201106390 六、發明說明： 【發明所屬之技術領域】 本發明之領域大體上係關於磁性元件及其製造，且更明 確言之，係關於諸如電感器及變壓器之磁性、表面安裝電 子元件。 本申請案主張2009年5月4曰申請之美國臨時專利申請案 第61/175,269號及2008年7月11曰申請之美國臨時專利申請 案第61/080,115號之權益，且係2009年4月24日申請之美國 專利申請案第12/429,856號之部分接續申請案，其等之揭 示内容以引用之方式全部併入本文中。 本申請案亦係關於以下共同擁有且共同待審之專利申請 案中所揭示之標的物：2008年10月8日申請之題為「高電 流非晶性粉末怎電感器（High Current Amorphous Powder Core Inductor)」之美國專利申請案第12/247,281號；2008年7月 29日申請之題為「磁性電子器件（A Magnetic Electrical Device)」之美國專利號第12/181,436號；2008年7月11曰申 請之題為「 高性能高電流功率電感器（High Performance High Current Power Inductor)」之美國臨時專利申請案第 61/080,1 15號及2008年6月13日申請之題為「小型磁遮罩元 件（Miniature Shielded Magnetic Component)」之美國專利申請 案第12/138,792號；及2006年9月12日申請之題為「用於磁 性元件之低輪廓層壓線圈及磁芯（Low Profile Layered Coil and Cores for Magnetic Components)」之美國專利申請案第 11/519,349 號。 148034.doc 201106390 【先前技術】 · 隨著電子封裝之進步，製造更小但功能更強大之電子器 件已成為可能。為了減少此等器件之總體大小，用於製造 它們之電子元件已逐漸變得小型化。製造符合此等要求之 電子組元件呈現出許多困難，從而使製程花費更多，且不 必要地增加該等電子元件之成本。 已以在競爭激烈之電子製造產業中減少成本之方式來仔 細檢查諸如電感器及變壓器之磁性元件、類似其他元件之 製程。當製造之元件係低成本、大批量元件時，製造成本 之減少尤其係需要的。在此等元件以及利用該等元件之電 子器件之大批量、大規模生產過程中，製造成本之任何減 少當然具有重要意義。 【發明内容】 本文揭示磁性元件總成及製造該等總成之方法之例示性 貫施例，該等實施例有利地用於實現以下益處之—或多 個.更適合於以小型化位準生產之元件結構；更容易以小 型化位準組裝之元件結構；容許消除已知磁性構造共同之 製造步驟之元件結構；經由更有效製造技術而具有增加之 可靠性之元件結構；相較於現有磁性元件，在類似或減少 之封裝大小中具有改良性能之元件結構；相較於習知、小 型化磁性元件具有增加之電力能力之元件結構；及具有相 對於已知磁性元件構造提供明顯性能優勢之獨特磁允 圈構造之元件結構。 v 舉例而言，咸信例示性元件總成尤其有利於構造電感哭 148034.doc 201106390 及變壓器。該等總成可 —人生 罪也以小封裝大小而提供，且可 包各表面安裝特徵以易於安裝至電路板。 【實施方式】 參考以下圖式料非_及㈣盡實闕 有指定’相似參考數字是指遍及各種圖中之相似部分。201106390 VI. INSTRUCTIONS OF THE INVENTION: FIELD OF THE INVENTION The field of the invention relates generally to magnetic components and their manufacture, and more specifically to magnetic, surface mount electronic components such as inductors and transformers. The present application claims the benefit of U.S. Provisional Patent Application No. 61/175,269, filed May 4, 2009, and U.S. Provisional Patent Application No. 61/080,115, filed on Jul. 11, 2008, and which is incorporated herein. The copending application of U.S. Patent Application Serial No. 12/429,856, the disclosure of which is incorporated herein in The present application is also directed to the subject matter disclosed in the following commonly owned and co-pending patent application: "High Current Amorphous Powder Core", filed on October 8, 2008, entitled "High Current Amorphous Powder Core" U.S. Patent Application Serial No. 12/247,281, entitled "A Magnetic Electrical Device", filed on July 29, 2008; U.S. Patent No. 12/181,436, filed July 29, 2008; U.S. Provisional Patent Application No. 61/080,115, filed on Jun. 13, 2008, entitled "Small Magnetics", entitled "High Performance High Current Power Inductor" U.S. Patent Application Serial No. 12/138,792, entitled "Miniature Shielded Magnetic Component"; and "Slow Profile Laminated Coils and Magnetic Cores for Magnetic Components", filed on September 12, 2006 U.S. Patent Application Serial No. 11/519,349, the disclosure of which is incorporated herein. 148034.doc 201106390 [Prior Art] · With the advancement of electronic packaging, it has become possible to manufacture smaller but more powerful electronic devices. In order to reduce the overall size of such devices, electronic components for manufacturing them have gradually become miniaturized. The manufacture of electronic components that meet these requirements presents a number of difficulties, resulting in more costly processes and unnecessarily increasing the cost of such electronic components. The process of magnetic components such as inductors and transformers, and other components, has been carefully examined in a manner that reduces costs in the highly competitive electronics manufacturing industry. When manufacturing components are low cost, high volume components, the reduction in manufacturing costs is particularly desirable. In the large-volume, large-scale production of such components and electronic components utilizing such components, any reduction in manufacturing cost is of course of importance. SUMMARY OF THE INVENTION [0005] Disclosed herein are exemplary embodiments of magnetic component assemblies and methods of making the same, which are advantageously used to achieve the following benefits - or more. More suitable for miniaturization levels Component structure for production; component structure that is easier to assemble in a miniaturized level; component structure that allows for elimination of manufacturing steps common to known magnetic structures; component structure with increased reliability through more efficient manufacturing techniques; Magnetic component, component structure with improved performance in a similar or reduced package size; component structure with increased power capability compared to conventional, miniaturized magnetic components; and provides significant performance advantages over known magnetic component configurations The component structure of the unique magnetic ring structure. v For example, the exemplary component assembly is particularly beneficial for constructing an inductor crying 148034.doc 201106390 and a transformer. These assemblies – life crimes – are also available in small package sizes and can be packaged with surface mount features for easy installation to the board. [Embodiment] Referring to the following figures, the following figures are not intended to be exhaustive. ‘The same reference numerals are used throughout the various figures.
G 本文揭不克服許多此項技術困難之本發明電子元件設計 之Γ性實施例。$了全面理解本發明，在不同分段或部 揭示内容’其中部分I討論特定問題及困 難’及部分11描述用於克服此等問題之例示性^件構造及 總成。 I ·本發明之介紹 用於電路板應用之諸如電感H之習知磁性元件通常包含 一磁心及一在該磁芯内之導電繞組（有時稱作一線圈）。該 磁怒可由磁性材料製造之離散磁怒件來製造，其中該繞組 放置於該等磁芯件之間。各種形狀及類型之磁芯件及總成 〇 對於此項技術者而言係熟悉的，其等包含但並不一定限於 U磁芯及I磁芯總成、ER磁芯及Γ磁芯總成、ER磁芯及ER磁 芯總成、一罐形磁芯及τ磁芯總成以及其他匹配形狀。該 等離散磁芯件可與一粘合劑接合在一起且通常彼此實體間 隔或具間隙。 在一些已知元件中，舉例而言，該等線圈係由繞組在該 磁芯或一端子夾周圍之一導線製造。即，在已完全形成該 等磁芯件之後，該線可纏繞在一磁芯件周圍，該磁芯件有 時稱作一鼓形磁芯或其他帶線磁芯。該線圈之各自由端可 148034.doc 201106390 稱作引線且可用於經由至一電路板之直接附接或經由透 過一端子夾之一間接連接而將該電感器耦合至一電路。尤 其對於小磁芯件而t，以具有成本效益且可靠方式纏繞該 線圈係具有挑戰性的。手玉纏繞之元件在性能上往往係不 一致的。該等磁芯件之形狀使其呈現非常脆弱且在纏繞線 圈時容易發生磁芯破裂，且該等磁芯件之間之間隙之變動 可在元件性能上產生不必要變動。另一困難係由於在纏繞 過程期間之不均勻纏繞及張力，DC電阻（「DCR」）可能不 合需求地變化。 在其他已知元件中，已知表面安裝磁性元件之線圈通常 分開地由磁芯件製造且隨後與該等磁芯件組裝。即，該等 線圈有時稱作係預先形成或預先纏繞的以避免歸因於該線 圈之手工纏繞之問題，且簡化該等磁性元件之組裝。此等 預先形成之線圈對於小元件尺寸而言尤其有利。 為了當該等磁性元件被表面安裝於一電路板上時造成電 連接至該等線圈，通常提供導電端子或夾。該等夹被組裝 於具有形狀之磁芯件上且電連接至該線圈之各自端。該等 端子夾通常包含大體上平坦且平面區域，該等區域可使用 例如已知銲接技術而電連接至一電路板上之導電跡線及 墊。當如此連接且當該電路板通電時，電流可自該電路板 流至該等端子夹之一者，通過線圈而至該等端子夾之另一 者’且回到該電路板。在電感器之情形下，流過線圈之電 流在磁芯中感應磁場及能量。可提供一個以上線圈。 在變壓器之情形下，提供一主線圈及一副線圈，其中流 148034.doc 201106390 l Λ主線圈之電流在該副線圈中感應電流H器元件之 製造呈現與電感器元件類似的挑戰。 /對於逐漸小型化之疋件而言，提供實體上具間隙之磁芯 ， 係、具有挑戰性的。難以用具有成本效益之方式可靠地實現 建立及保持一致間隙大小。 關於在小型化表面安裝磁性元件中之線圈與端子夹間建 +電連接亦呈現許多實際問題。該線圈與端子夾間之一相 Ο w脆弱連接通^係建立在該磁芯外部且因此容易分離。在 -些情形下’眾所周知係將線圈端纏繞在諸夾之一部分周 圍以確保料圈與料夾之間之可#機械及電連接。然 而’此從製造業角度已證明係單調乏味的，且更容易及更 快終止解決方案將係可取的。此外，線圈端之纏繞對於某 些類型線圈(諸如，具有矩形截面之線圈，而該矩形截面 具有不如薄、圓形線構造一般撓性之平坦表面）而言係不 切實際的。 ° 隨著電子器件繼續趨於逐漸強大，諸如電感ϋ之磁性元 件亦需要载送增加電流量。因此，通常增加用於製造線圈 之線規。因為用於製造該線圈之線大小增加，所以當圓形 線被用於製造該線圈時’諸端通常經平坦化至一合適厚度 及寬度以使用例如銲接、熔接或導電枯合劑及其類似物而 令人滿意地機械及電連接至端子夾。然而，該線規越大， 就越難將該線圈之端平坦化以將它們合適地連接至該等端 子夾。此等困難已導致該線圈與該等端子夾間之不一致連 接該等不&連接可導致不合需求之性能問題及磁性元 148034.doc 201106390 件在使用中之變動。減少此變動已證明非常困難且昂貴。 雖然由平坦而不是圓形導電體製造線圈可緩解某些應用 之此等問題’但是平坦導電體首先傾向於更硬且更難以形 成至線圈中’且因此引入其他製造問題。相對於圓形導電 體，平坦導電體之使用亦可改變使用中之元件之性能，有 時不合需求。另外，在一些已知構造中，尤其包含由平坦 導電體製造之線圈之構造，諸如鉤之終止特徵或其他結構 特徵可形成至該線圈之端中以促進連接至端子夾。然而， 形成此等特徵至該等線圈之端中可在製程中引入更多費 用0 雖然近來傾向於減少大小，但是增加電子器件之功率及 月匕力仍然呈現更多挑戰。隨著減少電子器件之大小，必須 相應減少其中所利用之電子元件之大小，i因此儘管載送 增加數量之電流以供電該器件，已努力經濟製造具有相對 小(有時小型化)結構之功率電感器及變壓器。磁芯結構需 要具有相對於電路板逐漸變低輪廊以容許該等電子器件之 輕薄且有時非常薄輪廓。符合此等要求仍^現更多困 難。連接至多相位電力系統之元件仍呈現其他困難，並中 在一小型化器件中適應電力之不同相位係困難的。 元件製造商極關注於最佳化磁性元件之佔用 I以尋求滿^代電子器件之尺寸要求。-電路板^ 各兀件可大體上由在平行於該電路板之 垂直寬度及深度尺寸所p 〜 電…… 該寬度及深度之乘積決定該 兀所佔用之表面面積，有時稱作該元件之 148034.doc 201106390 一佔用面積」另—方面，在正交於或垂直於該電路板之 一方向上量測之該料之總高度有時被稱作該元件之「輪 廓」。該等元件之佔用面積部分決定多少元件可安裝於一 • f路板上’且該輪廓部分決定該電子器件中之平行電路板 《間所容許之間隔。較小電子器件―般要求存在之各電路 板上安裝更多元件，減少鄰近電路板之間之間隙，或兩者 皆要求。 〇 然:而，用於磁性元件之許多已知端子夾當表面安裝至一 電路板時傾向於增加元件之佔用面積及/或輪廊。即，當 該等夾安裝至一電路板時傾向於延伸該等元件之深度、寬 度及/或高度，且不合需求地增加元件之佔用面積及/或輪 廓。尤其對於配合於該磁芯之頂部、底部或側部部分處之 磁心件之外表面上之夾而言，已完成之元件之佔用面積及/ 或輪廓可藉由該等端子夾而延伸。即使元件輪廊或高度之 延伸相對較小，由於在任何給定電子器件中元件及電路板 〇 之數目增加’結果亦可能變大。 π.例示性本發明磁性元件總成及其製造方法 現將时論解決此項技術中習知磁性元件之問題之一些之 磁性兀件總成之例示性實施例。與所述器件相關聯之製造 ，步驟部分係顯而易見的且部分在下文中明確地描述。同 樣’與所述方法步驟相關聯之器件部分係顯而易見的且部 分在下文中明確描述。即，本發明之器件及方法並不一定 分開描述於以下討論中，而是咸信將會適當地落入此項技 術範圍而無須進一步解釋。 148034.doc 201106390 圖1 -4為根據本發明之一例示性實施例之一例示性表面 女裝磁性元件100之各種視圖。更明確言之，圖1為一表面 安裝磁性元件1〇〇之部分分解圖，圖2為該磁性元件1〇〇之 俯視透視示意圖’圖3為該磁性元件1 〇〇之俯視透視總成 圖’及圖4為該磁性元件1 〇〇之仰視透視總成圖。 該兀件100大體上包含一磁芯1〇2、一大體上包含於該磁 芯102中之線圈1〇4及端子夾1〇6、ι〇8。在圖1-4中所示之 例示性實施例中’雖然該磁芯1 〇2製造於一單件丨丨〇中但 疋在另一貫施例中，若所需，則該磁芯i 〇2可包含一個以 上磁芯件，其中該等磁芯件當組裝時彼此實體上具有間 隙。 該磁芯件110可使用例如此項技術中亦眾所周知之鐵粉 材料或非晶性磁芯材料而製造為一整件，該整件可壓製在 該線圈104周圍。此等鐵粉材料及非晶性磁芯材料可呈現 分散式間隙性質，該等性質避免在該磁芯結構中需要任何 一個實體間隙。在一例示性實施例中，該元件1〇〇之該單 個磁芯件110可由此項技術者熟悉之一磁性粉末材料製 造，且該材料可壓製或壓縮在一線圈1〇4周圍以形成一整 體磁芯及線圈構造。 在另一及/或替代性實施例中，該磁芯件丨1〇可由堆疊且 壓製在該線圈104周圍之磁粉材料層或薄片形成。用於製 造此等層或薄片之例示性磁粉顆粒可包含鐵磁顆粒、鐵 (Fe)顆粒、鋁矽鐵（Fe_Si_A1)顆粒、Mpp(Ni_M〇_Fe)顆粒、 Hlghflux(N卜Fe)顆粒、Megaflux(Fe_Si合金）顆粒、鐵為主 148034.doc 201106390 中已卜知曰^末顆粒、始為主之非晶性粉末顆粒或此項技術 叫材料、-二等效材料。當此等磁粉顆粒與-聚合物接合 ^ 。時，所得磁崎料展現分散式_性質，該等 性質避免需要實體間隙或分離不同磁性材料件。因此，有 利避免與建立且保持—致實體間隙大小相關聯之困難及費 用。對於高電流應用而言，與一聚合物接合劑組合之一預 退火磁性非晶性金屬粉末可能係有利的。G This document discloses an ambiguous embodiment of the electronic component design of the present invention which overcomes many of the technical difficulties. A full understanding of the present invention is disclosed in various sections or sections, in which part I discusses specific problems and difficulties, and section 11 describes exemplary constructions and assemblies for overcoming such problems. I. Introduction to the Invention Conventional magnetic components such as inductor H for circuit board applications typically include a core and a conductive winding (sometimes referred to as a coil) within the core. The magnetic anger can be fabricated from discrete magnetic anger pieces made of magnetic material, wherein the windings are placed between the magnetic core pieces. Magnetic core members and assemblies of various shapes and types are familiar to those skilled in the art, and the like, but not necessarily limited to U core and I core assembly, ER core and neodymium core assembly , ER core and ER core assembly, a can core and τ core assembly and other matching shapes. The discrete core members can be joined to an adhesive and are typically physically separated or gapped from each other. In some known components, for example, the coils are fabricated from a wire around a winding of the core or a terminal clip. That is, after the magnetic core members have been completely formed, the wires can be wound around a core member, which is sometimes referred to as a drum core or other wire core. Each of the coils may be referred to as a lead by 148034.doc 201106390 and may be used to couple the inductor to an electrical circuit via direct attachment to a circuit board or via indirect connection through one of the terminal clips. Especially for small core pieces, t, it is challenging to wind the coil system in a cost-effective and reliable manner. The components of the hand jade are often inconsistent in performance. The shape of the core members is such that they are very fragile and the core breaks easily when the coil is wound, and variations in the gap between the core members can cause unnecessary variations in the performance of the components. Another difficulty is that the DC resistance ("DCR") may change undesirably due to uneven winding and tension during the winding process. Among other known components, coils of known surface mount magnetic components are typically manufactured separately from magnetic core members and subsequently assembled with the magnetic core members. That is, the coils are sometimes referred to as pre-formed or pre-wound to avoid problems due to manual winding of the coil and to simplify assembly of the magnetic components. Such pre-formed coils are particularly advantageous for small component sizes. In order to electrically connect the magnetic elements to the coils when they are surface mounted on a circuit board, conductive terminals or clips are typically provided. The clips are assembled to a magnetic core member having a shape and electrically connected to respective ends of the coil. The terminal clips typically comprise substantially planar and planar regions that can be electrically connected to conductive traces and pads on a circuit board using, for example, known soldering techniques. When so connected and when the board is energized, current can flow from the board to one of the terminal clips, through the coil to the other of the terminal clips' and back to the board. In the case of an inductor, the current flowing through the coil induces a magnetic field and energy in the core. More than one coil can be supplied. In the case of a transformer, a primary coil and a secondary coil are provided, wherein flow 148034.doc 201106390 l Current of the primary coil induces current in the secondary winding The manufacture of the secondary component presents a similar challenge to the inductor component. / For the gradual miniaturization of the components, it is challenging to provide magnetic cores with physical gaps. It is difficult to reliably establish and maintain consistent gap sizes in a cost effective manner. There are also many practical problems with regard to the electrical connection between the coil and the terminal clip in the miniaturized surface mounted magnetic component. The coil is in contact with one of the terminal clips. The frangible connection is established outside the core and is therefore easily separated. In some cases, it is known to wrap the coil ends around a portion of the clips to ensure a mechanical and electrical connection between the loop and the binder. However, this has proven to be tedious from a manufacturing perspective, and it would be desirable to terminate the solution more easily and more quickly. In addition, the winding of the coil ends is impractical for some types of coils, such as coils having a rectangular cross-section with a flat surface that is less flexible than a thin, circular wire construction. ° As electronic devices continue to become more powerful, magnetic components such as inductors also need to carry an increased amount of current. Therefore, the wire gauge for manufacturing the coil is usually added. Because the size of the wire used to make the coil is increased, when the circular wire is used to make the coil, the ends are typically planarized to a suitable thickness and width to use, for example, soldering, welding or conductive dryness agents and the like. It is satisfactorily mechanically and electrically connected to the terminal clamp. However, the larger the gauge, the more difficult it is to flatten the ends of the coils to properly connect them to the terminal clips. Such difficulties have led to inconsistent connections between the coil and the terminal clips. These unsinkable connections can result in undesirable performance issues and variations in the use of magnetic elements 148034.doc 201106390. Reducing this change has proven to be very difficult and expensive. While fabricating coils from flat rather than circular conductors may alleviate these problems of certain applications 'but flat conductors tend to be harder and more difficult to form into the coils first' and thus introduce other manufacturing issues. The use of flat conductors can also alter the performance of the components in use relative to a circular conductor, sometimes undesirable. Additionally, in some known configurations, particularly including the construction of coils made of flat conductors, termination features such as hooks or other structural features may be formed into the ends of the coil to facilitate connection to the terminal clips. However, the formation of such features into the ends of the coils can introduce more expense into the process. Although there has recently been a tendency to reduce size, increasing the power and power of the electronics still presents more challenges. As the size of the electronic device is reduced, the size of the electronic components utilized therein must be correspondingly reduced, so that while carrying an increased amount of current to power the device, efforts have been made to economically fabricate power having a relatively small (and sometimes miniaturized) structure. Inductors and transformers. The core structure needs to have a lower pitch relative to the board to allow for a thin and sometimes very thin profile of the electronics. Meeting these requirements is still more difficult. Components connected to a multi-phase power system still present other difficulties, and it is difficult to adapt to different phase phases of power in a miniaturized device. Component manufacturers are extremely concerned with optimizing the use of magnetic components. I seek to meet the size requirements of full-scale electronic devices. - circuit board ^ each component can be substantially parallel to the vertical width and depth dimension of the circuit board p ~ electric ... the width and depth of the product of the surface determines the surface area occupied by the crucible, sometimes called the component 148034.doc 201106390 A footprint" In other respects, the total height of the material measured in the direction orthogonal to or perpendicular to one of the boards is sometimes referred to as the "profile" of the element. The footprint portion of the components determines how many components can be mounted on a "f-board' and the contour portion determines the spacing allowed between parallel boards in the electronic device. Smaller electronics—there are more components on the board that are required to be present, reducing the gap between adjacent boards, or both. However, many known terminal clips for magnetic components tend to increase the footprint of the components and/or the rim when surface mounted to a circuit board. That is, the clips tend to extend the depth, width and/or height of the components when mounted to a board and undesirably increase the footprint and/or profile of the components. In particular for the clips that are fitted to the outer surface of the core member at the top, bottom or side portions of the core, the footprint and/or profile of the completed components can be extended by the terminal clips. Even if the component rim or height extension is relatively small, the result may increase due to the increased number of components and board 在 in any given electronic device. π. Illustrative Magnetic Component Assembly of the Invention and Method of Manufacture Thereof An exemplary embodiment of a magnetic component assembly that addresses some of the problems of conventional magnetic components in the art will now be discussed. The fabrication, step-by-step steps associated with the device are apparent and partially described below. The same components as those associated with the method steps are apparent and partially described below. That is, the device and method of the present invention are not necessarily described separately in the following discussion, but the letter will be appropriately included in the technical scope without further explanation. 148034.doc 201106390 Figures 1-4 are various views of an exemplary surface feminine magnetic element 100 in accordance with an exemplary embodiment of the present invention. More specifically, FIG. 1 is a partially exploded view of a surface mount magnetic component 1 ,, FIG. 2 is a top perspective view of the magnetic component 1 ' FIG. 3 is a top perspective view of the magnetic component 1 〇〇 'And FIG. 4 is a bottom perspective assembly of the magnetic element 1 。. The element 100 generally includes a core 1 2, a coil 1 〇 4 substantially included in the core 102, and terminal clips 1 〇 6 and ι 8 . In the exemplary embodiment illustrated in Figures 1-4, 'although the core 1 〇 2 is fabricated in a single piece but in another embodiment, the core i 若 if desired 2 may comprise more than one magnetic core member, wherein the magnetic core members have a physical gap with each other when assembled. The core member 110 can be fabricated as a single piece using, for example, an iron powder material or an amorphous core material, also well known in the art, which can be pressed around the coil 104. These iron powder materials and amorphous core materials can exhibit discrete gap properties that avoid any physical gaps required in the core structure. In an exemplary embodiment, the single core member 110 of the component 1 can be fabricated from a magnetic powder material familiar to those skilled in the art, and the material can be pressed or compressed around a coil 1〇4 to form a The overall core and coil construction. In another and/or alternative embodiment, the core member 形成1〇 may be formed from a layer or sheet of magnetic powder material stacked and pressed around the coil 104. Exemplary magnetic powder particles used to make such layers or sheets may comprise ferromagnetic particles, iron (Fe) particles, aluminum barium iron (Fe_Si_A1) particles, Mpp (Ni_M〇_Fe) particles, Hlghflux (Nb Fe) particles, Megaflux (Fe_Si alloy) particles, iron-based 148034.doc 201106390 has been known as the end of the particles, the first amorphous powder particles or this technology is called material, - two equivalent materials. When these magnetic powder particles are bonded to the -polymer ^. At this time, the resulting magnesia exhibits a dispersion-type property that avoids the need for physical gaps or separation of different pieces of magnetic material. Therefore, it is advantageous to avoid the difficulties and costs associated with establishing and maintaining the physical gap size. For high current applications, it may be advantageous to pre-anneal the magnetic amorphous metal powder with one of the polymeric binder combinations.
々圖2中最佳可見之該線圈1〇4由一段圓形線製造且包含一 第一端或引線15G、—與該第—端相反之第二端或引線152 及一介於該等線圈端150與152之間之繞組部分154，其中 該線繞著-線圈軸! 5 6而纏繞許多區數以達成一所需效 果’舉例而言’諸如用於該元件1〇〇之—選定最終用途之 -所需電感值。另外’該線圈係以沿著該軸156之螺旋方 式及相對於該軸156之盤旋形式兩者而纏繞以提供一更緊 湊線圈設計來滿足低輪廓要求，同時還提供一所需電感 值。相對於s亥繞組部分154而彎曲該等端丨5〇、丨52，使得 該等端平行於該線圈軸156而延伸以促進終止該等線圈端 150、152，如以下所解釋。 若所需，則用於形成該線圈1〇4之線可塗佈有搪瓷塗層 及其類似物以改良線圈104之結構及功能態樣。如熟習此 項技術者所瞭解，線圈104之電感值部分取決於線類型、 該線圈中線匝數及線直徑。因此，該線圈1 〇4之電感額定 值對於不同應用而言可能相差很大。該線圈1〇4可使用已 知技術而由該等磁芯件110單獨製造，且可提供為該元件 148034.doc -11 - 201106390 100之總成之一預纏繞結構。在一例示性實施例中，雖然 以自動方式形成該線圈104以提供已完成之線圈之一致電 感值’但是若所需’則替代性地可手動纏繞該等線圈。應 瞭解，若提供一個以上線圈，則可同樣需要額外端子夾以 電連接至所利用之線圈之全部。 該線圈104僅係例示性的，且應瞭解可替代利用其他類 型線圈。舉例而言，可使用平坦導電體而不是圖2中繪示 之圓形線製造一線圈。另外，該繞組部分154可假設各種 替代形狀及組態，其等包含但不限於螺旋或盤旋組態（但❹ 非如圖2中所示兩者）’且繞組部分組態具有替代曲形區段 (蛇形、C形等）之筆直、多邊形區段。同樣，若所需則 可利用一個以上線圈。 如所繪示實施例中所示，該磁芯件U 〇形成於一大體上 矩形之本體中，該本體具有一底壁114及複數個大體上正 交之側壁116、118、120及122，該等側壁自該底壁114之 杈向邊緣延伸。在圖1-4中所示之實施例中，該底壁114有 時可稱作—底部壁。該等側壁116及118彼此相對且有時可 〇 为別稱作一左側及一右側。該等壁120及122彼此相對且有 日守可分別稱作一前側及一後側。該等側壁116、118、120 及122界定在該底壁114之上之一封圍或腔，當組裝該元件 日守’ 5亥封圍或腔大體上含有該線圈丨〇4。 亦如圖1中所示，該第一磁芯件11 0之側壁116亦包含一 凹陷表面123 ’且該相對側壁丨丨8包含一相應凹陷表面 。該等凹陷表面123及125僅沿著各自側壁116及118之 148034.doc •12- 201106390 一長度延伸一部分距離。該等凹陷表面123及125亦自該底 壁114向上延伸達到小於在垂直於底面之一方向上所量測 之該等側壁116及118之高度之一距離。因此，該等凹陷表 面123及125自該等側壁116及118之頂部邊緣隔開，而毗連 該底壁114之該等凹陷表面126及128達到鄰近該底壁114延 伸之該等側壁116及11 8之長度之一部分。 該磁芯件110之底壁114之外表面係波狀的且包含分離第 ❹ 一及第二凹陷表面I26及128之一非凹陷表面124。該等凹 Ρα表面126及128在該非凹陷表面124之相對側上延伸。第 二及第四凹陷表面130及132亦設置於該底壁114之相對角 隅上。第五及第六凹陷表面134、136與該磁芯件i 1〇之剩 餘角隅上之第三及第四凹陷表面13〇及132相對。在所繪示 實施例中，該等第五及第六凹陷表面134、136以彼此大體 上共面之關係且亦以與第三及第四凹陷表面13〇及132大體 上共面之關係延伸。因此，該底壁丨14係階梯式具有三位 Ο 準表面，其中第一位準為非凹陷表面124,第二位準為與 第一級間隔開一第一數量之凹陷表面126及128，及第三位 準為與第一及第二級之各者間隔開之凹陷表面13〇、132、 134、136。δ亥等凹陷表面126、132及134被間隔開且由該 非凹陷表面124而與該等凹陷表面128、13〇及136分離。該 等凹1½表面130及136被間隔開且由該凹陷表面128分離， 及該等凹Pa表面132及134被間隔開且由該凹陷表面126分 離。 圖1中所示之例示性端子夾106及108在構造上實質上相 148034.doc 13· 201106390 同，但是當施加至該第一磁芯件110時被反轉1 8 〇度，且因 此延伸為彼此之鏡射影像。該元件1 〇〇之端子夾1 〇6及108 各自分別包含安裝區段140、大體上平坦且平面之底部區 段142及在該等底部區段142之相對端上自該等安裝區段 140延伸之線圈區段144。一垂直定位凸片區段i 45亦大體 上垂直於各夾106及108中之底部區段142而延伸。該等定 位凸片區段經定形狀及定尺寸以容納於該第一磁芯件1 i 〇 之側壁116及11 8中之凹陷表面123、125中。 在所繪示實施例中’該等安裝區段14〇以與該等線圈區 段144大體上共面之關係延伸且偏移該等底部區段142之平 面或與该等底部區段142之平面間隔開。該等夾1 、1 〇8 被組裝至該磁芯件11 〇，其中該等底部區段i 42對接該等凹 «表面126及128，該等線圈區段144對接該等凹陷表面13〇 及132 ’及該等安裝區段ι4〇對接該等凹陷表面134及136。 亦如圖1及2中所示，該等線圈端15〇及152穿過通孔146而 延伸在該等端子夾i 06、i 〇8之線圈區段丨44中，其中它們 可旎被銲接、熔接或另外附接以確保該等線圈端丨5〇、！ 52 亥線圈104之間之電連接。然而，因為該等線圈端15〇、 定位於該磁芯件11〇之底壁114之凹陷表面上，所以它 們不會自該磁芯件110之總外部表面凸出，且當處理該元 件100時不易不合需求地分離。 孩等端子夾106、1〇8及所描述之所有其區段可藉由自一 導電材料切割、彎曲或另外成形該等夾1〇6及1〇8而以相對 直接之方式製造。在—例示性實施财，耗該等端子係 148034.doc -14- 201106390 自一銅鍍板衝壓出且彎曲成一最終形式，但是可替代利用 其他材料及成形技術。該等夾106、1〇8可在隨後生產階段 預先成形且組裝至該磁芯件11 〇。 因為該磁芯件110被壓製在該線圈1 〇4周圍，所以該等線 圈端150、152與該等端子夾1〇6、108之間之電連接定位於 δ亥磁芯結構外部。如圊3中所示，當該元件1 被安裝至該 電路板180時，該第一磁芯件11 〇之底壁i丨4面對且對接該 0 板表面184且各端子夾1〇6、1〇8之平坦且平面之底部區段 142係經由銲接技術或此項技術中所知之其他技術而電連 接至β亥板180上之導電跡線182。各爽106、1〇8之線圈區段 144各面對該電路板180且該等線圈端15〇、152與該等炎之 線圈部分144之間之電連接實質上受保護於該磁芯結構之 下。該等夾106及108在相對簡單、高效及具有成本效率之 製造過程中促進該等線圈端15〇及152之安全且可靠電連 接。 〇 圖 5-8為根據本發明之一例示性實施例之另一表面安裝 磁性元件200之各種視圖。圖5為該元件2〇〇之局部分解 圖’圖6為該元件200之俯視透視示意圖，圖7為該元件2〇〇 之俯視透視總成圖。圖8為該磁性元件200之仰視透視總成 圖。 雖然該元件200類似於該元件1 〇〇，但是該元件2〇〇包含 離散磁芯件110及112 ’其中該第二磁芯件112被組裝至該 第一者，而線圈104定位於其間。該磁芯件11〇及112可由 熟習此項技術者所知之一合適磁芯材料製造，該材料包含 148034.doc 15- 201106390 但不限於鐵磁材料及亞鐵磁材料，如 π 划上所述之其他材料及 根據已知技術在此項技術中已知之材料。 圖9部分繪示利用一終止製造層38〇之—終止技術。該終 止製造層380可由根據已知技術在此項技術中已知之一導 電材料(例如，銅)或導電合金製造。該製造層可經形成以 包含-引線框架382’該引線框架具有連接至該引線框架 382之邊緣之相對的成對端子夾384。雖然顯示兩對端子夾 則’但是可替代提供更多或更少數目之端子夾。間隙或 間隔界定於各對中之端子夾384之各者之間。如下所解 釋’可在此等間隙或間隔中形成磁性本體。 如圖ίο中所示，且類似於上述之端子夾1〇6及1〇8，各端 子夾384包含一中央部分386，其具有位於側面之偏移凸片 或凸緣388、390，該等凸片或凸緣在與該中央部分386之 平面間隔開之一平面上延伸。雖然在圖〗〇中所示之透視圖 中該等凸片或凸緣388、390看似自中央部分386凸出，但 是當倒置該等夾時，該等凸片或凸緣388、390將以一類似 於上述夾106及108之方式而相對於該中央部分386凹陷。 因此’該等中央部分3 86可視為該等底部區段丨42，及該等 凸緣或凸片388、390可視為在上述夾1〇6及1〇8中之區段 140及144 。 在一例示性實施例中，各端子夾384之升起凸緣388之一 者包含一磁芯柱392 ’且該等升起凸緣390之另一者包含一 終止槽394。該等各自磁芯柱392將該等夹384輔助固定至 一磁性本體’且該終止槽394作為一線圈引線之一連接 148034.doc -16· 201106390 點。雖然在一實施例中提供終止槽394，但是在另一實施 例中可替代地提供通孔以容納線圈引線。如圖9及1〇中所 不，雖然各自成對端子夾384在一實施例中形成為彼此之 鏡射影像，但是在至少一些實施例中其無須為鏡射影像。The coil 1〇4, which is best seen in FIG. 2, is fabricated from a length of circular wire and includes a first end or lead 15G, a second end opposite the first end or lead 152, and a coil end Winding portion 154 between 150 and 152, wherein the wire wraps around a number of zones around the coil axis! 5 6 to achieve a desired effect 'for example' such as for the component 1 - selected end use - the required inductance value. In addition, the coil is wound with both a helical pattern along the axis 156 and a spiral pattern relative to the shaft 156 to provide a more compact coil design to meet low profile requirements while also providing a desired inductance value. The ends 丨5〇, 丨52 are bent relative to the s-winding portion 154 such that the ends extend parallel to the coil axis 156 to facilitate termination of the coil ends 150, 152, as explained below. If desired, the wires used to form the coils 1〇4 can be coated with an enamel coating and the like to improve the structure and functional aspects of the coils 104. As will be appreciated by those skilled in the art, the inductance of coil 104 depends in part on the type of wire, the number of turns in the coil, and the diameter of the wire. Therefore, the inductance rating of the coil 1 〇 4 may vary greatly for different applications. The coils 1〇4 can be fabricated separately from the core members 110 using known techniques and can be provided as one of the pre-wound structures of the assembly of the elements 148034.doc -11 - 201106390 100. In an exemplary embodiment, although the coil 104 is formed in an automated manner to provide one of the completed coils with a sense of the sense of 'but if desired', the coils may alternatively be manually wound. It should be understood that if more than one coil is provided, an additional terminal clip may be required to electrically connect to all of the utilized coils. The coil 104 is merely illustrative and it should be understood that other types of coils may be used instead. For example, a coil can be fabricated using a flat conductor instead of the circular line depicted in FIG. Additionally, the winding portion 154 can assume various alternative shapes and configurations, including but not limited to spiral or spiral configurations (but not as shown in Figure 2) and the winding portion configuration has a replacement curved region. Straight, polygonal sections of segments (snake, C, etc.). Also, more than one coil can be utilized if desired. As shown in the illustrated embodiment, the core member U 〇 is formed in a substantially rectangular body having a bottom wall 114 and a plurality of substantially orthogonal sidewalls 116, 118, 120, and 122, The sidewalls extend from the rim of the bottom wall 114 to the edge. In the embodiment illustrated in Figures 1-4, the bottom wall 114 may sometimes be referred to as a bottom wall. The side walls 116 and 118 are opposite each other and may sometimes be referred to as a left side and a right side. The walls 120 and 122 are opposite each other and may be referred to as a front side and a rear side, respectively. The side walls 116, 118, 120 and 122 define a perimeter or cavity above the bottom wall 114 which, when assembled, is substantially contained within the enclosure or cavity. As also shown in Fig. 1, the sidewall 116 of the first core member 110 also includes a recessed surface 123' and the opposing sidewalls 8 include a corresponding recessed surface. The recessed surfaces 123 and 125 extend only a portion of the length along the length of the respective sidewalls 116 and 118 of 148034.doc • 12-201106390. The recessed surfaces 123 and 125 also extend upwardly from the bottom wall 114 to a distance less than one of the heights of the sidewalls 116 and 118 measured in a direction perpendicular to the bottom surface. Accordingly, the recessed surfaces 123 and 125 are spaced apart from the top edges of the sidewalls 116 and 118, and the recessed surfaces 126 and 128 adjoining the bottom wall 114 reach the sidewalls 116 and 11 extending adjacent the bottom wall 114. One of the lengths of 8. The outer surface of the bottom wall 114 of the core member 110 is undulating and includes a non-recessed surface 124 that separates the first and second recessed surfaces I26 and 128. The concave Ρα surfaces 126 and 128 extend on opposite sides of the non-recessed surface 124. Second and fourth recessed surfaces 130 and 132 are also disposed on opposite corners of the bottom wall 114. The fifth and sixth recessed surfaces 134, 136 are opposite the third and fourth recessed surfaces 13A and 132 of the remaining corners of the core member i1. In the illustrated embodiment, the fifth and sixth recessed surfaces 134, 136 are substantially coplanar with each other and also extend substantially coplanar with the third and fourth recessed surfaces 13A and 132. . Therefore, the bottom wall 14 has a three-position surface in a stepped manner, wherein the first level is a non-recessed surface 124, and the second level is spaced apart from the first level by a first number of recessed surfaces 126 and 128, And the third level is a recessed surface 13〇, 132, 134, 136 spaced apart from each of the first and second stages. The recessed surfaces 126, 132 and 134 are spaced apart and separated from the recessed surfaces 128, 13 and 136 by the non-recessed surface 124. The concave surfaces 118 and 136 are spaced apart and separated by the recessed surface 128, and the concave Pa surfaces 132 and 134 are spaced apart and separated by the recessed surface 126. The exemplary terminal clips 106 and 108 shown in FIG. 1 are substantially identical in construction to 148034.doc 13·201106390, but are reversed by 18 degrees when applied to the first core member 110, and thus extend Mirror images for each other. The terminal clips 1 〇 6 and 108 of the component 1 respectively include a mounting section 140, a substantially flat and planar bottom section 142, and the opposite end of the bottom section 142 from the mounting sections 140 Extended coil section 144. A vertical positioning tab section i45 also extends generally perpendicular to the bottom section 142 of each of the clips 106 and 108. The positioning tab segments are shaped and dimensioned for receipt in recessed surfaces 123, 125 in sidewalls 116 and 117 of the first core member 1 i 。. In the illustrated embodiment, the mounting sections 14 延伸 extend in a substantially coplanar relationship with the coil sections 144 and offset the plane of the bottom sections 142 or the bottom sections 142 The planes are spaced apart. The clips 1 and 1 are assembled to the core member 11 〇, wherein the bottom portions i 42 abut the recesses 126 and 128, and the coil segments 144 abut the recessed surfaces 13 132' and the mounting sections ι4〇 abut the recessed surfaces 134 and 136. As also shown in FIGS. 1 and 2, the coil ends 15A and 152 extend through the through holes 146 and extend in the coil segments 丨44 of the terminal clips i06, i 〇8, wherein they can be soldered , welded or otherwise attached to ensure that the coil ends are 〇5〇,! 52 Electrical connection between the coils 104. However, since the coil ends 15 are positioned on the recessed surfaces of the bottom wall 114 of the core member 11〇, they do not protrude from the total outer surface of the core member 110, and when the component 100 is processed It is not easy to separate when it is not desirable. The terminal clips 106, 1 and 8 and all of the segments described can be fabricated in a relatively straightforward manner by cutting, bending or otherwise forming the clips 1〇6 and 1〇8 from a conductive material. In an exemplary implementation, the terminals are 148034.doc -14-201106390 stamped from a copper plate and bent into a final form, but can be replaced with other materials and forming techniques. The clips 106, 1 〇 8 can be pre-formed and assembled to the core member 11 随后 at a subsequent production stage. Since the core member 110 is pressed around the coil 1 〇 4, the electrical connection between the coil ends 150, 152 and the terminal clips 1 〇 6, 108 is positioned outside the δ core structure. As shown in FIG. 3, when the component 1 is mounted to the circuit board 180, the bottom wall i丨4 of the first core member 11 faces and abuts the 0-plate surface 184 and each terminal clip 1〇6 The flat and planar bottom section 142 of the first 8 is electrically coupled to the conductive traces 182 on the beta board 180 via soldering techniques or other techniques known in the art. Each of the coil segments 144 of 106, 1〇8 faces the circuit board 180 and the electrical connection between the coil ends 15〇, 152 and the coil portions 144 of the fuses is substantially protected by the core structure. under. The clips 106 and 108 facilitate safe and reliable electrical connection of the coil ends 15 and 152 during relatively simple, efficient and cost effective manufacturing processes. 5-8 are various views of another surface mount magnetic component 200 in accordance with an exemplary embodiment of the present invention. Fig. 5 is a partially exploded perspective view of the element 2, Fig. 6 is a top perspective view of the element 200, and Fig. 7 is a top perspective view of the element 2'. Figure 8 is a bottom perspective view of the magnetic component 200. Although the element 200 is similar to the element 1 〇〇, the element 2 〇〇 includes discrete core members 110 and 112 ' wherein the second core member 112 is assembled to the first one and the coil 104 is positioned therebetween. The core members 11 and 112 may be fabricated from a suitable core material known to those skilled in the art, including 148034.doc 15-201106390 but not limited to ferromagnetic materials and ferrimagnetic materials, such as π Other materials are described and materials known in the art in accordance with known techniques. Figure 9 is a partial illustration of a termination technique using a termination manufacturing layer 38. The termination fabrication layer 380 can be fabricated from a conductive material (e.g., copper) or a conductive alloy known in the art in accordance with known techniques. The fabrication layer can be formed to include a leadframe 382' having opposing pairs of terminal clips 384 connected to the edges of the leadframe 382. Although two pairs of terminal clips are shown, 'alternatively, a greater or lesser number of terminal clips may be provided. Gap or spacing is defined between each of the terminal clips 384 in each pair. The magnetic body can be formed in such gaps or spaces as explained below. As shown in FIG. 1, and similar to the terminal clips 1〇6 and 1〇8 described above, each terminal clip 384 includes a central portion 386 having offset tabs or flanges 388, 390 on the sides. The tabs or flanges extend in a plane spaced from the plane of the central portion 386. Although the tabs or flanges 388, 390 appear to protrude from the central portion 386 in the perspective view shown in the figures, when the clips are inverted, the tabs or flanges 388, 390 will It is recessed relative to the central portion 386 in a manner similar to the clips 106 and 108 described above. Thus, the central portions 386 can be considered as the bottom segments 丨42, and the flanges or tabs 388, 390 can be considered as segments 140 and 144 in the clips 1〇6 and 1〇8. In an exemplary embodiment, one of the raised flanges 388 of each terminal clip 384 includes a core post 392' and the other of the raised flanges 390 includes an end slot 394. The respective magnetic core posts 392 assist in securing the clips 384 to a magnetic body ' and the termination slots 394 are connected as one of the coil leads 148034.doc -16·201106390 points. Although the termination slot 394 is provided in one embodiment, a via is alternatively provided in another embodiment to accommodate the coil leads. As shown in Figures 9 and 1 , although the respective pair of terminal clips 384 are formed as mirror images of each other in one embodiment, in at least some embodiments they need not be mirror images.
圖11繪示利用該終止製造層380來製造一小型化磁性元 件之製造過程。士口圖11八中所*，該終止製造層38〇可*** 入至一模件400中，且可在各對端子夾384之間提供一線圈 402(圖9及1〇)。亦如圖11A中所示，各端子夹中之終止 槽394容納該等線圈端4〇3之一者。可為上述材料之任何者 之磁性材料接著可施加且壓製在該等線圈周圍以在各線圈 4〇2周圍形成磁性本體4〇4，如圖UB中所示。當模製該等 端子夾384時，該等端子夾384中之磁怒柱如（圖卵皮後入 於該等磁性本體404中。接著可從該模4⑼移除該等磁性本 體404及包含該等夾384之已附接之引線框架。圖加以俯 視圖繪示所得總成，及圖11D以仰視圖繪示所得總成。 如圖11D及HE中所示，該引線框架382可在—切割線咖 處修整或切斷’該切割線定位於與該等磁性本體404之橫 向邊緣相距—預定距離，且各端子夾384之一部分可經彎 曲圍繞該磁性本體之-側邊緣，如圖UF中所示。該爽州 之該部分被-曲實質上9〇度角度且沿著該磁性本體之側壁 而延伸。因為該等㈣線384距料磁性本體4G4之該預定 距離相對較小’所以該等夾384之彎曲部分僅部分向上延 伸至該等磁性本體4G4側之部分。即，該等央384之彎曲部 分之高度小於該等磁性本體404之側壁之高度。 148034.doc -17- 201106390 如圖11F中所示之該等夾384之彎曲部分可實質上對應於 上述該等端子夾106及108之定位部分〗45。類似於以上實 施例中所述之凹口 123及125之凹口可模製至該磁性本體之 側壁中以適應該等端子夾384之彎曲部分，而不會負面影 響该磁性元件之佔用面積。該等線圈端4〇3可經由銲接程 序、熔接程序或如圖11G中所示熟習此項技者熟悉之其他 技術而電連接至該等夾384。當使用相對較大之線規來製 造该等線圈時，銲接可能較佳，及當使用相對較小之線規 來製造S亥等線圈時，熔接可能較佳。 圖11H繪不一已完成之磁性元件，其包含該等端子夾 3 84。一旦完成該等磁性元件42〇，其可經由該等夾之 中央部分386而表面安裝至一電路板，如上所述。 圖12、，會示一磁性元件45〇之另一實施例，該磁性元件“ο 可類似於上述之方法而製造。在製造中，當修整該引線框 架382時，該元件45()、該等切割線彻（圖nD)與該磁性本 體4〇4間隔更遠。因此，當該等夾386被彎曲圍繞該磁性本 體404 % ’忒夾之經修整部分足夠長以延伸該磁性本體4⑽ 之側壁之整個⑤度且經進—步彎曲約9Q度角度以沿著該磁 !·生本體之頂壁之-部分而延伸，該頂壁可包含—凹口以適 應：已彎曲夾，而不會負面影響該元件之輪廓。如在圖！2 之實施例中，將该切割線與該磁性本體4〇4間隔更遠，呈 現降低污㈣題之風險及由模製操作或形成該磁性本體 404 %之其他製造步驟而產生之負面影響。 所不之基本方法之許多變動係有可能的。舉例而言，在 148034.doc -18- 201106390 修u引線框架之前及/或在該等夾386被彎曲包圍該磁性 本體之側之前，該望始IS! y 亥等線圈可經銲接、熔接或另外方式連接 至該等線圈端403。即，並不一定要求如上所述之步驟順 序。 另外，其他形狀之端子夾可形成於該引線製造層中而具 有類似效果及優點。即，該等夾需要具有在其他替代實施 例中所說明及描述之精確形狀。 〇 同樣’在某些實施例中，該等線圈不需與該終止製造層 刀開地提供以用於在模製程序中組裝。相反，該等線 圈可預先附接至該製造層或另外在某些實施例中與該終止 製造層整體形成。 、^可以各種方式完成銲接、熔接或另外電連接 該等線圈端至該等夾。舉例而言，該等夾中之該等槽 394(圖Π))可視為可選的，且可#代制通孔或促進線圈引 線，接合之其他機械特徵。作為另一實例，在一些實施例 0 Μ等夹中之通孔及槽可視為可選的，且在沒有利用機械 接合特徵的情況下，該等線圈引線4〇3可例如經炫接至該 等夾之表面。再進一步，有可能將該等端子爽熔接或銲接 至在—磁芯件内部之一位置處之該等引線端，如在2_年 4月24日中請之美國專财請案第12/429,856射所描述， ”已以引用之方式併入本文中。此外，該等線圈引線可焊 接或炫接至該等夾之内部面對表面（即，在已完成之元件 中面對該磁性本體之一表面）以及該等夾之外部面對表面 (在已完成之元件中背離該磁性本體之一表面）。 14S034.doc •19. 201106390 III.所揭示之例示性實施例 現應很明顯，可以各種組合來混合及匹配所述之各種特 徵。可有利地提供種類繁多之磁性元件總成以符合特定應 用之需要，該等總成具有不同磁性性質、不同數目及類型 之線圈，且具有不同性能特性。 此外’所述之某些特徵可有利地用於具有離散磁芯件之 結構中’該等離散磁芯件實體上彼此具間隙及隔開。 在以上闡述之本發明之範圍内之各種可能性中，咸信至 少以下實施例相對於習知電感器元件係具優勢。 本文揭示一表面安裝磁性元件之一例示性實施例，其中 該總成包含：一磁芯，該磁芯界定至少一外側，該外側具 有一階梯式底部S Φ;在該磁芯内冑之一導電線圈，該線 圈包含第一及第二端；該等第—及第二端之至少一 穿過該階梯式底部表面之—部分；及—端子夾，其經定形 狀以與該階梯式表面互補，該端子夾對接該階梯式表面且 連接至該至少一線圈端。 視情況而言，該階梯式表面包含一非凹陷表面及凹 面之至少㈣準。該夾可包含-中央區段及在該凹陷區名 任-側上之第一及第二凹陷區段。該夾之凹陷區段之一4 可包含嵌入於該磁芯中之一柱，及該等凹陷區段之另一4 可連接至該線圈端。該夾亦可包含容納該至少一線圈端之 一通孔或容納該至少一線圈端之一終止槽。 該磁性本體可視情況模製於該端子失上。該夹可包含至 少-90度彎曲。該磁性本體可包含自該底表面延伸之一彻 148034.doc -20- 201106390 壁’其中該夾之-部分沿著該側壁而延伸。該磁性本體可 包含與該階梯式底表面相反之一頂表面，其中該夹之一部 分沿著該頂表面而延伸。該總成亦可視情況包含一電路 & ’其中該底表面置於該電路板上。該磁性本體及線圈可 形成一電感器。 ’ 本發明亦揭示一種製造一磁性元件之方法之一例示性實 施例。該方法包括在至少-端子夾及與該端子夹相關聯之 〇 1少一線圈之上形成-磁性本體，據此該端子夾整體附接 至該已形成之磁性本體之一底表面。 視情況而言，形成該磁性本體包括形成具有一階梯式底 表面之一磁性元#，且該端子夾整體附接至該階梯式底表 面。該端子夾可包含至少一柱，且該方法可進一步包括當 形成該磁性本體時將該柱嵌入於該磁性本體中。該端子夾 可附接至-引線框架，且該方法可進一步包括修整該引線 框架以自該引線框架切斷該夾。 Ο 該方法可進一步且視情況包括彎曲該夾之一部分圍繞該 磁性本體之一側壁。該方法亦可進一步包括彎曲該夾以沿 著該磁性本體之一頂表面而延伸。 亦視情況而言，該方法可進一步包括將該端子夾電連接 至該線圈端。電連接該端子夾可包括將該線圈端熔接或銲 接至該夾。電連接該端子夾同樣可包括將該線圈端容納於 一通孔或終端槽之一者中，或將該磁性本體之該底表面上 之一暴露線圈端附接至該失。 形成該本體可視情況包括將該本體模製於該至少一夹 148034.doc -21- 201106390 上。該至；一端子夾可包含一對由一引線框架連結之端子 夾，该引線框架在該對夾間具有—間隙，其中該磁性本體 形成於該對端子失間之該間隙中。該端子夾可包含一中央 部分及在該中央部分任一側上之第一及第二凹陷部分，其 中該方法進一步包括將該線圈連接至該等凹陷部分之一 者。 IV·結論 現本發明之益處咸信可自前述實例及實施例而顯而易 見雖然、已特疋描述許多實施例及實4列，但是在所揭示之 例示〖生器件、總成及方法之範圍及精神内的情況下，其他 貫例及實施例是有可能的。 此書面描述使用實例來揭示本發明（包含最佳模式），且 亦使熟習此項技術者能夠實踐本發明，其包含製作且使用 任何器件或系、統且執行任何併人之方法。本發明之專利範 圍係由請求項界定，且可包含熟習此項技術者想到之其他 實例。若此等其他實例具有不同於請求項之文字語言之結 生因素，或右此等其他實例包含具有Y同於請求項之文 子° »之非貫質性差異之等效結構性因素，則此等其他實 例被視為在請求項之範圍内。 【圖式簡單說明】 圖1為根據本發明之—例示性實施例之-例示性表面安 裝磁性元件之局部分解圖； 圖2為圖1中所示之磁性元件之俯視透視示意圖； 圖3為圖1中所示之磁性元件之俯視透視總成圖； 148034.doc -22- 201106390 圖4為圖1中所示之磁性元件之仰視透視總成圖； 圖5為根據本發明之一例示性實施例之另一例示性磁性 元件之部分分解圖； 圖6為圖5中所示之磁性元件之俯視透視示意圖； 圖7為圖5中所示之磁性元件之俯視透視總成圖； 圖8為圖5中所示之磁性元件之仰視透視總成圖； 圖9繪不根據本發明之另一實施例形成之一端子總成； 〇 圖10為圖9中所示之總成之一部分之放大圖； 圖U繪示利用圖9及丨0中所示之端子總成之製造步驟； 其中 圖11A代表一磁性元件之製造之—第一階段； 圖UB代表該磁性元件之製造之—第二階段； 圖nc綠示來自圖11B之所得總成的俯視圖； 圖1呵示來自圖11B之所得總成的仰視圖； 圖1⑶代表該磁性元件之製造之一第三階段； Ο 圖1”代表該磁性元件之製造之一第四階段； 圖⑽代表該磁性元件之製造之—第五階段； 圖11Η顯示完成之磁性元件；及 •圖12繪示另一磁性元件。 【主要元件符號說明】 100 表面安裝磁性元件 102 磁芯 104 線圈 106 端子夾 148034.doc -23- 201106390 108 端子夾 110 單板 112 離散磁芯件 114 底壁 116 側壁 118 側壁 120 側壁 122 側壁 123 凹陷表面/凹口 124 非凹陷表面 125 凹陷表面/凹口 126 凹陷表面 128 凹陷表面 130 第三凹陷表面 132 第四凹陷表面 134 第五凹陷表面 136 第六凹陷表面 140 安裝區段 142 底部區段 144 線圈區段 145 定位凸片區段 146 通孔 150 線圈端 152 線圈端 148034.doc -24 201106390Figure 11 illustrates the fabrication process for fabricating a miniaturized magnetic component using the termination fabrication layer 380. The termination manufacturing layer 38A can be inserted into a module 400 and a coil 402 can be provided between each pair of terminal clips 384 (Figs. 9 and 1). As also shown in Fig. 11A, the terminating groove 394 in each terminal clip accommodates one of the coil ends 4〇3. A magnetic material, which may be any of the above materials, may then be applied and pressed around the coils to form a magnetic body 4〇4 around each coil 4〇2, as shown in UB. When the terminal clips 384 are molded, the magnetic anger bars in the terminal clips 384 are inserted into the magnetic bodies 404. The magnetic bodies 404 can then be removed from the dies 4 (9) and included. The attached lead frame of the clip 384. The view shows the resulting assembly in a top view, and the resulting assembly is shown in a bottom view in Fig. 11D. The lead frame 382 can be cut as shown in Fig. 11D and HE. The wire is trimmed or cut off. The cutting line is positioned at a predetermined distance from the lateral edges of the magnetic bodies 404, and a portion of each terminal clip 384 can be bent around the side edge of the magnetic body, as shown in FIG. The portion of the cool state is stretched substantially 9 degrees and along the sidewall of the magnetic body. Because the (four) line 384 is relatively small from the predetermined distance of the magnetic body 4G4, The curved portion of the clip 384 extends only partially upwardly to the portion of the magnetic body 4G4 side. That is, the height of the curved portion of the central portions 384 is less than the height of the side walls of the magnetic bodies 404. 148034.doc -17- 201106390 The bend of the clip 384 shown in Figure 11F The portion may substantially correspond to the positioning portion 45 of the terminal clips 106 and 108 described above. A recess similar to the recesses 123 and 125 described in the above embodiments may be molded into the sidewall of the magnetic body to accommodate the The curved portion of the terminal clip 384 does not adversely affect the footprint of the magnetic component. The coil ends 4〇3 may be familiar to other techniques familiar to those skilled in the art via soldering procedures, fusion procedures, or as shown in FIG. 11G. And electrically connected to the clips 384. When using relatively large gauges to fabricate the coils, soldering may be preferred, and when relatively small gauges are used to fabricate coils such as Shai, the fusion may be preferred. Figure 11H depicts a completed magnetic component that includes the terminal clips 384. Once the magnetic components 42 are completed, they can be surface mounted to a circuit board via the central portion 386 of the clips, as described above. Figure 12, another embodiment of a magnetic element 45 can be shown, which can be fabricated similar to the method described above. In fabrication, when the lead frame 382 is trimmed, the element 45() These cutting lines Figure nD) is spaced further from the magnetic body 4〇4. Therefore, when the clip 386 is bent around the magnetic body, the trimmed portion of the clip is sufficiently long to extend the entire 5 degree of the sidewall of the magnetic body 4 (10) And extending through an angle of about 9Q degrees to extend along a portion of the top wall of the magnetic body, the top wall may include a notch to accommodate: the bent clip without adversely affecting the component In the embodiment of Fig. 2, the cutting line is spaced further from the magnetic body 4〇4, exhibiting the risk of reducing the contamination problem and other manufacturing operations by molding or forming the magnetic body 404%. The negative impact of the steps. Many variations of the basic methods are not possible. For example, before the 148034.doc -18-201106390 repair u lead frame and/or before the clip 386 is bent to surround the side of the magnetic body, the coils such as the IS! y hai can be welded, welded or Another way is connected to the coil ends 403. That is, the order of steps as described above is not necessarily required. In addition, other shapes of terminal clips can be formed in the lead manufacturing layer to have similar effects and advantages. That is, the clips need to have the exact shape illustrated and described in other alternative embodiments. 〇 Also in some embodiments, the coils need not be provided with the termination manufacturing layer for assembly in a molding process. Instead, the coils may be pre-attached to the fabrication layer or otherwise formed integrally with the termination fabrication layer in some embodiments. , ^ can be welded, welded or otherwise electrically connected to the clamps in various ways. For example, the slots 394 (Fig.) in the clips can be considered optional and can be used to create vias or to facilitate coil leads, bonding other mechanical features. As another example, the vias and slots in some embodiments of the Μ Μ can be considered optional, and without the use of mechanical engagement features, the coil leads 4 〇 3 can be spliced to the The surface of the clamp. Further, it is possible to cool or solder the terminals to the lead ends at a position inside the core member, such as the US special account number 12/ in the April 24, 2 year. 429, 856, the disclosure of which is hereby incorporated hereinby incorporated by reference herein in its entirety in its entirety in its entirety in its entirety in the in the in the One of the surfaces) and the outer facing surface of the clips (facing away from the surface of the magnetic body in the completed component). 14S034.doc • 19. 201106390 III. The illustrative embodiments disclosed should now be apparent. The various features described can be mixed and matched in various combinations. A wide variety of magnetic component assemblies can be advantageously provided to meet the needs of a particular application having different magnetic properties, different numbers and types of coils, and having different Performance characteristics. Further, some of the features described may be advantageously used in structures having discrete magnetic core members. The discrete magnetic core members are physically spaced and spaced apart from each other. The scope of the invention as set forth above Among the various possibilities, at least the following embodiments are advantageous over conventional inductor components. An exemplary embodiment of a surface mount magnetic component is disclosed herein, wherein the assembly comprises: a magnetic core, the magnetic core Defining at least one outer side, the outer side having a stepped bottom S Φ; one of the conductive coils in the magnetic core, the coil includes first and second ends; at least one of the first and second ends a portion of the stepped bottom surface; and - a terminal clip shaped to complement the stepped surface, the terminal clip abutting the stepped surface and coupled to the at least one coil end. Optionally, the stepped The surface comprises at least (4) a non-recessed surface and a concave surface. The clip may comprise a central section and first and second recessed sections on the name-side of the recessed area. One of the columns embedded in the magnetic core may be included, and the other 4 of the recessed sections may be connected to the coil end. The clip may further include a through hole for receiving the at least one coil end or a receiving the at least one coil end One of the termination slots. The magnetic The body may be molded to the terminal to be lost. The clip may comprise a bend of at least -90 degrees. The magnetic body may comprise a 148034.doc -20- 201106390 wall extending from the bottom surface, wherein the clip-partial edge Extending the sidewall. The magnetic body can include a top surface opposite the stepped bottom surface, wherein a portion of the clip extends along the top surface. The assembly can also optionally include a circuit & A bottom surface is disposed on the circuit board. The magnetic body and the coil may form an inductor. The present invention also discloses an exemplary embodiment of a method of fabricating a magnetic component. The method includes at least a terminal clip and the A magnetic body is formed on the coil 1 associated with the first one of the coils, whereby the terminal clip is integrally attached to one of the bottom surfaces of the formed magnetic body. Optionally, forming the magnetic body includes forming a magnetic element # having a stepped bottom surface, and the terminal clip is integrally attached to the stepped bottom surface. The terminal clip can include at least one post, and the method can further include embedding the post in the magnetic body when the magnetic body is formed. The terminal clip can be attached to the - lead frame, and the method can further include trimming the lead frame to sever the clip from the lead frame. Ο The method may further and optionally include bending one of the clips around a side wall of the magnetic body. The method can also include bending the clip to extend along a top surface of the magnetic body. Also optionally, the method can further include electrically connecting the terminal clip to the coil end. Electrically connecting the terminal clip can include welding or soldering the coil end to the clip. Electrically connecting the terminal clip can also include receiving the coil end in one of a through hole or a terminal slot, or attaching one of the bottom surfaces of the magnetic body to the exposed coil end to the loss. Forming the body as appropriate includes molding the body over the at least one clip 148034.doc -21 - 201106390. The terminal clip may include a pair of terminal clips connected by a lead frame, the lead frame having a gap between the pair of clips, wherein the magnetic body is formed in the gap between the pair of terminals. The terminal clip can include a central portion and first and second recessed portions on either side of the central portion, wherein the method further includes connecting the coil to one of the recessed portions. IV. CONCLUSIONS The benefits of the present invention are readily apparent from the foregoing examples and examples, although many embodiments and four columns have been specifically described, but the scope of the disclosed devices, assemblies, and methods are disclosed. Other examples and embodiments are possible in the context of the mind. The written description uses examples to disclose the invention, including the best mode of the invention, and is to be understood by those skilled in the art. The patent scope of the invention is defined by the claims and may include other examples that are apparent to those skilled in the art. If such other instances have a different factor than the word language of the request, or if the other instance to the right contains an equivalent structural factor that has a non-permanent difference from the text of the request item, then this Other instances are considered to be within the scope of the request. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a partially exploded perspective view of an exemplary surface mount magnetic component in accordance with an exemplary embodiment of the present invention; FIG. 2 is a top perspective view of the magnetic component shown in FIG. FIG. 4 is a bottom perspective view of the magnetic component shown in FIG. 1; FIG. 5 is an exemplary perspective view of the magnetic component shown in FIG. Figure 6 is a top perspective view of the magnetic element shown in Figure 5; Figure 7 is a top perspective view of the magnetic element shown in Figure 5; Figure 8 is a top perspective view of the magnetic element shown in Figure 5; Figure 5 is a bottom perspective view of the magnetic component shown in Figure 5; Figure 9 depicts a terminal assembly not formed in accordance with another embodiment of the present invention; Figure 10 is a portion of the assembly shown in Figure 9. Figure U shows the manufacturing steps of the terminal assembly shown in Figures 9 and 0; wherein Figure 11A represents the manufacture of a magnetic element - the first stage; Figure UB represents the manufacture of the magnetic element - Two stages; Figure nc green shows the resulting assembly from Figure 11B 1 is a bottom view of the assembly obtained from FIG. 11B; FIG. 1 (3) represents a third stage of manufacture of the magnetic element; Ο FIG. 1 ′′ represents a fourth stage of manufacture of the magnetic element; FIG. The magnetic element is manufactured in the fifth stage; Fig. 11A shows the completed magnetic element; and • Fig. 12 shows another magnetic element. [Main element symbol description] 100 Surface mounted magnetic element 102 Core 104 Coil 106 Terminal clamp 148034 .doc -23- 201106390 108 Terminal clamp 110 Single plate 112 Discrete core piece 114 Bottom wall 116 Side wall 118 Side wall 120 Side wall 122 Side wall 123 Concave surface / Notch 124 Non-recessed surface 125 Concave surface / Notch 126 Concave surface 128 Concave surface 130 third recessed surface 132 fourth recessed surface 134 fifth recessed surface 136 sixth recessed surface 140 mounting section 142 bottom section 144 coil section 145 positioning tab section 146 through hole 150 coil end 152 coil end 148034.doc - 24 201106390
154 156 180 182 184 200 380 382 384 386 388 390 392 394 400 402 403 404 410 繞組部分 線圈轴 電路板 導電跡線 板表面 表面安裝磁性元件 終止製造層 引線框架 端子夾 中央部分 凸片或凸緣 凸片或凸緣 磁芯柱 終止槽 模件 線圈 線圈端 磁性本體 切割線 148034.doc 25-154 156 180 182 184 200 380 382 384 386 388 390 392 394 400 402 403 404 410 Winding part coil shaft circuit board Conducting trace surface surface Mounting magnetic element termination Manufacturing layer lead frame terminal clip central part tab or flange tab Or flange core post termination slot module coil coil end magnetic body cutting line 148034.doc 25-