# US 11,501,906 B2 · Inductor manufacturing method

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- Number: US 11,501,906 B2
- Document ID: US11501906B2
- Status: Granted
- Kind: B2
- Application number: 16/420,226
- Filed: 2019-05-23
- Published: 2020-11-26
- Granted: 2022-11-15
- Earliest claimed: 2019-05-23
- Assignees: Chilisin Electronics Corp.
- Applicants: Chilisin Electronics Corp.
- Inventors: Chia Chen Chen
- Web page: https://patentgrep.com/patent/US11501906B2

## CPC

- H01F 17/04: with magnetic core
- H01F 27/06: Mounting, supporting, or suspending transformers, reactors, or choke coils {not being of the signal type}
- C25D 5/10: Electroplating with more than one layer of the same or of different metals (for bearings C25D7/10)
- C25D 7/00: Electroplating characterised by the article coated
- C25D 7/001: {Magnets}
- H01F 27/2828: {Construction of conductive connections, of leads}
- H01F 27/2852: {Construction of conductive connections, of leads}
- H01F 27/292: {Surface mounted devices}
- H01F 41/024: {Manufacturing of magnetic circuits made from deformed sheets (magnetic cores made from deformed sheets H01F27/2455)}
- H01F 41/042: {by thin film techniques}
- H01F 41/06: Coil winding
- H01F 41/10: Connecting leads to windings (making electric connections in general H01R43/00)
- H01F 2017/048: {with encapsulating core, e.g. made of resin and magnetic powder}
- Y10T 29/4902: Electromagnet, transformer or inductor
- H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- C25D: PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

An inductor manufacturing method includes making a coil with a wire member, the coil has two end portions, bending a dependent segment from one end portion of the coil, and bending a lateral extension from the dependent segment, bending a bent segment from the second end portion of the coil, and bending a lateral segment from the bent segment, a base member is then engaged into a space between the coil and the lateral extension and the lateral segment of the coil for forming a coil assembly, the coil assembly is then engaged into a mold cavity of a mold device and punched together with an iron powder, the lateral extension and the lateral segment of the coil are electroplated with an electroplating layer.

## Claims

### Claim 1

An inductor manufacturing method comprising:
making a coil with a wire member, said coil including a first end portion and a second end portion,
bending a dependent segment from said first end portion of said coil, and bending a lateral extension from said dependent segment,
bending a bent segment from said second end portion of said coil, and bending a lateral segment from said bent segment,
forming a space between said coil and said lateral extension and said lateral segment of said coil,
engaging a base member into said space between said coil and said lateral extension and said lateral segment of said coil, for forming a coil assembly,
engaging said coil assembly into a mold cavity of a mold device,
filling an iron powder into said mold cavity of said mold device,
punching said coil assembly and said iron powder to form a prototype,
disengaging said prototype from said mold cavity of said mold device,
annealing said prototype,
lasering said lateral extension and said lateral segment of said coil, and
electroplating an electroplating layer to said lateral extension and said lateral segment of said coil.

### Claim 2 (depends on 1)

The inductor manufacturing method as claimed in claim 1, wherein said electroplating layer includes a copper layer.

### Claim 3 (depends on 1)

The inductor manufacturing method as claimed in claim 1, wherein said electroplating layer includes a nickel layer.

### Claim 4 (depends on 1)

The inductor manufacturing method as claimed in claim 1, wherein said electroplating layer includes a tin layer.

### Claim 5 (depends on 1)

The inductor manufacturing method as claimed in claim 1, wherein said iron powder is selected from an outer diameter ranged from 0.1 to 200 micron.

### Claim 6 (depends on 1)

The inductor manufacturing method as claimed in claim 1, wherein said coil assembly and said iron powder are subjected with a punching force ranged from 0.1-10 ton.

### Claim 7 (depends on 1)

The inductor manufacturing method as claimed in claim 1, wherein said prototype is subjected with an annealing temperature ranged between 300-600° C. for one hour.