# US 10,121,585 B2 · Method of manufacturing magnetic core elements > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,121,585 B2 - Document ID: US10121585B2 - Status: Granted - Kind: B2 - Application number: 14/746,854 - Filed: 2015-06-23 - Published: 2015-12-24 - Granted: 2018-11-06 - Earliest claimed: 2014-06-23 - Assignees: Cyntec Co., Ltd. - Applicants: Cyntec Co., Ltd. - Inventors: Hsieh-Shen Hsieh; Shih-Feng Chien; Yu-Lun Chang; Chih-Hung Wei - Web page: https://patentgrep.com/patent/US10121585B2 ## CPC - H01F 41/0233: {Manufacturing of magnetic circuits made from sheets (magnetic cores made from sheets H01F27/245; soft magnetic alloys in the form of sheets H01F1/16)} - H01F 27/24: Magnetic cores - H01F 27/245: made from sheets, e.g. grain-oriented (H01F27/26 takes precedence) - Y10T 156/1052: with cutting, punching, tearing or severing - H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A method of manufacturing magnetic core elements includes preparing a plurality of magnetic green sheets and a plurality of non-magnetic green sheets; alternately laminating the plurality of magnetic green sheets and non-magnetic green sheets directly upon one another, thereby forming a green sheet laminate; cutting the green sheet laminate into individual bodies with desired dimension; and sintering the individual bodies, thereby forming a magnetic core element with discretely distributed gaps. ## Claims ### Claim 1 A method of manufacturing magnetic core elements, comprising: preparing a plurality of magnetic green sheets; preparing a plurality of support intermediate paste pattern embedded with an ashable pattern therein; alternately laminating the plurality of magnetic green sheets and the support intermediate paste pattern embedded with an ashable pattern directly upon one another, thereby forming a laminate; subjecting the laminate to a sintering process, wherein the ashable patterns that are interposed between the magnetic green sheets are burned out during the sintering process, thereby forming cavities in the laminate; filling the cavities with an adhesive; and cutting the laminate into individual bodies with desired dimension. ### Claim 2 (depends on 1) The method according to claim 1, wherein each said support intermediate paste pattern has the same composition as that of the magnetic green sheets. ### Claim 3 (depends on 1) The method according to claim 1, wherein a printing process is performed to print the ashable pattern into a central opening of each said support intermediate paste pattern. ### Claim 4 (depends on 1) The method according to claim 1, wherein the ashable pattern is composed of carbon or carbon-based materials. ### Claim 5 (depends on 1) The method according to claim 1, wherein after filling the cavities with an adhesive, the adhesive is cured. ### Claim 6 (depends on 1) The method according to claim 1, wherein said cutting the laminate into individual bodies with desired dimension further comprises: removing the support intermediate paste pattern. ### Claim 7 A method of manufacturing magnetic core elements, comprising: preparing a capping magnetic piece; preparing a plurality of lower magnetic pieces, wherein each of the lower magnetic pieces has at least two upwardly protruding legs; laminating the lower magnetic pieces and the capping magnetic piece, thereby forming a plurality of cavities therebetween; filling the cavities with an adhesive, thereby forming a laminate; subjecting the laminate to a curing process; and cutting the laminate into discrete core elements with desired dimension and configuration. ### Claim 8 (depends on 7) The method according to claim 7, wherein the legs are separated from the discrete core element by the cutting process. ### Claim 9 (depends on 7) The method according to claim 7, wherein each of the lower magnetic pieces has an E shape. ### Claim 10 (depends on 7) The method according to claim 7, wherein the capping magnetic piece and the plurality of lower magnetic pieces are already treated by sintering process before lamination. ### Claim 11 (depends on 7) The method according to claim 7, wherein the capping magnetic piece or the plurality of lower magnetic pieces comprises Mn-Zn or Ni-Zn. ### Claim 12 (depends on 7) The method according to claim 7, wherein a thickness of the adhesive in each of the cavities is substantially equal to a height of the at least two upwardly protruding legs. ### Claim 13 A method of manufacturing magnetic core elements, comprising: preparing a monolithic magnetic body; performing a diamond wire sawing process to form a plurality of trenches with high-aspect ratio and uniform trench width into a top surface of the magnetic body, wherein the trenches separate a plurality of sidewall pieces from one another, wherein the plurality of sidewall pieces are connected together by a bottom connecting portion; filling the trenches with an adhesive; and performing a polishing process or a cutting process to remove the bottom connecting portion, thereby forming a magnetic core element. ### Claim 14 (depends on 13) The method according to claim 13, wherein each of the trenches has substantially the same trench top width and trench bottom width. ### Claim 15 (depends on 13) The method according to claim 13, wherein a width of each of the trenches depends upon the diameter of the diamond wire used in the diamond wire sawing process. ### Claim 16 (depends on 13) The method according to claim 13, wherein the plurality of trenches has a trench depth ranging between 1-160 mm. ### Claim 17 (depends on 13) The method according to claim 13, wherein the high-aspect ratio of the plurality of trenches ranges between 4-2000.