# US 2017/0287631 A1 · Manufacturing method of magnetic element > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2017/0287631 A1 - Document ID: US20170287631A1 - Status: Published application - Kind: A1 - Application number: 15/464,269 - Filed: 2017-03-20 - Published: 2017-10-05 - Earliest claimed: 2016-03-31 - Assignees: Fsp Technology Inc. - Applicants: Fsp Technology Inc. - Inventors: Kuo-Fan Lin; Fu-Kai Tu - Web page: https://patentgrep.com/patent/US20170287631A1 ## CPC - H01F 27/346: {Preventing or reducing leakage fields (using magnetic shields H01F27/36; using auxiliary windings H01F27/38)} - H01F 3/14: Constrictions; Gaps, e.g. air-gaps (in magnetic shunt paths H01F3/12) - H01F 17/043: {with two, usually identical or nearly identical parts enclosing completely the coil (pot cores)} - H01F 2017/046: {helical coil made of flat wire, e.g. with smaller extension of wire cross section in the direction of the longitudinal axis} - H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES ## Abstract A manufacturing method of a magnetic element includes the following steps: forming a block including a central post and at least one lateral post with magneto-conductive materials; cutting the block along a first plane passing through the central and lateral posts to form a first half body and a second half body; combining the first half body with the second half body to form a first air gap between the central post of the first half body and the central post of the second half body and a second air gap between the lateral post of the first half body and the lateral post of the second half body; and cutting or grinding the combined first half body and second half body along a second plane passing through the central post and the lateral post to form a third half body including the first and second air gaps. ## Claims ### Claim 1 A manufacturing method of a magnetic element, comprising: forming a block with magneto-conductive materials, wherein the block comprises a central post and at least one lateral posts; cutting the block along a first plane passing through the central post and the lateral posts to form a first half body and a second half body; combining the first half body with the second half body to form a first air gap between the central post of the first half body and the central post of the second half body and a second air gap between the lateral post of the first half body and the lateral post of the second half body; and cutting or grinding the combined first half body and second half body along a second plane passing through the central post and the lateral post to form a third half body comprising the first air gap and the second air gaps. ### Claim 2 (depends on 1) The manufacturing method according to claim 1, wherein the block comprises a first connecting portion connecting the central post and the lateral post and a second connecting portion connecting the central post and the lateral post, the first half body comprises the first connecting portion, and the second half body comprises the second connecting portion. ### Claim 3 (depends on 2) The manufacturing method according to claim 2, wherein the step of cutting or grinding the combined first half body and second half body along the second plane further comprises: cutting or grinding the first connecting portion of the first half body. ### Claim 4 (depends on 3) The manufacturing method according to claim 3, wherein a thickness of the first connecting portion is smaller than a thickness of the second connecting portion. ### Claim 5 (depends on 4) The manufacturing method according to claim 4, wherein the thickness of the first connecting portion is greater than or equal to 2 mm and smaller than or equal to 5 mm. ### Claim 6 (depends on 1) The manufacturing method according to claim 1, wherein the step of combining the first half body with the second half body further comprises: forming a first combination gap between the first half body and the second half body; and filling and sintering an adhesive in the first combination gap. ### Claim 7 (depends on 6) The manufacturing method according to claim 6, wherein the adhesive is a Bond-Ply material. ### Claim 8 (depends on 1) The manufacturing method according to claim 1, further comprising: placing a winding between the third half body and another third half body and around the central posts thereof; and combining the third half body and the other third half body. ### Claim 9 (depends on 8) The manufacturing method according to claim 8, wherein the step of combining the third half body and the other third half body further comprises: forming a second combination gap between the third half body and the other third half body; forming a third air gap between the central post of the third half body and the central post of the other third half body; and forming a fourth air gap between the lateral post of the third half body and the lateral post of the other third half body. ### Claim 10 (depends on 8) The manufacturing method according to claim 8, wherein the winding comprises coils winded by electro-conductive flat wires. ### Claim 11 (depends on 1) The manufacturing method according to claim 1, further comprising: fixing an isolating member to the lateral posts and maintaining a predetermined distance between the isolating member and the lateral post. ### Claim 12 (depends on 11) The manufacturing method according to claim 11, wherein the isolating member is comprised of magneto-conductive materials. ### Claim 13 (depends on 11) The manufacturing method according to claim 11, wherein the isolating member covers the second air gap completely. ### Claim 14 (depends on 1) The manufacturing method according to claim 1, wherein the block is formed by sintering magneto-conductive metal powder. ### Claim 15 (depends on 14) The manufacturing method according to claim 14, wherein the magneto-conductive metal powder comprises manganese-zinc alloy powder. ### Claim 16 (depends on 1) The manufacturing method according to claim 1, wherein the block is cut by a diamond wire or a diamond wheel along the first plane to form the first half body and the second half body. ### Claim 17 (depends on 1) The manufacturing method according to claim 1, wherein the combined first half body and second half body are cut by a diamond wire or a diamond wheel along the second plane to form the third half body.