iron, fillers, resins, and lubricants, such as the materials described in U.S. Patent Nos. 6,198,375 ("Inductor coil structure") and 6,204,744 ("High current, low profile inductor"). While it is contemplated that the first body portion 3110 and the second body portion 3120 can be formed in a similar manner and of the same material, the first body portion 3110 and the second body portion 3120 can be formed using different methods and of different materials, as is known in the art.

[0084] The first body portion 3110 and the second body portion 3120 surround portions of the coil and leads, and can be pressed or overmolded around the coil 3150, leaving exposed portions of the leads 3140a and 3140b initially, until they are folded under the first body portion 3110, as shown in the partially transparent example of Figures 4A-4C In the completed inductor or "part," each lead 3140a and 3140b can extend along a side of the first body portion 3110, as shown in Figure 4B As shown in Figure 1As can be seen, each lead 3140a and 3140b terminates at a contact portion 3130 that bends below the first body portion 3110.

[0085] like Figure 1 As can be seen, the frame 3160, step, or notch can be formed by a portion of the lead 3140a that bends along the outside of the inductor body 3110. The frame 3160 is formed near the junction of the lead and the coil 3150, which can also be seen in Figure 3 The frame 3160 can transition to a diameter smaller than that of other portions of the lead 3140. The frame 3160 allows for a smaller lead thickness away from the body, improving the ability to form this portion. The frame 3160 allows for additional space for the coil within the body. It is understood that the frame 3160 is not necessary in all cases, and the inductor, coil, or lead according to the invention can be formed without the frame.

[0086] like Figure 1 As can be seen, the configuration of coil 3150 may include coil notch 3170, which is located on the inside of the coil adjacent to the transition of the frame 3160 to the bends C1 and C2. Coil notch 3170 allows for separation (space) between the lead and the coil.

[0087] Figure 2 The body of the inductor is shown to include a first notch 3180 or groove in a first body portion 3110 to provide an inlet for disposing a lead contact portion 3130 below and abutting against the bottom 3111 of the outer surface of the first body portion 3110. Figure 3 It is shown that a second notch 3190 or groove may also be provided in the first body portion 3110 to provide another entry for placing the lead contact portion 3130 below and against the bottom 3111 of the outer surface of the first body portion 3110.

[0088] Figures 4A-4C Another view of the inductor 3100 is shown. Figure 4A A partially transparent view of the inductor 3100 is shown, through which the coil 3150 is visible. Figure 4B A side view of the inductor 3100 as seen from the edge of lead 3140a is shown. Figure 4C A side view of inductor 3100 as seen from the non-lead edge is shown. As shown, coil 3150 can be shaped into an "S" or "Z" depending on its orientation. As used herein and as shown in the accompanying drawings, the "S" or "Z" shape can also include a mirror image of this shape when viewed from above. For example, it can be understood that the orientation of coil 3150 can be rotated 180 degrees to form another configuration of the "S" or "Z" arrangement.

[0089] Figure 5 A method 3500 for manufacturing an inductor 3100 is shown. At step 3510, the inductor is produced by stamping to create the lead wires in the desired shape and the feature of the coil between the lead wires. This stamping can be done on a flat copper sheet to create the features that make up the electrical leads and the coil that joins the two leads, with one electrical lead on one side of the part and one electrical lead on the other side of the part, and the coil formed in an "S" shape. This stamped S-coil inductor is a simple and cost effective way to produce a consistent inductor with an inductance below luH. This stamped S-coil inductor is a simple and cost effective way to produce a consistent inductor with a DC resistance that is lower than current high current lower profile manufacturing methods and up to 80% of that.

[0090] As Figure 6 seen, the copper sheet can have a residual copper strip that has progressive holes for alignment into manufacturing equipment, which is referred to as a carrier strip or is a frame portion. The stamped copper sheet can be referred to as a "lead frame".

[0091] Continuing Figure 5 the method shown, at step 3520, the pressed powder (e.g. powdered iron) is poured into a mold and pressed into a body around the coil from which the leads extend. For example, the body can be pressed to form the desired shape, the body similar to an IHLP inductor. The core and lead frame can now be referred to as a "part".

[0092] At step 3530, the part is cured in an oven. The curing process bonds the core together.

[0093] After curing, at step 3540, the carrier strip is trimmed off from the leads on the lead frame.

[0094] At step 3550, the leads are folded around the body of the inductor to form the lead contact portions.

[0095] The stamped coil and leads can also be assembled using other known core materials known in the art.

[0096] Figures 6-7 A lead frame 3600 formed from the stamping step (step 3510) in the method 3500 is shown. Figure 6 An isometric view of the lead frame 3600 is shown, and Figure 7 A top view of the lead frame 3600 is shown. Figures 6-7A leadframe 3600 is shown that includes two coil 3150 structures as part of the leadframe. It is understood that any number of coils can be formed along the leadframe during the manufacturing process, and two coils are shown merely for ease of illustration and understanding.

[0097] The leadframe 3600 includes a first frame portion 3620 at the end of the leads and a second frame portion 3630 (also referred to as a "carrier strip"), and the coil is positioned in the middle between the first frame portion 3620 and the second frame portion 3630. The inductor assembly includes leads 3140 and a coil 3150. Adjacent to the lead 3140a is a shelf 3160. The coil 3150 includes a coil cutout 3170. The first frame portion 3620 includes an alignment hole pattern 3610. The pattern 3610 can be aligned as part of the manufacturing process. For example, during pressing.

[0098] Figure 8-1 1A top view of a leadframe 3600 is shown. Figure 5 A component 3800 of an inductor formed in the pressing step (step 3520) in the method discussed. Figure 8 An isometric view of the component 3800 formed in the pressing step is shown, showing only the inner core 3115 around the coil. Figure 9 An isometric view of the component 3800 formed in the pressing step is shown, showing: Figure 8 A top view of the component 3800 is shown. Figure 10 An isometric view of the component 3800 formed in the pressing step is shown, showing: one inductor with the bodies 3110, 3120 contained, and in the other inductor, the bodies 3110, 3120 are shown in partial transparency, allowing the inner core 3115 and coil 3150 to be seen. Figure 11A The component 3800 is shown in a top view of the component 3800, with the outer body 3125 in partial transparency to show the positioning of the inner core 3115 and coil 3150. Figure 11B A partial transparent side view of the component 3800 from Figure 10 is shown and provided.

[0099] The component 3800 includes a leadframe 3600 that includes a first frame portion 3620 and a second frame portion 3630 on opposite ends of leads 3140a and 3140b and a coil 3150. Adjacent to the lead 3140a is a shelf 3160, notch or step. On the coil 3150 is a coil cutout 3170. The first frame portion 3620 includes an alignment hole pattern 3610. The pattern 3610 can be aligned during the manufacturing process.

[0100] In one embodiment of the application, the component 3800 includes a body 3125 and the first frame portion 3620 and the second frame portion 3630, wherein the body is pressed around the coil 3150 and a portion of the lead 3140, leaving exposed portions of the leads 3140a and 3140b. The body 3125 can include a first body portion 3110 and a second body portion 3120 as described. The body 3125 can be formed by pressing a ferrite material around the coil 3150. The body 3125 can be separate from the inner core 3115 or they can be formed together, for example as a unitary component. The inner core can be formed in different ways: the material can be formed separately, typically from ferrite, and then placed on top of the coil, and then the body can be pressed around it; or, the inner core can be pressed around the coil separately, typically using some type of iron, and then an outer core can be pressed around the inner core using the same or a different material. The inner core can be used as the sole source of permeable material, or as the sole body of the device, without an outer core. When an inner core is used, the body 3125 can encase the inner core 3115. Further, the body 3125 can be formed as a unitary piece with the inner core 3115 or in combination with it. Further, the body can be only the inner core.

[0101] Figure 10 and 11A and 11B show the inductor body 3125, showing the body 3125 and the inner core 3115, wherein the body 3125 is shown in transparency. The inner core 3115 can or can not be a separate portion of the body 3125, and in Figure 8 and 9 are shown separately for illustrative purposes. The inner core 3115 is generally cylindrical and includes a channel shaped to receive the central portion 3151 of the coil 3150. The curved portions CI, C2 of the coil 3150 surround the inner core 3115, as shown in Figure 10 When the first body portion 3110 and the second body portion 3120 are combined, they can form the inner core 3115 or otherwise contain the inner core 3115.

[0102] In one embodiment, as shown in the example of Figures 12-14 , the inductor can have multiple stacked coils. Figure 12 An isometric view of an inductor 3100 having two coils is shown. As shown in Figure 12 , wherein the coils are attached to a lead frame, the second coil 3150b is aligned and adhered to (e.g., stacked to) the first coil 3150a. Solder can be used in adhering the coils 3150a, 3150b together. In addition to adhering and maintaining alignment, the solder provides an electrical connection between the first coil 3150a and the second coil 3150b. Figure 12The multi-coil structure can be formed by aligning and attaching coils held by two lead frames or by aligning and attaching a second coil that has been separated by lead frames and / or leads to the first coil. Once aligned and attached, the lead frame for the second coil 3150b can be removed to expose the single lead 3140 for subsequent processing steps.

[0103] Figure 13 It shows Figure 12 A top view of a multi-coil, multi-layer embodiment. From this view, only the second coil 3150b is visible. The lead frame associated with the second coil 3150b has been removed, exposing the lead 3140a from the lead frame of the first coil 3150a. If formed by aligning the two lead frames, a boundary 3145b or edge may be formed where the lead frame of the second coil 3150b is removed. The coils may also be separated from each other within the body using an insulator between each coil layer. This insulator can provide improved inductor performance in certain situations. The insulator may include Kapton. TM Nylon TM or Teflon TM Or other insulating materials known in the art. The coils can be connected at the ends using methods such as welding and / or brazing.

[0104] Figure 14 An inductor 3100 with multiple coils is shown, illustrating a three-coil design. As shown, a first coil 3150a is contained within a lead frame, a second coil 3150b is aligned and adhered to the top of the first coil 3150a, and a third coil 3150c is aligned and adhered to the bottom of the first coil 3150a. When adhering coils 3150a, 3150b, and 3150a, 3150c, as... Figure 23 As shown, solder 3232 can be used. This solder, in addition to adhering and maintaining alignment, provides an electrical connection between the first coil 3150a and the second coil 3150b. Once aligned and adhered, the lead frames for the second coil 3150b and the third coil 3150c can be removed respectively to expose the single lead 3140 for subsequent processing steps.

[0105] The lead frame associated with the second coil 3150b has been removed, exposing lead 3140a from the lead frame of the first coil 3150a. Boundary 3145b is formed by the removal of the lead frame of the second coil 3150b. The lead frame associated with the third coil 3150c has been removed, exposing lead 3140a from the lead frame of the first coil 3150a. Boundary 3145c is formed by the removal of the lead frame of the third coil 3150c. The first coil 3150a, the second coil 3150b, and the third coil 3150c can be formed by... Figure 23The insulator 3231 shown is split, or can not be.

[0106] Figure 15 Formation of a coil is shown, where the reduced lead frame has only one carrier strip 3621. In Figure 15 the stamped "S" shaped coil 3150 can have the same elements as Figure 1 described above. The "S" shaped coil 3150 includes a first lead 3140a connected to the carrier strip 3621 and a second lead 3140b extending from an opposite side of the coil 3150.

[0107] Figure 16 An alternative shape for an inductor coil is shown. In Figure 16 an "N" shaped coil 3159 is provided (where "N" is up relative to the length of the carrier strip 3561). The "N" shaped coil 3159 includes a first portion Nl connected to the second lead 3140b and a second portion N2 connected to the first lead 3140a, which is connected to the carrier strip 3621. The two portions Nl and N2 are connected by a central portion N3 of the coil 3159. In contrast to the curved portions Cl and C2 of Figure 1 the "S" shaped coil 3150, the two portions Nl and N2 of the "N" shaped coil 3159 are generally straight. The outer corners of the portions Nl and N2 where they curve to meet the leads 3140a, 3140b are curved away from the central portion N3 of the coil. Figure 16

[0108] Figure 17 A view of an assembled inductor 3100 according to the present application is shown. The inductor 3100 includes a first body 3110 and a second body 3120. Also shown are the leads 3140, which include steps near where the leads exit the bodies.

[0109] Figure 18A and 18B A view of an assembled inductor 3100 according to the present application is shown.

[0110] Figure 19 An inductor is shown, with the second body 3120 shown partially transparent and cut away from the top. The coil 3150 is shown connected to the leads 3140a and 3140b. The coil 3150 includes regions Cl, C2 with cross members 3151.

[0111] Figures 20-21 A view of a coil 3150 from an assembled inductor 3100 (e.g., with curved leads) is shown, with other portions of the inductor 3100 removed. Figure 20 A view of a coil 3150 from above is shown, and Figure 21 ​An isometric view from below is shown of the coil 3150. The coil 3150 is shown connected to the lead 3140. The coil 3150 includes curved or arcuate regions or portions CI and C2 which have a cross member or central portion 3151.

[0112] Figure 22A and 22B An embodiment of the first body 3110 ( Figure 22B ) and the second body 3120 ( Figure 22A ) from the assembled inductor 3100 is shown in transparency, wherein other portions of the inductor 3100 are removed. The first body 3110 and the second body 3120 include the inner core recess 3221 and the channel recess 3222 for receiving or housing the separate inner core and for the channel of the coil, as described above. The first body 3110 and the second body 3120 can also form the inner core and include the channel for the coil as described above. In an example, the top of the first body 3110 interfaces with the bottom of the second body 3120 to create the inner core recess 3221 and the channel recess 3222.

[0113] Figure 24 An isometric view of another embodiment of a coil according to the present invention is shown. An example coil 190 is shown which includes lead wires 130a, 130b extending from opposite ends of the coil 190. The coil 190 can be formed from a conductor 100 having a width 150 and a height (or thickness) 160. The formed coil and lead wires 130a, 130b can be referred to as a "lead frame." The conductor 100 can be formed from a metal strip. Acceptable metals for forming the coil can be copper, copper, aluminum, platinum or other metals known in the art for use as inductor coils. Acceptable metals for the lead wires can be copper, aluminum, platinum or other metals known in the art for use as inductor lead wires.

[0114] In a preferred example, as shown in Figure 24 , the width 150 of the conductor 100 is greater than the height 160. In one aspect of the present invention, the width of the coil 190 is associated with the width of the conductor 100. In another orientation of the coil, the height of the conductor can be greater than the width, and the height of the coil can be associated with the height of the conductor. The conductor 100 can be a wire, a metal strip or a form of metal stamped from a sheet of metal, or another conductive material known in the art. The conductive material preferably has flat surfaces and flat edges. However, it is understood that the conductive material can have rounded, oval or ovoid surfaces, edges or shapes, either before or after being formed into a coil of the present invention. Thus, the coil and / or lead wires can have rounded or curved surfaces or edges.

[0115] In a preferred embodiment, the coil 190 can include a first curved portion 110 and a second curved portion 120. The curved portions 110 and 120 are preferably curved away from and / or around a central portion 140 of the coil 190, and thus can be considered to be "curved outwardly" with respect to the central portion 140. Each curved portion 110 and 120 of the coil 190 can extend along a portion of a perimeter of a curved circular or arcuate path around the central portion 140 of the coil 190.

[0116] Referring to Figure 25 , the first curved portion 110 can have a first end 180a connected to the first lead 130a and a second end 115 curved into the central portion 140. The second curved portion 120 can have a first end 180b connected to the second lead 130b and a second end 125 curved into the central portion 140. The central portion 140 is preferably transverse to the center of the coil and extends substantially diagonally or at an oblique angle from the second end 115 of the first curved portion 110 to the second end 125 of the second curved portion 120.

[0117] As shown in the Figure 25 view, the leads 130a, 130b can be offset from a centerline 131 extending along the length of the coil before the leads are bent or further shaped. In another embodiment, the leads 130a, 130b can be aligned along the centerline extending along the length of the coil.

[0118] As shown in the figures, a typical serpentine coil having an "S" shape can be seen in Figure 24 , 25 , 27, 29, 31 and 32 when viewed from the top. Alternatively, the coil can be formed in any other suitable shape, such as a "Z" or "N". The length of the conductor can vary during production, as the length of the conductor is subject to the number of inductors to be manufactured, the number of coils formed from the length of the conductor, or the raw material used to produce the conductor. The coil 190 can have a vertical height 170 extending from the top of the coil (when oriented as in Figure 25 , 27 and 29) to the bottom of the coil. The vertical height 170 can contribute to the space occupied by the coil when placed in an inductor core or body. The width 150 and / or height 160 of the conductor 100 can be less than the vertical height 170 of the coil formed. The coil 190 can be shaped in a unique configuration that provides increased efficiency and performance for inductors in a small volume. In a preferred embodiment, for example as Figure 25The shape of the coil 190 can be "S" shaped when viewed from the side of the coil 190, as indicated by the orientation of the arrow. The shape of the coil 190 is designed to optimize the path length of the conductor 100 to fit within the available space inside the core 260 of the inductor 200, while minimizing the electrical resistance and maximizing the inductance. The shape can be designed to increase the ratio of the space used in the inductor body 200 relative to the available space. In one embodiment, an inductor according to the present application can achieve an inductance of 0.135 μH at 0.21 mΩ.

[0119] In one embodiment, the conductor can be square in cross-section, as opposed to a flattened shape where the width can be greater than the height. The conductor can also exhibit any shape in cross-section, such as rectangular, triangular, prismatic, circular, oval, or the like. In any example, embodiment, or discussion of a conductor discussed herein, the cross-section of the conductor can take any shape as discussed herein.

[0120] Figures 26-30 An assembled inductor 200 is shown, with the core 260 formed around the coil 190. As shown in the figure, the inductor 200 can be oriented vertically, with the core or body 260 oriented in an upright manner, with the leads 135a, 135b at the bottom for mounting to, for example, a circuit board.

[0121] Figure 26 A view is shown from the front side 263a of the inductor 200 with an example core 260, with the inductor leads 130a, 130b formed around the lower surface 261b of the core 260. Portions of the leads 130a, 130b can be bent at points 180c, 180d, respectively, as they exit the core. The leads 130a, 130b and the coil 190 can be formed as a unitary piece without soldering. The core can be square, rectangular, or another other shape that encompasses the dimensions of the core 260. The core 260 can have a height 220 from the top 261a to the bottom 261b, which in one embodiment is greater than the vertical height 170 of the coil 190.

[0122] Figure 27A front side view of the inductor 200 is shown, with the core 260 being partially transparent to view the interior. The leads 130a, 130b terminate at lead ends 135a, 135b, respectively, after winding around the core 260 a distance 230 at points 210a, 210b, respectively, from their points of departure 180c, 180d, respectively. The leads 130a, 130b can preferably be bent around the bottom 261b of the core 260 at points 210a, 210b, respectively, thereby causing the leads 130a, 130b to "hug" or lie directly against the core 260 to create surface mount terminals at the portions of the leads 135a and 135b that extend along the bottom surface 261b. Each lead 130a, 130b can extend along a portion of the bottom surface 261b of the core 260.

[0123] In one embodiment, a magnetic material, such as iron, can be poured into a mold and pressed into the core 260 that contains the coil 190. In other embodiments, other materials besides iron can be used to form the core 260 or core portions. For example, a magnetic molding material can be used for the core 260, including powdered iron, a filler, a resin, and a lubricant, such as described in U.S. Patent Nos. 6,198,375 ("Inductor coil structure") and 6,204,744 ("High current, low profile inductor").

[0124] In other embodiments, the core can be formed as multiple pieces that are formed together. For example, the core can be a two-piece core, having a first portion and a second portion of the core; the two portions can be formed in a similar manner and of the same material, or the first and second portions can be formed using different methods and of different materials. The core can be shaped similarly to the IHLPTM inductor known in the art, and can be sized appropriately to contain the coil 190. The core and lead frame can be assembled after the coil has been formed.

[0125] Figure 28 and 29 isometric views of an inductor as shown in Figure 26 and 27 isometric views of an inductor as shown in

[0126] Figure 28 The departure and bend point 180c is shown, where the lead 130a departs the core 260 approximately at the midpoint of the first side 262a.

[0127] In the orientation as shown in Figure 29 the coil 190 and leads 130a, 130b are visible through the transparent core 260 for illustrative purposes only. In Figure 29In the core 260, the width 150 of leads 130a and 130b extends between the front side 263a and the back side 263b of the core 260. On a second side 262b of the core 260, lead 130b exits the core 260 at point 180d. In one embodiment, the width 150 of leads 130a and 130b may be less than the depth 250 of the core 260 from the front side 263a to the back side 263b. In another embodiment, the width 150 of leads 130a and 130b may be the same as the depth 250 of the core 260 from the front side 263a to the back side 263b. The core 260 may also include a back side 263b, a top side 261a, and a bottom side 261b.

[0128] A unique feature of this invention is the positioning of the coil 190 and leads 130a and 130b relative to the core 260. For example... Figure 29 As indicated by the orientation, coil 190 and leads 130a, 130b have a width 150 extending at least a portion of a depth 250 along the core 260.

[0129] Figure 30 A bottom view of an example inductor 200 is shown. Lead ends 135a, 135b are shown wound around portions of the side of the core 260 and around portions of the bottom surface 261b. These can form electrical contact points for the inductor 200, such as surface mount leads. The bottom 261b is opposite to the top 261a of the core 260. Lead ends 135a, 135b may have a width 150 that may be less than the depth 250 of the core 260. In an alternative embodiment, leads 130a, 130b may have a width similar to or the same as the depth 250 of the core 260.

[0130] Figure 31 An isometric view of an example coil production is shown, in which multiple coils 190 are formed from conductor 100. For a single coil production, the coils 190 may be formed to the same shape and size or may be formed to different shapes and sizes. Lead portions 130 may be aligned along a generally straight path or line extending along the length of the conductor. Alternatively, lead portions 130 may be offset relative to each other in different planes. Figure 24 In the example, there is a single example of coil 190, but it can be known that, as Figure 31 As shown in the example, there can be multiple coils formed from a single piece of material. Conductor 100 may include metal (e.g., copper) or any other suitable material suitable for making inductor coils. Conductor 100 may be plated, for example, with nickel and / or tin.

[0131] Figure 32 An isometric view of the component production example, showing a coil 190 and a formed component 270. Figure 32In this embodiment, the core 260 has been assembled with the previously formed coil 190 from the conductor 100 to produce a component 270. The component 270 includes an inductor 200 in which the lead portions 130 have not been separated or bent around the body of the core 260. The lead portions 130 of the conductor 100 between the components 270 can be separated to form leads 130a, 130b, each having a lead end 135a, 135b, respectively.

[0132] Figure 33 A method of manufacturing an example of an inductor is described. In one embodiment, at step 1010, a conductor, such as a rectangular nickel (Ni) and tin (Sn) electroplated uninsulated copper wire, can be bent to form a plurality of "S" coils. At step 1020, a core made of iron can be produced separately or can be produced during the same production process and can be attached or pressed on each coil. At step 1030, the components can be cured in an oven to bond the coils and the core together. Thereafter, the components can be separated and the lead portions of the lead frame can be folded around each core to produce an inductor. The coils and leads of the present invention are preferably formed as a complete unit; that is, there is no interruption or break in the formation of the coils from one lead to the next coil before the lead portions are separated / cut.

[0133] In another embodiment, an inductor can be made from a folded conductor, such as a metal strip, wire, or conductive metal stamping. The metal strip, wire, or conductive metal stamping is preferably flat. The conductor can be folded and shaped to form a coil and leads. Figure 34A An isometric view of one example of a folded conductor 1101 used in the manufacture of an inductor according to the present invention is shown. Figure 34B The formation of the folded conductor 1101 is shown from a front view of an example conductor 1102. The folded conductor 1101 can be formed as a conductor that folds itself into a generally U-shape when viewed in cross-section at the middle 1103 of the width of the conductor. The folded conductor 1101 can be folded along its width such that the fold creates two sides or layers of equal width 1105a and 1105b that are joined by a curved or bent portion 1103. In some embodiments, the two layers can not be equal. The conductor can be folded to create more than two layers. Figure 34C The folded conductor 1101 is shown from a front view with an insulator between the two folded layers. The insulator can be in each layer of folded material, or the insulator can be in selected layers.

[0134] In this folded conductor configuration, several options can be considered. The conductor can be folded to form the folded conductor 1101 and an insulator can be added between the layers after the folding manufacturing process. In another embodiment, the conductor can have a surface coated with an insulator prior to folding. When folded, the folded conductor 1101 will cause the insulating surfaces of the layers to come into contact. In another embodiment, the conductor is folded to form the folded conductor 1101 and no insulator is provided between the layers. In another embodiment, the conductor can be folded such that the layers directly contact each other. In this case, the layers can be pressed into each other.

[0135] In one example of forming a conductor 1102, the conductor 1102 can have two edges 1105a and 1105b that are moved down relative to the middle 1103 of the width 1104a of the conductor 1102 to form the folded conductor 1101. Note that the width 1104b of the folded conductor 1101 is about half the width 1104a of the conductor 1102. In one aspect, the folded conductor can have an insulating material sandwiched between the two layers 1105a and 1105b. In the case of more than one fold, an insulating material can be present between each layer to insulate the folded layers. This material can be made of any material that has insulating properties (i.e., non-conductive) that can be used by one of ordinary skill in the art, such as, but not limited to, ceramic, glass, gas, plastic, rubber, etc.

[0136] Figure 35 An example of an inductor coil 1202 made of a folded conductor with lead portions 1201 and 1203 in a serpentine shape is shown, which is similar to the configuration of Figure 24 but the coil is made of a folded conductor 1101 configuration. The coil 1202 can take a shape similar to the serpentine shape configuration shown and described with respect to Figures 24-33 and formed similarly thereto. Figure 35 An "S" shaped coil is shown as viewed from the top. Alternatively, the coil 1202 can take a non- "S" shape and be formed according to other shapes discussed herein, such as an "N", "Z" or some other form that produces inductance.

[0137] In an alternative embodiment, Figure 36 An example of an inductor coil 1202 is also shown, which is similar to the configuration of Figure 35 but the lead portions 1201 and 1203 extending from the coil are made of a folded conductor 1101 that has been split or cut or separated along a general middle point 1301 of the conductor 1101 to form a slit or gap. In Figure 36In this case, only leads 1201 and 1203 have been separated into two halves 1303 and 1304, and coil 1202 remains as a whole with two sides, two layers, two walls, or two sides.

[0138] Figure 37 An isometric view of an example inductor coil 1202 is shown, wherein lead portions 1201 and 1203 have been formed as surface mount leads by folded conductor 1101. Coil 1202 may have a central portion 1240. These leads are formed by splitting and / or opening at opposite ends of folded conductor 1101 and by flattening and / or unfolding lead portions 1201 and 1203. For example, lead 1203 unfolds from folded conductor 1101 to conductor 1102, creating a generally triangular side surface portion 1404. Lead 1203 may be further formed by bending this side surface portion 1404 at edge 1401, creating a flat surface 1406b (e.g., for surface mounting) partially below and along a portion of the bottom surface of inductor core body 1501. The side surface portion 1404 may begin at the end of the coil 1405, and when it is formed to create the side surface portion 1404, it may also have folded edges 1402a and 1402b due to the stacking of the folded conductors 1101. The same processing method and formation may occur on another lead 1201 on the opposite side, so that the two leads 1201 and 1203 have similar structures.

[0139] Figure 38 An isometric view of an example inductor 1500 is shown, in which Figure 37 The coil 1202 is encased within a core 1501. The core 1501 is partially transparent to allow its interior to be seen. The core 1501 may employ a design similar to that referenced herein. Figures 24-33 The core 260 shown is shaped and formed similarly to the shape and method described above. Lead 1203 may exit from core 1501 and be wound around the bottom 1502 of core 1501, thereby creating electrical contact points for inductor 1500, such as surface mount leads. The same processing method and formation may occur on another lead 1201 on the opposite side, such that the two leads 1201 and 1203 have a mirror structure relative to coil 1202. Leads 1201 and 1203 may exit from core 1501 in the form of flattened folded conductors 1101 and then be formed as described above.

[0140] Figure 39 Showing Figure 38 A top view of an example inductor 1500, which has a partially transparent core 1501 to show the coil 1202, leads 1201, 1203 and mounting surfaces 1406a, 1406b inside.

[0141] Figure 40 Another embodiment of an inductor coil 1202 formed from a folded conductor is shown, where the leads 1201 and 1203 are made from a partially split folded conductor, for example. Figure 36 The lead 1203 is split into portions 1303 and 1304, and formed and shaped in a similar or identical manner to the modification of the lead 1203 described with respect to Figure 37 . Figure 41 and Figure 42 A partially transparent view of the coil 1202 and the lead positioned around the core 1501 is shown, where the lead 1303 and 1304 are split into portions 1303 and 1304 at the split 1301.

[0142] Figure 43 An isometric view of another embodiment of a coil 1202 with cut and folded leads is shown. The coil 1202 is formed from a folded conductor with split lead portions. In this embodiment, one side of the split portions of the lead is cut, unfolded, and bent to conform to the surface of the core 1501, where one side of each of the lead portions remains as a surface mount lead. As can be seen in Figure 44 and 45 , the leads 1201 and 1203 are cut and folded in such a manner as to create contact points, such as surface mount leads, on the top side surface of the inductor. For example, the mounting surface 2001 can be the contact surface of the lead 1203. The lead 1203 can also have a flat side surface 2003 that extends adjacent to and along the side of the core 1501. The lead 1203 exiting the coil 1202 is bent at portion 2004. The lead 1203 is further bent at portion 2002. Figure 44 is an isometric view, showing a partially transparent core 1501 for the purpose of visibility around the coil 1202 shown in Figure 43 . Figure 45 is a partially transparent top perspective view of Figure 44 showing an inductor 2100 with cut and folded leads. The lead 1201 is formed in a similar manner.

[0143] Figures 46A-46D An example processing method is shown, where leads can be cut and folded to form Figure 43 , 44 and 45. Figure 46A Step 2301 is shown, where the leads 1201 and 1203 extending from the core 1501 can be seen. The leads 1201 and 1203 are made from a folded conductor, which can be seen is similar to Figure 34A and 34Bof the U. The cut can be made along cut line 2302, and similarly along the cut line in lead 1201. Figure 46B A step 2303 is shown, where lead 1203 is unfolded in direction 2304 to produce an L shape extending from core 1501. The same process can be applied to lead 1201. Figure 46C A step 2305 is shown, where leads 1201 and 1203 are flattened or pressed against the side surface of core 1501, and are bent along motion line 2306 at portion 2004. Figure 46D A step 2307 is shown, where leads 1201 and 1203 are bent again in a folding motion 2308 to conform to the top surface portion of core 1501, thereby producing a contact or surface mount portion as shown in Figure 44 、 45 and 46A-46D.

[0144] Figures 47A-47D A process is shown for forming an example of a lead frame for an inductor made by stamping and folding, according to one embodiment. Figure 47A A first step 2401 is shown, where a metal frame 2402 has been formed by stamping a piece of metal. Holes 2404a at the top and 2404b at the bottom can be used to secure the metal in place during the forming process. The metal can be any electrically conductive metal or combination of metals. For example, and not by way of limitation, the metal can be a copper sheet plated with nickel (Ni) and tin (Sn). At the inner top side of frame 2402, a lead portion 2406a extends downward to a coil connection point 2408a, a piece of conductor 2410, and another coil connection point 2408b with another lead 2406b. Slots are formed adjacent to coil connection points 2408a, 2408b. A gap 2412a is formed where the stamping has separated frame 2402 and bottom lead 2406b.

[0145] Figure 47B A step 2403 is shown, which shows the central portion of flat metal conductor 2410 folded perpendicular to the plane of frame 2402. Figure 47C A step 2405 is shown, where coil 2410 is formed from folded conductor 2410, for example by bending, into an "S" shape, such that previous gap 2412a is enlarged to the size of gap 2412b. Alternatively, coil 2410 can be formed into any shape as described herein. Figure 47D An embodiment is shown with a large piece of metal, where multiple frames have been stamped simultaneously as shown at 2407.

[0146] Figure 48 An embodiment is shown utilizing a piece of metal from Figures 47A-47DAn inductor of the punch-formed method of the example. In step 2501, the coil 2410 (not visible) has been loaded into the core 2510, and the lead 2406b has been folded in the motion 2512 bent at 2502 and 2506 to wrap around the surface of the core 2510, creating a surface portion 2504 for the lead 2406b and a contact point 2508 or surface mount terminal. Similar processing methods and formations are performed in relation to the lead 2406a.

[0147] Figures 49A-49D An embodiment is shown for forming the above-described splayed folded conductor associated with various embodiments. The splayed conductor has an H-shape with slots at opposite ends. Figure 49A A step 2601 is shown with a flat piece of conductor 2602. Figure 49B A step 2603 is shown in which the conductor 2602 can be splayed, separated, cut or punched to form an elongated H-shape with a top extension 2604a and a bottom extension 2604b, with slots between the top and bottom extensions 2604a and 2604b. Figure 49C A step 2605 is shown in which the conductor 2602 is folded along a portion 2606 so that the top and bottom extensions 2604a and 2604b are parallel to each other and close to each other. Figure 49D A step 2607 is shown in which the splayed folded conductor can be seen from a front perspective view, folded at the portion 2606 and with the extensions 2604a and 2604b parallel to each other and with a central U-shape.

[0148] Figures 50A-50D A processing method is shown for forming an example of an inductor with the splayed folded conductor of Figure 49 to produce a coil, lead and / or inductor as shown in, for example, Figure 30 , 31 and 32. Figure 50A A step 2701 is shown in which a core 2702 is formed around a coil (inside the core), while leads extend outward from opposite sides of the core. Figure 50B A step 2703 is shown in which the lead extensions 2604a and 2604b are bent away from each other in the direction indicated by 2608. Figure 50C A step 2705 is shown in which the lead extensions 2604a and 2604b are bent over themselves in a downward motion 2610 so that the folded portion partially covers the unfolded portion. Figure 50D A step 2707 is shown in which the lead extensions 2604a and 2604b are bent under the core 2702 in the direction indicated by the arrow 2612. This can be seen from the additional perspective view in Figure 50E and Figure 50F .

[0149] Figures 51A-51H A processing method for forming an example of an inductor coil and an inductor with lead terminals is shown for an alternative embodiment, the lead terminals are formed separately and then joined to the coil, the lead portions extend from the inductor core. Figure 51A Step 2801 is shown where a coil 190 (such as the coil shown in Figure 24 ) is formed from a conductor with lead portions 130a and 130b. Figure 51B Step 2803 is shown where a core 260 is formed around the coil 190. The lead portions 130a and 130b extend outwardly from the core 260. Figure 51C Step 2805 is shown where the lead portions 130a and 130b are trimmed, clipped or cut so that they extend a distance from the core 260. The distance can be related to a thickness, such as the thickness of the flat lead conductor shown in Figure 51D . Figure 51D A flat lead conductor is introduced / generated at step 2807, where one or more flat lead conductors are formed, each flat lead conductor having a base 2802 and extensions 2804a and 2804b (collectively also referred to as 2804), a slot being between the extensions 2804a and 2804b, formed in a general U-shape. The extensions 2804 of each flat lead conductor extension will surround each of the lead portions 130a and 130b. Figure 51E Step 2809 is shown where the U-shaped flat lead conductor is connected to the lead portions 130a and 130b so that the slot between the extensions 2804 is filled by the trimmed lead portions 130a and 130b; the flat lead conductor can be attached by soldering or similar. Also at step 2809, the base 2802 extends beyond the edge surface of the core 260 at the bottom surface of the core 260. Figure 51F and Figure 51G Steps 2811 and 2813 are shown respectively where the base 2802 is bent at the corners 2806 in the direction indicated by the arrows 2808 so that it will wrap around the bottom of the core 260 and serve as a contact point or surface mount terminal. Figure 51H Step 2815 is shown where the inductor is shown partially transparent with the core 260 to show the base 2802 wrapped around the bottom surface of the core 260, and the coil 190 positioned inside the core 260.

[0150] Inductors according to any of the embodiments discussed herein can be used in electronic applications (e.g., DC / DC converters) for one or more of the following purposes: low DC resistance; tight tolerances on inductance and / or DC resistance; inductance below 1 μH; low profile; and high current; efficiency in situations where the circuit and / or similar products cannot meet current requirements. In particular, inductors can be useful in DC / DC converters operating at 1 MHz and above.

[0151] The present invention provides an inductor configured with a high current serpentine coil (e.g., an "S" shaped coil) having a low DC resistance (IHVR). The design simplifies manufacturing by eliminating the soldering process. The design reduces DC resistance by eliminating the high resistance solder joint between the coil and the lead. This allows inductors with inductance ratings below 1 μH to be consistently produced. The "S" shape for the coil optimizes inductance and resistance values compared to similar stamped coil configurations and other non-coil configurations.

[0152] The resulting serpentine coil inductor (e.g., with the S shape described herein) provides a simple and cost effective way to produce consistent inductors, and the produced inductors have a DC resistance that is less than comparable known inductors (e.g., IHLP inductors) and up to 80% of them.

[0153] It is to be understood that the above-referenced elements are merely intended to present the discussion herein according to an example and not by way of limitation. Descriptions of the embodiments in terms of an example are intended to be illustrative only and in no way limit the scope of the present invention. Numerous alternative constructions can be substituted for the disclosed embodiments without departing from the spirit and scope of the present invention. Accordingly, many modifications and variations will be apparent to those skilled in the art upon reading this disclosure, and it is intended to cover in the appended claims all such modifications and variations as fall within the scope of the present invention. Thus, the present invention is not to be limited to the precise details of the embodiments discussed herein.

Claims

1. An electromagnetic component, comprising: A coil formed of a conductive material, the conductive material having a width and a thickness perpendicular to the width, wherein the width is greater than the thickness; A first lead extending from the first end of the coil; A second lead extending from the second end of the coil; The body comprises a magnetic material that surrounds the entire coil and leaves exposed portions of the first lead and the second lead. The body includes a top surface configured to be away from a surface mounting portion of the body, and an opposite bottom surface, a front surface, and an opposite rear surface configured to be positioned adjacent to the surface mounting portion of the body, as well as a first side surface and an opposite second side surface. The depth of the body extends between the front surface and the rear surface, and the height of the body extends between the top surface and the bottom surface, wherein the height is greater than the depth. The central vertical axis of the body extends along the height of the body, and the width of the conductive material extends parallel to the depth of the body. The coil has a first region positioned adjacent to a first side surface of the body and a second region bent inward toward the central vertical axis of the body, wherein the coil has a third region positioned adjacent to the second side surface of the body and a fourth region bent inward toward the central vertical axis of the body, and wherein the first region and the third region are bent away from each other. The exposed portion of the first lead includes a surface-mount portion extending along at least a portion of the bottom surface of the body between a first side surface of the body and the central vertical axis of the body; and The exposed portion of the second lead includes a surface mounting portion extending along at least a portion of the bottom surface of the body between the second side surface of the body and the central vertical axis of the body.

2. The electromagnetic component according to claim 1, characterized in that, The exposed portion of the first lead includes a side portion extending along at least a portion of the first side surface of the body, and wherein the exposed portion of the second lead includes a side portion extending along at least a portion of the second side surface of the body.

3. The electromagnetic component according to claim 1, characterized in that, The coil is formed from flat wire.

4. The electromagnetic component according to claim 1, characterized in that, The coil and leads are formed from continuous sheets of conductive material.

5. The electromagnetic component according to claim 2, characterized in that, The first lead includes a bent portion located between the surface mount portion and the side portion, and wherein the second lead includes a bent portion located between the surface mount portion and the side portion.

6. The electromagnetic component according to claim 3, characterized in that, The coil has a width greater than the thickness of the coil, and the coil is positioned such that the width of the coil extends along the depth of the body.

7. The electromagnetic component according to claim 1, characterized in that, The width of the first lead is less than the depth of the body, and the width of the second lead is less than the depth of the body.

8. The electromagnetic component according to claim 1, characterized in that, The shape of the coil is configured to optimize the path length of the coil to fit the available space within the body of the electromagnetic component, while minimizing resistance and optimizing inductance.

9. The electromagnetic component according to claim 1, characterized in that, The coil is formed by stamping, bending, cutting, folding, or a combination thereof.

10. A method for manufacturing an electromagnetic component, the method comprising the following steps: A coil is formed using a conductive material, the conductive material having a width and a thickness perpendicular to the width, wherein the width is greater than the thickness, wherein at least a portion of the coil extends along a curved path, the coil having a first lead extending from a first end of the coil and a second lead extending from a second end of the coil; A body containing magnetic material is formed around the coil, leaving exposed portions of the first lead and the second lead. The body includes a front surface and an opposite rear surface, a top surface and an opposite bottom surface, and a first side surface and an opposite second side surface. The depth of the body extends between the front surface and the rear surface, and the height of the body extends between the top surface and the bottom surface, wherein the height is greater than the depth. The central vertical axis of the body extends along the height of the body, and the width of the conductive material extends parallel to the depth of the body. A portion of the exposed portion of the first lead is extended to form a surface-mount portion between the first side surface of the body and the central vertical axis of the body, along at least a portion of the bottom surface of the body; as well as A portion of the exposed portion of the second lead extends to form a surface-mount portion between the second side surface of the body and the central vertical axis of the body, along at least a portion of the bottom surface of the body; The coil has a first region positioned adjacent to a first side surface of the body and a second region bent inward toward the central vertical axis of the body. The coil also has a third region positioned adjacent to a second side surface of the body and a fourth region bent inward toward the central vertical axis of the body, wherein the first region and the third region are bent away from each other.

11. The method according to claim 10, characterized in that, Further includes: At least a portion of the exposed portion of the first lead is extended to form a side portion extending along at least a portion of the first side surface of the body, and at least a portion of the exposed portion of the second lead is extended to form a side portion extending along at least a portion of the second side surface of the body.

12. The method according to claim 10, characterized in that, The coil is formed from flat wire.

13. The method according to claim 10, characterized in that, The coil and leads are formed from continuous sheets of conductive material.

14. The method according to claim 11, characterized in that, The first lead includes a bent portion located between the surface mount portion and the side portion, and wherein the second lead includes a bent portion located between the surface mount portion and the side portion.

15. The method according to claim 12, characterized in that, The coil has a width greater than the thickness of the coil, and the coil is positioned such that the width of the coil extends along the depth of the body.

16. The method according to claim 10, characterized in that, The width of the first lead is less than the depth of the body, and the width of the second lead is less than the depth of the body.

17. The method according to claim 10, characterized in that, The shape of the coil is configured to optimize the path length of the coil to fit the available space within the body of the electromagnetic component, while minimizing resistance and optimizing inductance.

18. The method according to claim 10, characterized in that, The coil is formed by stamping, bending, cutting, folding, or a combination thereof.

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