# US 11,908,611 B2 · Manufacturing method for surface mounted inductor

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- Number: US 11,908,611 B2
- Document ID: US11908611B2
- Status: Granted
- Kind: B2
- Application number: 17/074,168
- Filed: 2020-10-19
- Published: 2021-02-04
- Granted: 2024-02-20
- Earliest claimed: 2014-07-18
- Assignees: Murata Manufacturing Co., Ltd.
- Applicants: Murata Manufacturing Co., Ltd.
- Inventors: Yoshitoshi Shoda; Kozo Sato; Makoto Murakami; Kunio Sasamori; Naoto Takahashi
- Web page: https://patentgrep.com/patent/US11908611B2

## CPC

- H01F 27/292: {Surface mounted devices}
- H01F 17/04: with magnetic core
- H01F 27/2828: {Construction of conductive connections, of leads}
- H01F 41/0246: {Manufacturing of magnetic circuits by moulding or by pressing powder (magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36)}
- H01F 41/076: Forming taps or terminals while winding, e.g. by wrapping or soldering the wire onto pins, or by directly forming terminals from the wire
- 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
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A formed body incorporating a coil by using: a coil formed by winding a conductive wire, and a formed body incorporating the coil, the formed body being formed with a sealing material containing a resin and a magnetic material. The coil is formed by winding the conductive wire so that lead-out ends are positioned at an outer periphery of a wound portion. The formed body is formed so that surfaces of the coil are partially exposed on four side surfaces of the formed body which are parallel to a winding axis of the coil, and the area of a portion of the formed body outside the outer periphery of the wound portion is almost equal to or smaller than the area of a portion of the formed body inside an inner periphery of the wound portion of the coil.

## Claims

### Claim 1

A manufacturing method for a surface mounted inductor including a coil formed by winding a conductive wire, and a formed body incorporating the coil, the formed body being formed with a sealing material containing a resin and a magnetic material, the manufacturing method comprising the steps of:
forming a coil by winding a conductive wire so that lead-out ends are positioned at an outer periphery of a wound portion;
forming a formed body by placing the coil between a pair of plate-shaped tablets which are formed with the sealing material, and integrating the tablets by a compression molding method so that the coil is partially exposed on four side surfaces of the formed body which are parallel to a winding axis of the coil, and the area of a portion of the formed body outside the outer periphery of the wound portion of the coil is almost the same as or smaller than the area of a portion of the formed body inside an inner periphery of the wound portion of the coil; and
forming external terminals connected to the lead-out ends of the coil on surfaces of the formed body.

### Claim 2 (depends on 1)

The manufacturing method for a surface mounted inductor according to claim 1, comprising, in the step of forming the coil,
forming a coil having a wound portion formed in an elliptical shape by winding a conductive wire shape so that both of its ends are positioned at an outer periphery, and lead-out ends led out from the outer periphery of the wound portion,
wherein a size in a minor axis direction of the wound portion and a size in a width direction of the formed body are made the same, and
wherein a size in a major axis direction of the wound portion is made to have a size obtained by subtracting a size of two conductive wires from a size in a length direction of the formed body or less,
and, in the step of forming the formed body,
forming a formed body so that surfaces in the minor axis direction of the wound portion of the coil are exposed on two side surfaces opposed in the width direction of the formed body, and surfaces of the lead-out ends of the coil are exposed on two side surfaces opposed in the length direction of the formed body so as to connect the lead-out ends of the coil to external terminals.