Electromagnetic components and methods for manufacturing electromagnetic components

Abstract

This invention provides a simple and cost-effective method for manufacturing inductors, including inductors with improved DC resistance and inductance of 1 μH or less. [Solution] An electromagnetic component (inductor 3100) having a coil 3150 made of a conductive material, a first lead 3140a extending from a first end of the coil, and a second lead extending from a second end of the coil, wherein at least a portion of the exposed part of the first lead has a contact portion 3130 which is a surface mount portion that extends along at least a portion of the bottom surface of the main body adjacent to the first side surface of the main body, and at least a portion of the exposed part of the second lead has a contact portion which is a surface mount portion that extends along at least a portion of the bottom surface of the main body adjacent to the second side surface of the main body.

Description

Related Applications

[0001] This application claims priority to U.S. Provisional Patent Application No. 62 / 382,182, filed on August 31, 2016. The entire disclosure of this specification is incorporated herein by reference.

Technical Field

[0002] This application relates to the field of electronic components, particularly inductors and methods of manufacturing inductors.

Background Art

[0003] Inductors are generally passive two-terminal electronic components in which the resistance changes in the current flowing through these components. Inductors have a conductor such as a wire wound in a coil shape. When current flows through the coil, energy is temporarily stored in the magnetic field within the coil. When the current flowing through the inductor changes, a time-varying magnetic field induces a voltage in the conductor according to Faraday's law of electromagnetic induction. As a result of operating based on the magnetic field, inductors can generate electric and magnetic fields that interfere with the performance of other electronic components, inhibiting or degrading this performance. Further, other electric fields, magnetic fields, and electrostatic charges (electrostatic charging) from electrical components on the substrate also tend to interfere with the performance of inductors, inhibiting and / or degrading this performance.

[0004] In the case of some known inductors, generally, they have a core body of a magnetic material, with a conductor provided inside, and in some cases, this conductor is formed as a wound coil. Examples of known inductors are disclosed in USP6,198,375 (inductor coil structure) and USP6,204,744 (high-current small inductor), and both disclosures are incorporated herein by reference. Attempts to improve the design and reduce the manufacturing cost of inductors are common. Thus, there is a need for a simple and cost-effective manufacturing method for manufacturing inductors, including inductors with an inductance of 1 uH or less with improved DC resistance.

Prior Art Documents

Patent Documents

[0005] [Patent Document 1] USP6,198,375 [Patent Document 2] USP6,204,744 [Overview of the project]

[0006] An inductor and a method for manufacturing the inductor are disclosed herein. The inductor may have a coil formed from a conductor. The coil may have two lead portions, which extend from opposite ends of the coil. A body surrounds the coil and a portion of the first and second lead portions. The lead portions can be wound around the body, forming contact points such as surface mount terminals on the outer surface of the conductor.

[0007] A method for manufacturing an inductor is also disclosed. Conductors such as metal plates, metal strips, and metal wires can be formed in the form of a coil and two lead portions coming from opposite ends of the coil. The coil can be formed in a specific shape, such as a zigzag or winding shape, and preferably in an S-shape. The conductor can be folded, bent, and / or stamped to form a coil and two lead portions. The conductor body can surround the coil and the body can be pressed around the coil, causing the lead portions to protrude from the body. Next, the lead portions can be bent and wrapped around the body, forming a contact point on one outer surface of the body.

[0008] One aspect of the present invention provides a flat inductor coil having a lead portion formed as a single piece by stamping (pressing, punching) a sheet of metal such as copper. Other conventionally known conductive materials, such as those used in inductor coils, can also be used without departing from the scope of the present invention. Depending on the specific application, insulating material may be used around or between parts of the coil and / or lead portion, if necessary. The lead portion can be aligned along a generally linear path and has a certain width. The coil may have portions that extend outside the width of the lead portion, are curved, or preferably spaced apart from the center of the coil, and these portions are connected by connecting portions that cross the center of the coil at a certain angle. In its initial state, the coil and lead portion can exist in a plane during manufacturing, such as during formation from a flat piece of metal. The lead portion can ultimately be bent around and below the inductor body surrounding the coil. In one embodiment of the finished inductor, it is preferable that all parts of the coil are contained within a plane. The coil is housed by pressing it around the coil of the inductor body.

[0009] The coil extending between the lead portions and connecting them has a certain shape. In a preferred embodiment, the coil joins the opposing lead portions (or lead portions) and has a first curved portion and a second curved portion as a whole. The curved portions are preferably curved apart from and / or around the center of the coil, and are therefore considered to have an "outward" curve. Each curved portion of the coil can extend along a part of the circumference of a circular path that curves around the center of the central portion. Each curved portion has a first end extending from one of the lead portions and a second end opposite the first end. The central portion or connecting portion extends at a predetermined angle between the second ends of the first and second curved portions and crosses the center of the central portion. As a result, a zigzag-shaped coil is formed that can take the shape of an "S" when viewed from above or below.

[0010] Multiple coil layers can be formed. Insulating material can be provided between the multiple coil layers. The coil of the present invention can be formed as a flat, circular, or elliptical metal piece.

[0011] In one embodiment of the present invention, it is preferable that the coil and lead portion of the present invention be formed as a flat, completely integrated piece by stamping or the like. In other words, no interruptions or breaks are observed in the coil from one lead portion to the opposing lead portion. The lead portion and coil are formed simultaneously by stamping during manufacturing. The coil does not need to be joined to the lead portion by welding or the like. In other embodiments, the lead portion is formed separately and then joined to the coil. [Brief explanation of the drawing]

[0012] [Figure 1] This is an isometric projection view showing the induction element of the present invention partially transparent. [Figure 2] This is an end view showing the induction in Figure 1 as seen from the lead end. [Figure 3] This is an end view showing the inductor in Figure 1 as seen from the non-lead end. [Figure 4A] This is a view from above of the inducer shown in Figure 1, with a portion of it made transparent. [Figure 4B] This is a side view showing the inducer in Figure 1 as seen from the lead edge. [Figure 4C] This is a side view of the inducer in Figure 1, as seen from the non-lead edge. [Figure 5] This is a schematic diagram illustrating a method for manufacturing an inducer according to one embodiment of the present invention. [Figure 6] This figure shows the lead frame formed in the stamping process using the method shown in Figure 5. [Figure 7] Figure 5 is a top-down perspective view showing the lead frame formed in the stamping process using the method described in Figure 5. [Figure 8] This figure shows the portion formed by the pressing process in the method shown in Figure 5. [Figure 9]It is a top-down perspective view showing the portion formed in the pressing process in the method of FIG. 5. [Figure 10] It is a view showing the portion formed in the pressing process in the method of FIG. 5. [Figure 11A] It is a top-down perspective view showing the portion formed in the pressing process in the method of FIG. 5. [Figure 11B] It is a side perspective view showing the portion formed in the pressing process in the method of FIG. 5. [Figure 12] It is a view showing the lead frame in an embodiment of the inductor coil of the present invention. [Figure 13] It is a top view showing the lead frame and the inductor coil of FIG. 12. [Figure 14] It is a view showing the lead frame in an embodiment of the inductor coil of the present invention. [Figure 15] It is a top view showing the lead frame in an embodiment of the inductor coil of the present invention. [Figure 16] It is a view showing another embodiment of the lead frame and the coil of the present invention. [Figure 17] It is a perspective view showing the inductor configured according to an embodiment of the present invention. [Figure 18A] It is a perspective view showing the inductor configured according to the present invention. [Figure 18B] It is a perspective view showing the inductor configured according to the present invention. [Figure 19] It is a view showing the inductor with the second body seen through and the core and the body removed. [Figure 20] It is a top view showing the coil from the configured inductor with other parts of the inductor 3100 removed. [Figure 21] It is a bottom view showing the coil from the configured inductor with other parts of the inductor 3100 removed. [Figure 22A] It is a view showing the body from the configured inductor with other parts of the inductor removed. [Figure 22B] It is a view showing the body from the configured inductor with other parts of the inductor removed. [Figure 23] This diagram shows the connection of the insulating coil by welding and / or soldering. [Figure 24] This is an isometric projection drawing showing an embodiment of an inductor coil. [Figure 25] This is a side view showing an embodiment of an inductor coil. [Figure 26] This is a side view showing a main body embodiment in which the induction lead portion is formed around the side of the core. [Figure 27] This is a side view showing an embodiment of a core in which the main body is made transparent so that the inside of the coil can be seen, and an inductor lead portion is formed around the side of the core. [Figure 28] This is an isometric projection view showing an embodiment of the main body in which the induction lead portion is formed around the core side. [Figure 29] This is an isometric projection drawing showing an embodiment of the main body in which the core is made transparent so that the inside of the coil is visible, and an inductor lead portion is formed around the side of the core. [Figure 30] This is a bottom perspective view showing an embodiment of the main body with the lead portion formed therein. [Figure 31] This is an isometric projection drawing showing an embodiment of an inductor with multiple coils. [Figure 32] This is an isometric projection drawing showing an embodiment of an inductor with the coil and its components attached. [Figure 33] This figure shows an embodiment of a method for manufacturing an inducer according to one embodiment. [Figure 34A] This is an isometric projection drawing showing an example of a foldable conductor. [Figure 34B] This is a front perspective view showing an embodiment of a foldable conductor. [Figure 34C] This is a front perspective view showing an embodiment of an insulated, foldable conductor. [Figure 35] This is an isometric projection drawing showing an example of an inductor coil manufactured from a foldable conductor. [Figure 36] This is an isometric projection showing an example of an inductor coil manufactured from a splayed and folded conductor. [Figure 37]This is an isometric projection drawing showing an example of an inductor coil manufactured from a foldable conductor with a lead portion formed therein. [Figure 38] This is an isometric projection drawing showing an embodiment of the main body in which the core is made transparent so that the inside of the coil is visible, and an inductor lead portion is formed around the side of the core. [Figure 39] This is a top perspective view showing an embodiment of the main body in which the core is made transparent so that the inside of the coil is visible, and an inductor lead portion is formed around the side of the core. [Figure 40] This is an isometric projection drawing showing an example of a coil manufactured from a stretched and folded conductor with a lead portion formed. [Figure 41] This is an isometric projection drawing showing an embodiment of the main body in which the core is made transparent so that the inside of the coil is visible, and an inductor lead portion is formed around the side of the core. [Figure 42] This is a top perspective view showing an embodiment of the main body in which the core is made transparent so that the inside of the coil is visible, and an inductor lead portion is formed around the side of the core. [Figure 43] This is an isometric projection drawing showing an example of a coil manufactured from a stretched and folded conductor with a lead portion formed. [Figure 44] This is an isometric projection drawing showing an embodiment of the main body in which the core is made transparent so that the inside of the coil is visible, and an inductor lead portion is formed around the side of the core. [Figure 45] This is a top perspective view showing an embodiment of the main body in which the core is made transparent so that the inside of the coil is visible, and an inductor lead portion is formed around the side of the core. [Figures 46A-46D] This figure shows an embodiment of a method for manufacturing an inducer according to one embodiment. [Figures 47A-47D] This figure shows an embodiment of a method for manufacturing an induction component according to one embodiment. [Figure 48] This figure shows an embodiment of a method for manufacturing an inducer according to one embodiment. [Figures 49A-49D] This figure shows an embodiment of a method for manufacturing an inductor component according to one embodiment. [Figures 50A-50F] This figure shows an embodiment of a method for manufacturing an inducer according to one embodiment. [Figure 51A-51H] This figure shows an embodiment of a method for manufacturing an inducer according to one embodiment. [Modes for carrying out the invention]

[0013] The terms used in the following description are for convenience only and are not intended to be limiting. The terms “right,” “left,” “up,” and “down” indicate the direction in the attached drawings to which they should be referenced. Unless otherwise specified, singular expressions in the claims and corresponding parts of the specification refer to one or more parts. In this specification, these terms encompass the words and derivatives mentioned above, as well as synonyms. “At least one” preceding individual units such as “A, B, or C” may refer to A, B, or C individually, or to any combination thereof. Note that some drawings are partially transparent for illustrative and demonstrable purposes only, but this does not indicate that the elements themselves are transparent in their final manufactured form.

[0014] Figure 1 shows an embodiment of an inductor 3100 configured according to one embodiment of the present invention. This inductor has a molded coil 3150 formed from a conductor such as a metal plate, metal sheet, or metal strip. The molded coil 3150 can be configured in a specific shape, can improve efficiency and performance with a small capacity, and is easy to manufacture. The coil 3150 and lead portions 3140a and 3140b can be flat in their initial state, and are preferably formed by stamping a conductive sheet such as a copper sheet that becomes a flat coil, as shown in Figure 6, for example. The surface of the coil 3150 may be somewhat or slightly circular, or bow-shaped, or curved, depending on the method used to form the coil 3150. Its side edges may also be circular or curved. Metals that can be used to form the coil and lead portions include copper, aluminum, platinum, and other metals that have been conventionally known to be used in inductor coils. The term "flat" used here means "flat overall," and some manufacturing tolerances are acceptable. Furthermore, the flat surface of the coil 3150 may be somewhat or slightly circular, bow-shaped, curved, or wavy, depending on the method used to form the coil 3150. Similarly, its side edges may be somewhat or slightly circular, bow-shaped, curved, or wavy, and all of these are included in the definition of "flat."

[0015] After stamping, a residual copper strip called a carrier strip or frame portion remains, and at least one of these strips has a continuous hole at the opposite end of the lead portion. These holes can be used for alignment with the manufacturing equipment. The stamped copper coil, lead portion, and frame portion can be collectively called a "lead frame." Examples are shown in Figures 6 to 11. In the initial state, such as during manufacturing, the molded coil and lead portion can be located in the same plane. Each lead portion 3140a and 3140b can ultimately be bent around the inductor body, and the lead portion contact portion 3130 can be bent below the bottom of the inductor body. It is preferable that the lead portions 3140a and 3140b and the coil 3150 be formed as a single piece without welding.

[0016] In the embodiments shown in Figures 1, 4A, 5, and 6, the coil 3150 has a zigzag or winding shape that, when viewed from above in the corresponding drawings, takes the form of an "S" shaped coil or "S-coil". The central portion 3151 of the coil 3150 intersects the center of the coil perpendicularly. The first curved portion C1 has a first end 3152 extending from one of the lead portions 3140b and a second end 3153 curving around the center of the coil 3150. The second curved portion C2 has a first end 3155 extending from another lead portion 3140a and a second end 3154 curving in the opposite direction from the first curved portion C1 around the center of the coil 3150. Each curved portion forms an arc surrounding a part of the center of the coil 3150. Each curved portion can pass through a circumferential path around the center.

[0017] The central portion 3151 of the coil 3150 can be formed as a flat, straight strip, extending from the second end 3153 of the first curved portion C1 across the center of the coil 3150 to the second end 3154 of the second curved portion C2. This central portion 3151 completes the "S" shape.

[0018] This S-coil or "S" shape is a preferred embodiment. Other configurations are also possible, as will be partially described below, including arc-shaped coils, Z-coils, and N-coil configurations. A coil configuration in which a portion of the coil intersects the centerline or central portion of the coil or inductor body and extends along a winding path between lead portions can be considered a "zigzag-shaped" coil. For example, but are not limited to, S-coils, Z-coils, N-coils, and other shaped coils having a winding path that travels from one lead portion to another can also be considered "zigzag-shaped" coils. A zigzag-shaped coil may differ from a "winding" coil, which surrounds the central portion of the inductor core but is formed from wire that does not intersect or cross the central portion or centerline of the inductor core.

[0019] As shown in Figures 4A and 7, the first path P1 of the zigzag-shaped coil 3150 of the present invention extends in a first direction from one side of the inductor to the opposite side. For example, this first path P1 extends from the side of the inductor having lead portion 3140b to the opposite side of the inductor having lead portion 3140a. In a preferred embodiment, the first path P1 is a curved path or arc-shaped path that curves and separates from the central portion of the coil.

[0020] The second path P2 takes over from the first path P1 and extends in the second direction, along the center line L of the coil. A It intersects with the center line L of the coil. In a preferred embodiment, the second path P2 is inclined and folds back from the end of the first path P1 to the beginning of the first path P1. A It intersects orthogonally with respect to the first path. For example, the second path P2 extends so as to fold back from the side of the inductor having lead portion 3140a to the opposite side of the inductor having lead portion 3140b. The second path P2 can be a straight path overall along most of its length.

[0021] The third path P3 takes over from the second path P2 and extends in a third direction from one side of the inductor to the opposite side. For example, the third path P3 extends from one side of the inductor having lead portion 3140b to the opposite side of the inductor having lead portion 3140a. In a preferred embodiment, the third path P3 is a curved or arc-shaped path that curves away from the central portion of the coil. In a preferred embodiment, the first and third directions are the same as a whole but curve in opposite directions and both are different from the second direction. Thus, it is preferable that the combination of paths P1, P2 and P3 constitutes a continuous zigzag path that does not interfere with each other and is formed from the same conductor.

[0022] The first path P1 and the third path P3 can follow curved paths, straight paths, or a combination of curved and straight paths. For example, as shown in another embodiment in Figure 16, in the case of an "N" shaped coil, the first path P1 is linear overall from the first side of the inductor to the opposite side, the second path P2 is perpendicular to the center line LA and turns back toward the first side, and the third path P3 is linear overall along most of the total length of those paths from the first side of the inductor to the opposite side.

[0023] In the case of an "S"-shaped, "N"-shaped, or "Z"-shaped coil, spaces or gaps are provided between each part of the coil. For example, spaces or gaps are provided between the curved portion C1 and the central portion 3151, and between the curved portion C2 and the central portion 3151. In the embodiment of the "S"-shaped coil, as shown in Figures 4A, 7, 25, and 39, the shape of these spaces or gaps is semicircular overall. In the embodiment of the "N"-shaped coil, as shown in Figure 16, the shape of the spaces or gaps is triangular overall, and in the "Z"-shaped coil, the shape of the spaces or gaps is similarly triangular overall.

[0024] The shape of the coil 3150 is optimized by designing the path length so that it fits into the available space inside the inductor while minimizing resistance and maximizing inductance. Alternatively, the design may be such that the ratio of the usable space to the available space inside the inductor body is high. In the embodiments of the present invention, the coil 3150 is preferably flat and substantially oriented in a plane.

[0025] In the case of an "S" shaped coil, the inductance and resistance values ​​are optimized compared to other non-coiled conductor structures. For an S coil, an inductance value in the range of 0.05uH can be obtained at 2.2mΩ in a 1212 mounting size (approximately 0.12 inches x 0.12 inches x 0.04 inches). Furthermore, for an S coil, an inductance value in the range of 0.15uH can be obtained at 0.55mΩ in a 4040 mounting size (approximately 0.4 inches x 0.4 inches x 0.158 inches), an inductance value of 0.075uH can be obtained at a 1616 mounting size, and an inductance value of 0.22uH can be obtained at a 6767 mounting size.

[0026] In the embodiments shown in Figures 1 to 4, in which a portion of the inductor body is made transparent to allow the interior to be seen, the completed inductor 3100 of the present invention has an inductor body, shown partially transparent, which is formed around, or pressed onto, or otherwise housed around, at least a portion of the coil and lead portion, and this inductor body has a first body portion 3110 and a second body portion 3120. As shown in Figures 1 to 4C, the first body portion 3110 and the second body portion 3120 sandwich the molded coil 3150 and the lead portions 3140a and 3140b between them, or are pressed around them, or otherwise housed therein to form the completed inductor 3100. As shown in Figures 2 and 3, from the side, the first body portion 3110 of the inductor 3100 appears to be at the bottom, and the second body portion 3120 appears to be at the top.

[0027] In the embodiments shown in Figures 2 and 3, which are partially transparent, the first body portion 3110 and the second body portion 3120 are used as separate or discrete parts to manufacture the completed inductor 3100, as shown in the figures, but they may be a single body or an integrated body. In another embodiment, any number of body portions can be used. The body can be formed from an iron-based material. The body may also be made of, for example, iron, a metal alloy, or ferrite, or a combination of these, or other materials known in the inductor field that are used to form such bodies. As further described below, the first body 3110 and the second body portion 3120 may be made of powdered iron or similar materials. Other materials known in the inductor field that can be used in the present invention, such as known magnetic materials, can be used to form the body or body portions. For example, as described in USP6,198,375 (Inductor coil structures) and USP6,204,744 (High-current miniature inductors), a magnetic molding material having powdered iron, fillers, resins, and lubricants can be used for the main body. The first main body portion 3110 and the second main body portion 3120 can be formed using the same material and in a similar manner, but as is already known, the first main body portion 3110 and the second main body portion 3120 may also be formed from different materials and in different manners.

[0028] The first body portion 3110 and the second body portion 3120 surround the coil and part of the lead portion, and are pressed or overmolded around the coil 3150, leaving the lead portions 3140a and 3140b exposed in the initial state until they are folded under the first body portion 3110, as illustrated in the final state of the partially transparent embodiment in Figures 4A to 4C. In the finished inductor, i.e., the “component”, each lead portion 3140a and 3140b can extend along the side of the first body portion 3110, as shown in Figure 4B. Each lead portion 3140a and 3140b terminates at a contact portion 3130 folded under the first body portion 3110, as shown in Figure 1.

[0029] As shown in Figure 1, a shelf 3160, step, or recess can be formed by the portion of the lead 3140a that is bent along the outside of the inductor body 3110. This shelf 3160 is formed adjacent to the portion where the lead meets the coil 3150, as also shown in Figure 3. This shelf 3160 can transition to a smaller diameter than the rest of the lead 3140. The presence of the shelf 3160 makes the thickness of the lead drawn out from the body thinner, improving the ability to form the inductor (component). The presence of this shelf 3160 also increases the space inside the body to accommodate the coil. This shelf 3160 is not necessary in all cases, and the inductor, coil, or lead of the present invention can be formed without such a shelf.

[0030] As can be seen from Figure 1, the coil 3150 configuration allows for the addition of a coil notch 3170 adjacent to the inside of the coil where the shelf portion 3160 transitions to curved portions C1 and C2. Because of this coil notch 3170, the lead portion and the coil can be separated; that is, a space can be created between them.

[0031] Figure 2 shows that the lead contact portion 3130 can be positioned in contact with the bottom portion 3111 of the outer surface of the lead contact portion 3130, because the lead contact portion 3130 has a first notch 3180, i.e., a groove, in the first body portion 3110. Figure 3 shows that the lead contact portion 3130 can also be positioned in contact with the bottom portion 3111 of the outer surface of the lead contact portion 3130, because the first body portion 3110 also has a second notch 3190, i.e., a groove.

[0032] Figures 4A to 4C are additional diagrams showing the inductor 3100. Specifically, Figure 4A shows a part of the inductor 3100 made transparent, making the coil 3150 visible. Figure 4B is a side view of the inductor 3100 as seen from the edge of the lead portion 3140a, and Figure 4C is a side view showing the inductor 3100 as seen from the edge of the non-lead portion. As shown in the figures, the coil 3150 can be "S" shaped or "Z" shaped depending on the viewing direction. That is, as shown in the attached drawings, when viewed from above, the "S" shape or "Z" shape may be a mirror image of this shape. For example, the viewing direction of the coil 3150 can be rotated 180 degrees to form either an "S" shape or a "Z" shape.

[0033] Figure 5 shows the manufacturing method 3500 for the inductor 3100. In step 3510, the inductor is manufactured by stamping to form lead portions and functional portions that form a coil of the desired shape between these lead portions. A flat sheet of copper is stamped to form electrical lead portions, one on one side of the component and the other on the other side of the component, and functional portions that constitute a coil connecting the two lead portions formed in an "S" shape. The S-coil inductor obtained by stamping ensures a simple and cost-effective method for manufacturing inductors with a low variation in inductance of less than 1 uH. The S-coil obtained by stamping ensures a simple and cost-effective method for manufacturing inductors with a low variation in DC resistance of less than 80%, which is more efficient than current manufacturing methods for smaller, higher-current components.

[0034] As can be seen from Figure 6, in the case of a copper sheet, there are residual copper strips, and these strips may have progressive holes that are positioned to fit the manufacturing equipment. These are called carrier strips or frame portions. The copper sheet obtained by stamping is called a “leadframe”.

[0035] Continuing the explanation of the method shown in Figure 5, in step 3520, pressed powder such as powdered iron is injected into the die and pressed to form the main body around the coil where the lead portion extends. For example, the main body can be pressed to form a desired shape with a body similar to that of an IHLP inductor. Hereinafter, the iron core and lead frame will be referred to as "parts".

[0036] In step 3530, the above-mentioned parts are cured in a furnace. During this curing process, the cores are joined together as a single unit.

[0037] After curing in step 3540, the carrier strip is separated from the lead portion of the lead frame by trimming.

[0038] The lead portion is folded around the body of the induction element, and the lead contact portion is formed in step 3550.

[0039] The stamped coil and lead sections can also be assembled using other conventionally known core materials.

[0040] Figures 6 and 7 show the lead frames 3600 formed in the stamping step (step 510) of method 3500. Figure 6 is an isometric projection showing the lead frame 3660, and Figure 7 is an overview of the lead frame 3600. Figures 6 and 7 show the lead frame 3600 having a structure consisting of two coils 3150 as part of the lead frame. Any number of coils can be formed along the lead frame in the manufacturing process, and showing two coils is for ease of illustration and understanding only.

[0041] The lead frame 3600 has a first frame portion 3620 and a second frame portion 3630 (sometimes called a "carrier strip") at the ends of the lead portion, and a coil is provided in the center between the first frame portion 3620 and the second frame portion 3630. The inductor has a lead portion 3140 and a coil 3150. A shelf portion 3160 is adjacent to the lead portion 3140a. The coil 3150 has a coil notch portion 3170. The first frame portion 3620 has an alignment hole pattern 3610. Because of this pattern 3610, alignment can be performed as part of the manufacturing process, such as during pressing.

[0042] Figures 8 to 11 show the induction component 3800 formed in the pressing process (process 3520) of the method described in relation to Figure 5. Figure 8 is an isometric projection showing the component 3800 formed in the pressing process, showing only the inner core 3115 surrounding the coil. Figure 9 is an overview view of the component 3800 shown in Figure 8. Figure 10 is an isometric projection showing the component 3800 formed in the pressing process, showing one induction containing the main body 3110 and 3120, with the main body 3110 and 3120 partially transparent and the inner core 3115 and coil 3150 visible. Figure 11A is an overview view of the component 3800, with the outer main body 3125 partially visible / transparent, showing the positions of the inner core 3115 and coil 3150. Figure 11B is a partially transparent side view showing the component 3800 of Figure 10.

[0043] Component 3800 has a lead frame 3600, which has a first frame portion 3620 and a second frame portion 3630 at the opposing ends of lead portions 3140a and 3140b, and a coil 3150. A shelf portion 3160, recess, or step portion is adjacent to the lead portion 3140a. The coil 3150 has a coil notch portion 3170. The first frame portion 3620 has a position alignment hole pattern 3610. Because of this pattern 3610, position alignment can be performed during the manufacturing process.

[0044] In one embodiment of the present invention, the component 3800 has a body 3125 and a portion of a lead portion 3140 pressed onto the coil 3150, with the lead portions 3140a and 3140b and portions of the first frame portion 3620 and the second frame portion 3630 exposed. The body 3125 has a first body portion 3110 and a second body portion 3120, as already described. The body 3125 can be formed by pressing a ferrite material around the coil 3150. The body 3125 may be separate from the inner core 3115, or they may be formed together as a single component. The inner core can be formed in different ways. That is, the material may be formed separately from, for example, ferrite and placed on top of the coil, and then the body may be pressed around the coil, or the inner core may be pressed separately onto the coil using, for example, a certain type of iron, and finally the outer core may be pressed around the inner core using the same or a different type of material. The inner core can be used as a standalone source of magnetic permeable material or as a standalone body of the device, without using the outer core. When the inner core is used, the inner core 3115 can be housed within the body 3125. Furthermore, the body 3125 may be integrated with the inner core 3115, or used in combination with it. Moreover, the body may consist solely of the inner core.

[0045] Figures 10, 11A, and 11B show the inductor body 3125, including the body 3125 and the inner core 3115, and also show the body 3125 in a transparent form. The inner core 3115 may or may not be separate from the body 3125, but is shown as separate for the purpose of illustration in Figures 8 and 9. The inner core 3115 is cylindrical as a whole and has a channel formed to receive the central portion 3151 of the coil 3150. The curved portions C1 and 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 integrated, they form the inner core 3115, or it can be enclosed by other means.

[0046] In one embodiment, as shown in the examples in Figures 12 to 14, the inductor can be formed with multiple stacked coils. Figure 12 is an isometric projection showing an inductor 3100 with two cores. As shown in Figure 12, with the coils attached to the lead frame, the second coil 3150b is aligned with the first coil 3150a and fixed to it by stacking or other means. Soldering can be used to integrate coils 3150a and 3150b. This soldering not only aligns and maintains the coils but also electrically connects the first coil 3150a and the second coil 3150b. In the case of the structure with multiple coils shown in Figure 12, it can be formed by aligning and fixing coils held by two lead frames. Alternatively, it may be formed by aligning the second coil, which has already been separated by the lead frame and / or lead portion, with the first coil and fixing it to the first coil. After alignment and fixing are complete, the lead frame of the second coil 3150b is removed, and the next processing step is performed to expose the individual lead portion 3140.

[0047] Figure 13 is a top view showing a multi-layered embodiment having multiple coils as shown in Figure 12. Figure 13 shows only the second coil 3150b. Since the lead frame corresponding to the second coil 3150b has been removed, the lead portion 3140a is exposed from the lead frame of the first coil 3150a. When formed by aligning the two lead frames, a boundary portion 3145b or edge portion can be formed in the portion of the second coil 3150b where the lead frame was removed. By insulating between each coil layer, it is also possible to separate the coils from each other within the main body. Depending on the case, such insulation can improve the performance of the inductor. Examples of insulating materials include Kapton®, Nylon®, Teflon®, and other known insulating materials. The ends of the coils can be connected using methods such as welding and / or soldering.

[0048] Figure 14 shows an inductor 3100 with multiple coils, specifically a design with three coils. As shown in the figure, the first coil 3150a is housed in a lead frame, the second coil 3150b is positioned on top of the first coil 3150a and fixed to it, and the third coil 3150c is positioned on the bottom of the first coil 3150a and fixed to it. When fixing coils 3150a, 3150b and 3150a, 3150c, soldering 3232 can be used as shown in Figure 23. Using soldering in this way not only allows for alignment and maintenance, but also enables electrical connection between the first coil 3150a and the second coil 3150b. After alignment and fixing, the lead frames of the second coil 3150b and the third coil 3150c are removed, and the next processing step is performed to expose the individual lead portions 3140.

[0049] Since the lead frame corresponding to the second coil 3150b has already been removed, the lead portion 3140a of the first coil 3150a is exposed from the lead frame. A boundary portion 3145b is formed because the lead frame of the second coil 3150b has been removed. Since the lead frame corresponding to the third coil 3150c has already been removed, the lead portion 3140a of the first coil 3150a is exposed from the lead frame. A boundary portion 3145c is formed because the lead frame of the third coil 3150c has been removed. As shown in Figure 23, the first coil 3150a, the second coil 3150b, and the third coil 3150c may or may not be separated by the insulation 3231.

[0050] Figure 15 shows the configuration of a coil having a smaller lead frame with only one carrier strip 3261. In Figure 15, the components of the stamped “S”-shaped coil 3150 are the same as in Figure 1. This “S”-shaped coil 3150 has a first lead portion 3140a connected to the carrier strip 3621, and a second lead portion 3140b extending from the opposite side of the coil 3150.

[0051] Figure 16 shows another shape of the inductor coil. Figure 16 shows an “N”-shaped coil 3159 (where “N” rises relative to the length of the carrier strip 3561). This “N”-shaped coil 3159 has a first portion N1 that connects to the second lead portion 3140b, and a second portion N2 that connects to the first lead portion 3140a that connects to the carrier strip 3621. The two portions N1 and N2 are connected by a central portion N3 of the coil 3159. The two portions N1 and N2 in Figure 16 are linear as a whole, in contrast to the curved portions C1 and C2 in Figure 1. The outer corners of portions N1 and N2 (where these portions bend over or meet the lead portions 3140a and 3140b) are curved and spaced apart from the central portion N3 of the coil.

[0052] Figure 17 shows an induction element 3100 assembled according to the present invention. The induction element 3100 has a first body 3110 and a second body 3120. A lead portion 3140 is also shown. As shown in the figure, the lead portion 3140 has a stepped portion adjacent to the part where the lead portion is drawn out from the body.

[0053] Figures 18A and 18B show the inductor 3100 assembled according to the present invention.

[0054] Figure 19 shows the inductor with the second body 3120 partially transparent and the upper part removed. The coil 3150 has connecting lead portions 3140a and 3140b. The coil 3150 has regions C1 and C2 equipped with a cross member 3151.

[0055] Figures 20 and 21 show the coil 3150 with the other parts of the assembled inductor 3100 removed (for example, with the lead portion bent). Figure 20 is an isometric projection of the coil 3150 viewed from above, and Figure 21 is an isometric projection of the coil 3150 viewed from below. The coil 3150 has a connecting lead portion 3140. The coil 3150 has a curved region or arc-shaped region or portion C1 and C2 with a cross member or central portion 3151.

[0056] Figures 22A and 22B are transparent views of embodiments of the assembled inductor 3100, with the other parts of the inductor 3100 removed, specifically the first body 3110 (Figure 22B) and the second body 3120 (Figure 22A). The first body 3110 and the second body 3120 have inner core recesses 3221 and 3222 for receiving or housing another inner core, and channels for coils, as described above. The first body 3110 and the second body 3120 can also form an inner core and have channels for coils, as described above. In one embodiment, the top of the first body 3110 meets the bottom of the second body 3120, forming the inner core recesses 3221 and 3222.

[0057] Figure 24 is an isometric projection showing another embodiment of the coil of the present invention. The illustrated coil 190 has lead portions 130a and 130b, which extend from opposite ends of the coil 190. The coil 190 can be formed from a conductor 100 having a width of 150 and a height (or thickness) of 160. The formed coil and lead portions 130a and 130b can be called a “lead frame”. The conductor 100 can be formed from a metal strip. Metals that can be used to form the coil include copper, aluminum, platinum, and other metals that have been conventionally used as inductor coils. Metals that can be used for the lead portions include copper, aluminum, platinum, and other metals that have been conventionally used as inductor lead portions.

[0058] In a preferred embodiment, 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 corresponds to the width of the conductor 100. In another orientation of the coil, the height of the conductor may be greater than the width, and the height of the coil may correspond to the height of the conductor. The conductor 100 can be a wire, a metal strip, a metal sheet formed by stamping, or other conventionally known conductive material. The conductive material preferably has a flat surface and a flat edge. The conductive material may have a circular surface, a rectangular surface, an elliptical surface, a circular edge, a rectangular edge, an elliptical edge, a circular shape, a rectangular shape, or an elliptical shape, either before or after forming the coil of the present invention. Thus, the coil and / or lead portion may have a circular surface, a circular edge, a curved surface, or a curved edge.

[0059] In a preferred embodiment, the coil 190 may have a first curved portion 110 and a second curved portion 120. Preferably, the curved portions 110 and 120 are curved so as to be spaced apart from the central portion 140 of the coil 190 and curved around the central portion 140. That is, they should be curved "outward" with respect to the central portion 140. Each of the curved portions 110 and 120 of the coil 190 may extend along a part of the circumference of a curved circular path or arc-shaped path around the central portion 140 of the coil 190.

[0060] Referring to Figure 25, the first curved portion 110 may have a first end 180a connected to the first lead portion 130a and a second end 115 that curves into the central portion 140. The second curved portion 120 may have a first end 180b connected to the second lead portion 130b and a second end 125 that curves into the central portion 140. The central portion 140 preferably crosses the center of the coil and extends substantially at a right angle or at an inclined angle from the second end 115 of the first curved portion 110 to the second end 125 of the second curved portion 120.

[0061] As shown in Figure 25, the lead portions 130a and 130b can be bent or further shaped after being offset from the center line 131 that extends along the length of the coil. In another embodiment, the lead portions 130a and 130b can be aligned along the center line that extends along the length of the coil.

[0062] An example of a zigzag-shaped coil having an "S" shape when viewed from above, as shown in the figures, is illustrated in Figures 24, 25, 27, 29, 31, and 32. Alternatively, this coil may be formed into other suitable shapes such as "Z" or "N". The length of the conductor may vary during manufacturing, as it is affected by the number of inductors to be manufactured, the number of coils formed from conductors of a predetermined length, and the raw materials used to manufacture the conductors. For coil 190, (when the orientation shown in Figures 25, 27, and 29 is taken) it is sufficient to have a vertical height of 170 from the top of the coil to the bottom of the coil. This vertical height of 170 ensures that there is space for the coil when it is installed in the inductor core or body. The width 150 and / or height 160 of the conductor 100 should be less than the vertical height of the formed coil of 170. For coil 190, it is sufficient to form a unique shape that can improve the efficiency and performance of the inductor with a small capacity. In a preferred embodiment, the shape can be "S" shaped when viewed from the side of the coil 190, for example, as shown in the orientation of Figure 25. The shape of the coil 190 is optimized by designing the path length of the conductor 100 to fit perfectly into the space available within the core 260 of the inductor 200 while minimizing resistance and maximizing inductance. The shape should also be designed so that the ratio of the available space to the space available within the inductor body 200 is high. In one embodiment, the inductor of the present invention can achieve an inductance of 0.135 μH at 0.21 mΩ.

[0063] In one embodiment, the conductor has a square cross-section, in contrast to a flat shape where the width is greater than the height. However, the conductor can have other cross-sectional shapes, such as rectangular, triangular, prism-shaped, circular, or elliptical. In any embodiment, example, or description of the conductor in the present invention, the cross-sectional shape of the conductor can be any shape described herein.

[0064] Figures 26 to 30 show an inductor 200 assembled by forming a core 260 around a coil 190. The orientation of the inductor 200 is vertical, as shown in the attached drawings. The orientation of the core or body 200 is upright, for example, with lead portions 135a and 135b at the bottom where it is mounted on a circuit board.

[0065] Figure 26 is a side view of an inductor 200, as seen from the front side 263a, having a core 260 with inductor lead portions 130a and 130b formed around the lower surface 261b of the core 260. Parts of the lead portions 130a and 130b may be curved at points 180c and 180d, respectively, when drawn out from the core. The lead portions 130a and 130b and the coil 190 may be formed as a single integrated part without welding. The shape of the core may be square, rectangular, or any other shape, as long as it fits the dimensions of the core 260. In one embodiment, the height 220 from the top 261a to the bottom 261b of the core 260 is greater than the vertical height 170 of the coil 190.

[0066] Figure 27 is a view of the inductor 200 from the front side, with the core 260 partially transparent so that the inside can be seen. After being wrapped around the core 260 at points 210a and 210b, which are at a distance of 230 from the lead-out points 180c and 180d, the lead portions 130a and 130b are terminated at lead ends 135a and 135b, respectively. Preferably, the lead portions 130a and 130b are curved at points 210a and 210b, respectively, around the bottom 261b of the core 260, so that they "hug" the core 260 or lean directly against the core 260, and have lead portions 130a and 130b that form surface mount terminals along the portion of the bottom surface 261b to which the lead portions 135a and 135b extend. Each lead portion 130a, 130b may extend along a part of the bottom surface 261b of the core 260.

[0067] In one embodiment, a magnetic material such as iron is injected into a die and pressed to form a core 260 that will surround the coil 190. In other embodiments, materials other than iron may be used to form the core 260 or a core portion. For example, a magnetic molding material can be used to form a core 260 consisting of powdered iron, filler, resin and lubricant, as described in USP 6,198,375 (Inductor coil structure) and USP 6,204,744 (High-current miniature inductor).

[0068] In other embodiments, the core can be formed as a plurality of integrated parts. For example, it can be formed as a two-piece core. That is, a core having a first part and a second part can be formed, and the first and second parts can be formed in the same way using the same material. Alternatively, the first and second parts may be formed in different ways using different materials. The shape of the core can be similar to that of a conventionally known IHLP® inductor, and its size can be such that it surrounds the coil 190. After the coil is formed, the core and the lead frame can be joined together.

[0069] Figures 28 and 29 are isometric projections showing the inducers shown in Figures 26 and 27, respectively.

[0070] Figure 28 shows the lead portion 130a at the point of curvature 180c where it is drawn out from the core 260 at approximately the midpoint of the first side portion 262a.

[0071] In the orientation shown in Figure 29, the coil 190 and lead portions 130a and 130b are visible through the transparent core 260, but this is for illustrative purposes only. In Figure 29, the width 150 of the lead portions 130a and 130b extends between the front side 263a and the back side 263b of the core 260. At the second side 262b of the core 260, the lead portion 130b is drawn out from the core 260 at point 180d. In one embodiment, the width 150 of the lead portions 130a and 130b is less than the depth 250 from the front 263a to the back 263b of the core 260. In another embodiment, the width 150 of the lead portions 130a and 130b may be the same as the depth 250 from the front 263a to the back 263b of the core 260. In this case, the core 260 may have a back side 263b, an upper side 261a and a bottom side 261b.

[0072] A unique feature of the present invention is the positioning of the coil 190 and lead portions 130a and 130b relative to the core 260. As shown in the orientation of Figure 29, the width 150 of the coil 190 and lead portions 130a and 130b extends along at least a portion of the depth 250 of the core 260.

[0073] Figure 30 is a bottom view of the illustrated inductor 200. As shown, the lead ends 135a and 135b are wrapped around parts of both sides of the core 260 and part of the bottom surface 261b. These will form electrical contact points with the inductor 200, such as surface mount leads. The bottom surface 261b faces the top surface 261a of the core 260. The width 150 of the lead ends 135a and 135b should be smaller than the depth 250 of the core 260. In another embodiment, the width of the lead portions 130a and 130b should be the same as or equal to the depth of the core 260.

[0074] Figure 31 is an isometric projection showing an example of coil manufacturing of multiple coils 190 formed from a conductor 100. The shape and size of the coils 190 may be the same or different. The lead portions 130 may be aligned along a linear path overall, or along a straight line extending along the length of the conductor. Alternatively, the lead portions 130 may be located in mutually different planes between each coil 190 (they may be offset from each other). Although Figure 24 shows only one coil 190, it is also possible to form multiple coils from only one type of material, as shown in the example in Figure 31. The conductor 100 can be made of a metal such as copper, or any other material suitable for forming an inductor coil. The conductor 100 may be plated with nickel and / or tin.

[0075] Figure 32 is an isometric projection view showing an embodiment in which the coil 190 and component 270 are formed. As shown in Figure 32, the conductor 100 is formed in advance on the core 260, and the coil 190 with the component 270 formed on it is connected to it. Component 270 has an inductor 200, and the lead portion 130 is not separated from the body of the core 260, nor is it bent around the body. The lead portion 130 of the conductor 100 between components 270 can be separated, and lead portions 130a and 130b, each having lead ends 135a and 135b, can be formed.

[0076] Figure 33 shows one embodiment of the method for manufacturing an inductor. In one embodiment, in step 1010, a rectangular conductor, such as nickel (Ni) and tin (Sn) plated non-insulated copper wire, can be bent to form multiple "S" coils. In step 1020, iron cores can be formed individually or simultaneously and attached to each coil or pressed. In step 1030, the parts are cured in a furnace to bond the coils and cores. After this, the parts can be separated, and the lead portions of the lead frame can be folded around each core to manufacture the inductor. It is preferable that the coils and lead portions of the present invention be formed as a complete, integrated unit. That is, it is preferable that there are no interruptions or breaks in the coil from one lead portion to the next coil before separating / cutting the lead portions.

[0077] In another embodiment, the inductor can be manufactured from a folded conductor such as a metal strip or a conductive metal wire or stamped piece. The metal strip, conductive metal wire, or stamped piece is preferably flat. The conductor can be folded and shaped to form a coil and lead portion. Figure 34A is an isometric projection showing an embodiment of a folded conductor 1101 used in manufacturing the inductor of the present invention. Figure 34B follows a front perspective view of the conductor 1102 and illustrates the formation of the folded conductor 1101. The folded conductor 1101 can be formed as a conductor that folds itself in the center 1103 of the width of a conductor that takes on an overall U-shape when viewed in cross-section. The folded conductor 1101 can be folded along its width such that folding forms two sides or layers of equal width 1105a and 1105b joined by the curved or bent portion 1103. In some embodiments, the two layers do not have to be the same. The conductor can be folded to form two or more layers. Figure 34C is a continuation of the front perspective view and shows a folded conductor 1101 with two folded layers insulated from each other. Each layer of the folded material may be insulated, or a predetermined layer may be insulated.

[0078] In the case of a folded conductor configuration, several options are possible. The conductor may be folded to form a folded conductor 1101, and the layers may be insulated after the folding process. In another embodiment, the conductor surface may be covered with an insulating material before folding. During folding, the folded conductor 1101 comes into contact with the insulating surfaces of the layers. In yet another embodiment, the conductor is folded to form a folded conductor 1101, but no insulation is provided between the layers. In yet another embodiment, the conductor is folded and the layers come into direct contact. In this case, the layers may be pressed against each other.

[0079] In one embodiment of forming the conductor 1102, the two edges 1105a and 1105b of the conductor 1102 are moved downward relative to the center 1103 of the width 1104a of the conductor 1102 to form a folded conductor 1101. The width 1104b of the folded conductor 1101 is approximately half the width 1104a of the conductor 1102. In one embodiment, the folded conductor can have an insulating material sandwiched between two layers 1105a and 1105b. If there is one or more folds, the insulating material is present between each layer and can insulate the folded layers. The insulating material can be any material with insulating properties (non-conductive) known to those skilled in the art, and is not limited to ceramics, glass, gases, plastics, or rubber.

[0080] Figure 35 shows an embodiment of an inductor coil 1202 in which the lead portions 1201 and 1203 are the same as in the configuration of Figure 24, but the coil is made of a zigzag-shaped folded conductor formed with the folded conductor 1101 configuration. The coil 1202 can take on a zigzag shape and can be formed in the same way as in the configuration described with reference to Figures 24 to 33. Figure 35 shows an S-shaped coil viewed from above. Alternatively, the coil 1202 can take on a shape other than "S" and can be formed according to other shapes described herein, such as "N" shape, "Z" shape, or other shapes that generate inductance.

[0081] Figure 36, which shows another embodiment, also shows an embodiment of the inductor coil 1202 similar to the configuration in Figure 35, but the lead portions 1201 and 1203 extending from the coil are formed from a folded conductor 1101 that has been divided, cut or separated along approximately the midpoint 1301 of the conductor 1101 to form a slit or seam. As shown in Figure 36, only the lead portions 1201 and 1203 are separated into halves 1303 and 1304, while the coil 1202 remains as a single structure consisting of two integrated sides, two layers, two walls or two sides.

[0082] Figure 37 is an isometric projection showing an inductor coil 1202 in which lead portions 1201 and 1203 are formed from a folded conductor 1101 to a surface mount lead portion. The coil 1202 may have a central portion 1240. These lead portions are formed by splitting and / or spreading, flattening and / or unfolding the lead portions 1201 and 1203 at the opposing ends of the folded conductor 1101. For example, lead portion 1203 is unfolded from the folded conductor 1101 to the conductor 1102, forming a triangular side portion 1404 overall. Furthermore, lead portion 1203 can be constructed by folding the side portion 1404 at the edge 1401, forming a flat surface 1406b for surface mounting or the like along a part of the bottom surface of the inductor core body 1501. The side portion 1404 starts from the end of the coil 1405, and since the folded conductor 1101 overlaps during the formation of the side portion 1404, it is also possible to have folded edges 1402a and 1402b. The other lead portion 1201 on the opposing side can be formed by the same process and formation so that the two lead portions 1201 and 1203 have a similar structure.

[0083] Figure 38 is an isometric projection showing an exemplary inductor 1500 in which the coil 1202 of Figure 37 is inserted into the core 1501. The core 1501 shown is partially transparent so that the inside of the core 1501 can be seen. The core 1501 can take the shape described above and can be formed in the same manner as the shape and method described with reference to the core 260 shown in Figures 24 to 33. The lead portion 1203 is pulled out from the core 1501 and wound around the bottom portion 1502 of the core 1501, thereby forming electrical contact points such as surface mount leads of the inductor 1500. The other lead portion 1201 on the opposite side may be formed in the same manner as described above so that the two lead portions 1201 and 1203 have a mirror image structure with respect to the coil 1202. The lead portions 1201 and 1203 may be pulled out from the core 1501 in the form of a flat folded conductor 1101 and then formed as described above.

[0084] Figure 39 is a top view showing an exemplary inductor 1500 of Figure 38, which has a core 1501 that is partially transparent so that the internal coil 1202, lead portions 1201, 1203, and mounting surfaces 1406a, 1406b can be seen.

[0085] Figure 40 shows another embodiment of an inductor coil 1202 formed from a folded conductor, with lead portions 1201 and 1203 formed from a partially separated folded conductor, as shown in Figure 36, for example. The lead portion 1203 is separated into portions 1303 and 1304 and formed in the same manner as, or in exactly the same manner as, the reshaping of the lead portion 1203 described in relation to Figure 37. Figures 41 and 42 show the coil 1202 and a core 1501 partially transparent around the lead portions, with the lead portions 1303 and 1304 separated and divided into portions 1301.

[0086] Figure 43 is an isometric projection showing another embodiment of the coil 1202 having cut and folded lead portions. The coil 1202 is formed from a folded conductor having divided lead portions. In this embodiment, one side of the divided portion of the lead portion is cut and folded to match the surface of the core 1501, while maintaining one side of each lead portion as a surface mount lead portion. As can be seen from Figures 44 and 45, the lead portions 1201 and 1203 are cut and folded to form contact points such as surface mount leads on the upper surface of the inductor. For example, the mounting surface 2001 can be the contact surface of the lead portion 1203. The lead portion 1203 may also have a flat side surface 2003 adjacent to and extending along the side of the core 1501. The lead portion 1203 drawn out from the coil 1202 is folded at portion 2004. Furthermore, the lead portion 1203 is bent at portion 2002. Figure 44 is an isometric projection showing a core 1501, partially transparent for viewing, provided around the coil 1202 shown in Figure 43. Figure 45 is a partially transparent top perspective view of Figure 44, showing the inductor 2100 with the cut and folded lead portion. The lead portion 1201 is formed in the same manner.

[0087] Figures 46A to 46D illustrate exemplary methods for cutting and folding lead portions to form the configurations shown in Figures 43, 44, and 45. Figure 46A shows step 2301, in which lead portions 1201 and 1203 are extended from the core 1501 as shown. Lead portions 1201 and 1203 are formed from the folded U-shaped conductor, similar to Figures 34A and 34B, but the height / width of the two layers are not equal, thus making it easier to grasp and unfold the lead portions. Cuts can be made along the cutting line 2302, and similarly along the cutting line of lead portion 1201. Figure 46B shows step 2303. In this step, the same method is applied to lead portion 1201, and lead portion 1203 is unfolded in direction 2304 to form an L-shaped conductor extending from the core 1501. Figure 46C shows step 2305. In this step, the lead portions 1201 and 1203 are flattened or pressed against the side surface of the core 1501 and bent at portion 2004 along the operating line 2306. Figure 46D shows step 2307. In this step, the lead portions 1201 and 1203 are bent again in a folding operation 2308 to align with the upper surface portion of the core 1501, forming the contact portion, i.e., the surface mount portion, as shown in Figures 44, 45, and 46A to 46D.

[0088] Figures 47A to 47D illustrate an exemplary method for forming an inductor lead frame by stamping and folding according to one embodiment of the present invention. Figure 47A shows the first step 2401. In this step, a metal frame 2402 is formed by stamping a metal piece, and the openings at the top 2404a and bottom 2404b are used to fix the metal in place during the forming process. Any conductive metal can be used as the metal, or a combination of these metals may be used. For illustrative purposes, but not limited to, examples of such metals include Ni and Sn plated copper plates. Lead portion 2406a extends downward from the inner top of the frame 2402 to the coil connection point 2408a, the conductor piece 2410, another coil connection point 2408b, and another lead portion 2406b. Slots are formed adjacent to the coil connection points 2408a and 2408b. A gap 2412a is formed in the portion where the frame 2402 and the bottom lead portion 2406b are separated by stamping.

[0089] Figure 47B shows step 2403. In this step, the central portion of the flat metal conductor 2410 is folded perpendicular to the plane of the frame 1402. Figure 47C shows step 2405. In this step, the folded conductor 2410 is formed into an "S" shape by bending or the like to widen the gap 2412a to the size of the gap 2412b. Alternatively, the coil 2410 can be formed into any shape described herein. Figure 47D shows an embodiment using a large metal sheet to stamp multiple frames simultaneously, as shown in 2407.

[0090] Figure 48 shows an exemplary inductor formed using the stamping method shown in Figures 47A to 47D. In step 2501, the coil 2410 (not shown) is placed inside the core 2510, the lead portion 2046b is folded in a bending operation 2512 at 2502 and 2506 and wrapped around the surface of the core 2510, forming a contact point 2508, i.e., a surface mount terminal, on which the surface portion 2504 and lead portion 2406b are mounted. The same process and formation are performed for the lead portion 2406b.

[0091] Figures 49A to 49D show embodiments for forming a stretched and folded conductor, as described in relation to each embodiment. The stretched conductor has an H-shape and slots at opposing ends. Figure 49A shows step 2601 using a flat piece of conductor 2602. Figure 49B shows step 2603. In this step, the conductor 2602 can be stretched, separated, cut, or stamped to form an elongated H-shape having an upper extension 2604a and a bottom extension 2604b with a slot in between. Figure 49C shows step 2605. In this step, the conductor 2602 is folded along portion 2606 such that the upper extension 2604a and the bottom extension 2604b are parallel and close to each other. Figure 49D shows step 2607. In this process, as shown in the front perspective view, folds are formed in the stretched and folded conductor portion 2606, and a central U-shape is provided in the mutually parallel extending portions 2604a and 2604b.

[0092] Figures 50A to 50D show an exemplary method for forming an inductor having the stretched and folded conductors of Figure 49. This method forms the coil, lead portion and / or inductor as shown in Figures 30, 31 and 32. Figure 50A shows step 2701. In this step, a core 2702 is formed around the coil (inside the core), and the lead portion is extended outward from the opposite side of the core. Figure 50B shows step 2703. In this step, the lead portions 2604a and 2604b are bent so that they are separated from each other in direction 2608. Figure 50C shows step 2705. In this step, the lead extensions 2604a and 2604b are bent inward in a downward movement 2610, partially overlapping the folded portion with the unfolded portion. Figure 50D shows step 2707. In this step, the lead extensions 2604a and 2604b are bent downwards from the core 2702 in the direction indicated by arrow 2612. This is also shown in other perspective views in Figures 50E and 50F.

[0093] Figures 51A to 51H show an exemplary method of another embodiment of an inductor in which the inductor coil and lead ends are formed separately and then joined to the coil, with the lead portions extending from the inductor core body. Figure 51A shows step 2801. In this step, a coil 190, such as the coil shown in Figure 24, is formed from a conductor having lead portions 130a and 130b. Figure 51B shows step 2803. In this step, a core 260 is formed around the coil 190. The lead portions 130a and 130b extend outward from this core 260. Figure 51C shows step 2805. In this step, the lead portions 130a and 130b are clipped, trimmed, or cut, extending a predetermined distance from the core 260. This distance corresponds to a thickness such as the thickness of the flat lead conductor shown in Figure 51D. In step 2807, the flat lead conductor shown in Figure 51D is introduced / formed. In this step, one or more flat lead conductors are formed, each having a base portion 2802 and extension portions 2804a and 2804b (collectively 2804), with a U-shaped slot formed between these extension portions 2804a and 2804b. Each extension portion 2804 of the flat lead conductor surrounds the respective lead portions 130a and 130b. Figure 51E shows step 2809. In this step, the flat U-shaped lead conductors are connected to the lead portions 130a and 130b so that the trimmed lead portions 130a and 130b fill the slot between the extension portions 2804, and the flat lead conductors can be attached by soldering or other means. In step 2809, the base portion 2802 is also extended beyond the edge surface of the core 260 at the bottom surface of the core 260. Figures 51F and 51G show steps 2811 and 2813, respectively. In these steps, the base portion 2802 is wrapped around the bottom of the core 260 and bent at the corner portion 2806 in the direction indicated by arrow 2808 so that it acts as a fixed contact point, i.e., a surface mount terminal. Figure 51H shows step 2815. In this step, the core 260 is formed on the inductor. Because the core 260 is shown partially transparent, the base portion 2802 wrapped around the bottom surface of the core 260 and the coil 190 provided inside the core 260 can be seen.

[0094] Inductors configured according to the embodiments described above can be used in electronic applications such as DC / DC converters and can achieve one or more of the following effects: low DC resistance, tight tolerances for inductance and / or DC resistance, inductance of less than 1uH, small size / high current, and efficiency in circuits and / or conditions where similar products cannot satisfy current requirements. In particular, the inductors of the present invention are useful for DC / DC converters operating at 1MHz or higher.

[0095] This invention provides an inductor equipped with a high-current zigzag-shaped coil, such as an "S"-shaped coil, which has low DC resistance (IHVR). The design of this invention simplifies manufacturing by eliminating the welding process. Furthermore, the elimination of high-resistance welding between the coil and the lead portion reduces DC resistance. This makes it possible to manufacture inductors with inductance ratings of less than 1 UuH with consistent variation. In the case of an "S"-shaped coil, the inductance and resistance values ​​are optimized compared to similar coil shapes produced by stamping or other non-coil shapes.

[0096] The zigzag-shaped coil inductors, such as the S-shaped coil described above, provide a simple and cost-effective method for manufacturing inductors with minimal variation and inductors that exhibit up to 80% lower DC resistance than known inductors such as the IHLP inductor used for comparison.

[0097] The above description is for illustrative purposes only and is not intended to limit the invention. Furthermore, various modifications can be made to the above embodiments without departing from the spirit and scope of the invention. As the invention has been described in detail above, those skilled in the art will understand that many physical modifications (only a few examples have been given in this detailed description of the invention) can be made without departing from the concepts and principles of the invention described above. Numerous embodiments that encompass only a small part of the preferred embodiments can also be implemented without changing the concepts and principles of the invention with respect to these parts. Therefore, all embodiments and configurations described above are for illustrative purposes only and are not intended to limit the invention, and the scope of the invention is as stated in the claims, not in the above description, and any other embodiments and modifications of these embodiments are all included in the claims. [Explanation of symbols]

[0098] 100, 1102: Conductor 110: First curved section 115, 125: 2nd end 120: Second curved section 130a: First lead section 130b: Second lead section 131: Center line 135a, 135b: Lead ends 140, 1240: Center part 150, 1104a, 1104b, 1105a, 1105b: width 160, 170, 220: Height 180a, 180b: First end 180c: Drawing point of curvature 190, 1405, 2410: Coil 200, 1500, 3100: Inductors 230: Distance 250: Depth 260, 2510, 2702: Cores 261a, 2404a: Upper part 261b, 2404b, 1502, 3111: Bottom 262a: First side 262b: Second side 263a: Front side, front side 263b: Back side, back side 1010, 1020, 1030, 2301, 2303, 2305, 2307, 2401, 2403, 2405, 2501, 2601, 2603, 2605, 2607, 270 1, 2703, 2705, 2707, 2801, 2803, 2805, 2807, 2811, 2813, 2815, 3510, 3520, 3530, 3540, 3550: Process 1101: Folding conductor 1103: Center, folded part 1105a, 1105b: Edge 1105a, 1105b: layer 1201, 1203: Lead section, lead part 1202: Inductor coil, coil 1203, 1304, 2046b: Lead section 1301: Midpoint 1401: Edge 1402, 2402: Frame 1402a, 1402b: Folding edge 1404: Side part 1406a, 1406b, 2001: Implementation side 1501: Inductor core body, core 2302: Cutting line 2304, 2608: Direction 2306: Operating line 2308: Folding operation 2406a, 2408b: Lead portion 2408a: Coil connection point 2410: Conductor piece, metal conductor 2412a, 2412b: gap 2504: Surface part 2512: Operation 2602: Conductor 2604a: Upper extension 2604b: Bottom extension 2610: Downward movement 2802: Base 2804, 2804a, 2804b: Extension part 2806: Corner 2808: Arrow 3110: 1st body part, 1st body 3115: Inner core 3120:Second main body part, second main body 3125: Main unit 3130: Contact part 3140, 3140a, 3140b: Lead section 3145b, 3145c: Border 3150: "S" shaped coil, coil 3150a: First coil 3150b: Second coil 3150c: Third coil 3151: Central part, cross member 3152, 3155: First end 3153, 3154: Second end 3159: “N” shaped coil 3160:Shelf 3170: Coil cutout 3180: First notch 3190: Second notch 3221: Inner core recess 3222: Channel recess 3231: Insulation 3261: Carrier strip 3500: Manufacturing method 3600: Lead frame 3610: Pattern 3620: First frame portion 3630: Second frame portion C1: First curved section, region C2: Second curved part, area P1: First route P2: Second route P3: Third Route LA: Center line N1: 1st part N2:Second part N3: Center part

Claims

[Claim 1] An electromagnetic component comprising a coil formed of a flat conductive material, wherein the conductive material has a width greater than the thickness of the conductive material, and the coil extends along a path that is at least partially curved, and the coil has a first lead extending from a first end and a second lead extending from a second end, The body, which is molded as a single unit, has magnetic material formed around the entire coil, leaving the exposed portions of the first lead and the second lead exposed. The main body has a top surface configured as a surface away from the surface mounting portion of the main body, a bottom surface located on the opposite side and in close proximity to the surface mounting portion of the main body, a front surface and a rear surface on the opposite side, and a first side surface and a second side surface on the opposite side. The depth of the main body extends between the front and the back, the height of the main body extends between the top and the bottom, the height of the main body is greater than the depth of the main body, the central vertical axis of the main body is located at the midpoint between the first side and the second side and extends along the height of the main body, The coil is arranged such that the width of the conductive material extends in the direction of the depth of the body. The coil has a first portion including an arc-shaped portion, which forms a second portion extending toward the central vertical axis of the main body, and the first portion of the first portion is located near the first side surface of the main body, and this first portion is provided closer to the first side surface than the second portion, and further, The coil has a second portion including an arc-shaped portion, which forms a second part extending toward the central vertical axis of the main body, and a first portion of the second portion is located near the second side surface of the main body, and this first portion is provided in a position closer to the second side surface than the second portion. Each of the first and second parts, including the aforementioned arc-shaped portion, is located in the left half near the first side and the right half near the second side of the main body, respectively, as separated by the central vertical axis, and the first and second parts, including the arc-shaped portion, have regions that curve away from each other, and furthermore, each of the first part and the second part is connected to a portion of the coil that passes through the central vertical axis. At least a portion of the exposed portion of the first lead has a surface mount portion that extends along at least a portion of the bottom surface of the body adjacent to the first side surface of the body, and An electromagnetic component characterized in that at least a portion of the exposed portion of the second lead has a surface-mount portion that extends along at least a portion of the bottom surface of the main body adjacent to the second side surface of the main body.

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