201106391 六、發明說明： 【發明所屬之技術領域】 本發明之領域一般而言係關於磁性元件及其製造，且更 具體而言係關於磁性表面安裝電子元件，諸如電感器及變 壓器。 本申请案凊求對20 09年5月4曰提出申請之美國臨時申請 案第61/175,269號及2〇〇8年7月11日提出申請之61/080 I。 之權益，且係2009年4月24曰提出申請之美國申請案第 12/429,856號之一部分接續申請案，該等申請案之全部揭 示内容以引用方式併入本文中。 本申請案亦與以下共同擁有且共同待決專利申請案中所 揭示之標的物相關：2008年10月8日提出申請且標題為 「High Current Amorphous Powder Core Inductor」之美國 專利申請案第12/247,281號；2008年7月29日提出申請且標 題為「A Magnetic Electrical Device」之美國專利第 12/181,436號·，2008年7月11曰提出申請且標題為「出的 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日提出申請且標 題為「Miniature Shielded Magnetic Component」之美國專 利申請案第12/138,792號；及2006年9月12日提出申請且標 題為「Low Profile Layered Coil and Cores for Magnetic201106391 VI. Description of the Invention: Field of the Invention The field of the invention relates generally to magnetic components and their manufacture, and more particularly to magnetic surface mount electronic components such as inductors and transformers. This application seeks 61/080 I of the US Provisional Application No. 61/175,269 filed on May 4, 2009, and July 11, 2008. </ RTI> <RTIgt; </ RTI> <RTIgt; </ RTI> <RTIgt; </ RTI> <RTIgt; </ RTI> <RTIgt; </ RTI> <RTIgt; </ RTI> <RTIgt; The present application is also related to the subject matter disclosed in the co-owned and co-pending patent application: U.S. Patent Application Serial No. 12/ filed on Oct. 8, 2008, entitled "High Current Amorphous Powder Core Inductor" 247, 281; US Patent No. 12/181,436, filed on July 29, 2008, entitled "A Magnetic Electrical Device", filed on July 11, 2008, entitled "Performance High Current Power Inductor" U.S. Patent Application Serial No. 61/080,115, filed on Jun. 13, 2008, and entitled, Serial No. 12/138,792, entitled "Miniature Shielded Magnetic Component"; and September 12, 2006 Application for the day and titled "Low Profile Layered Coil and Cores for Magnetic
Components」之美國專利申請案第1 1/519,349號。 【先前技術】 隨著電子封裝之進步’製造更小但又更強大之電子裝置 148071.doc 201106391 已成為可能。為減小此等裝置之一總大小，用於製造此等 裝置之電子元件已變得愈來愈微型化。製造滿足此等需求 之電子元件呈現諸多困難，因此使得製程更加昂貴，且不 合意地增加該等電子元件之成本。 如同其他元件，一直以來研究用於諸如電感器及變壓器 等磁性元件之製程以便在高競爭性的電子製造商業中降低 成本。當正製造之元件係低成本大量生產的元件時，製造 成本之降低係尤其合意的。在用於此等元件以及利用該等 元件之電子裝置之大批量生產過程中，製造成本之任何降 低當然係顯著的。 【發明内容】 本文中揭示磁性元件總成及製造該等總成之方法之實例 性實施例，其有利地用來達成以下益處中之—或多者：更 適合於以一微型化位準生產之元件結構；更易於以一微型 化位準組裝之元件結構；允許消除已知磁性構造常見之製 造步驟之元件結構；藉由更有效之製造技術而具有一增加 之可靠性之元件結構；與現有磁性元件相比，在類似^減 小之封裝大小中具有改良之效能之元件結構；肖習用微型 化磁性元件相比具有增加之功率能力之㈣結構；及相對 於已知磁性元件構造，具有提供不同效能優點之唯一芯及 線圈構造之元件結構。 據信，該等實例性元件總成尤其有利於構造（舉例而士） 電感器及變壓器。可可靠地以小封裝大小提供該等總成°且 其可包括易於安裝至電路板之表面安裝特徵。 14807 丨.d0c 201106391 【實施方式】 本文中闡述克服此項技術中之眾多困難之發明性電子元 件設計之實例性實施例。為在其最大程度上理解本發明， 以不同分段或部分提供以下揭示内容，其中第部分論述特 定問題及困難’且第部分闡述用於克服此等問題之實例性 元件構造及總成。 I.本發明之介紹 用於電路板應用之諸如電感器等習用磁性元件通常包括 一磁芯及該芯内之一導電繞組（有時稱作一線圈）^該芯可 由離散芯件（其由磁性材料製作）製作，其中繞組置於該等 芯件之間。熟習此項技術者熟悉各種形狀及類型之芯件及 總成，其包括但未必限於U芯與I芯總成、ER芯與丨芯總 成、ER芯與ER芯總成、一罐形芯與τ芯總成及其他匹配形 狀。該等離散芯件可藉由一黏合劑黏接在一起且通常在實 體上彼此分隔開或間隔開。 在某些已知元件中，舉例而言，線圈係由纏繞在芯或一 端子夾上之一導線製作。亦即’在芯件已完全形成之後， 該線可捲繞一芯件（有時稱作一鼓芯或其他線軸芯）。線圈 之每一自由端可稱作一引線且可用於將電感器耦合至一電 路（藉由直接附接至一電路板或藉由借助一端子夾之一間 接連接）。特別對於小芯件，以-成本高效且可靠之方式 纏繞線圈係-挑戰。手纏式元件往往在其效能上不一致。 芯件之形狀使其相當脆弱且在纏繞線圈時易發生芯破裂， 且怒件之間的間隙的變化可產生不合意之元件效能變化。 14807I.doc 201106391 一進一步困難係DC電阻（「DCR」）可因不均勻之纏繞及缠 繞過程期間之張力而不合意地變化。 在其他已知元件中，已知表面安裝磁性元件之線圈通常 與芯件分開製作且稍後與該等芯件組裝在一起。亦即，有 時將該等線圈稱為預形成或預纏繞，以避免因用手纏繞線 圈而產生之問題且簡化磁性元件之組裝。此等預形成之線 圈對於小元件大小而言特別有利。 為在磁性元件表面安裝於一電路板上時完成至線圈之電 連接，通常提供導電端子或夾。該等夾係組褒於所成形之 芯件上且電連接至線圈之各別端。該等端子夾通常包括大 體扁平且平坦之若干區，該等區可使用（舉例而言）已知軟 焊技術電連接至一電路板上之導電跡線及墊β當如此連接 且致能該電路板時，電流可自該電路板流動至該等端子夾 中之一者’流過線圈到達該等端子夾中之另一者，且流動 回至該電路板。在一電感器之情形下，穿過線圈之電流流 動感應磁芯中之磁場及磁能量。可提供多於一個線圈。 在一變壓器之情形下，提供--次線圈及一二次線圈， 其中穿過該一次線圈之電流流動感應該二次線圈中之電流 流動。變壓器元件之製造呈現與電感器元件類似之挑戰。 對於愈來愈微型化之元件，提供實體上間隔開之芯係一 挑戰。建立並維持一致之間隙大小難以可靠地以一成本高 效方式實現。 在完成微型化表面安裝磁性元件中之線圈與端子夾之間 的電連接方面亦呈現若干實際問題。通常在芯外部完成線 I4S071 ,d〇c 201106391 圈與端子夾之間的一相當脆弱之連接且該連接因此易於斷 開。在一些情形下，已知使線圈之端捲繞夾之一部分來確 保線圈與夹之間的一可靠機械與電連接。然而，此自一製 造觀點來看已證明係繁重的且將需要更容易且更快速之端 接解決方案。另外，線圈端進行捲繞對於某些類型之線圈 係不實際的，諸如具有矩形剖面之線圈，該等線圈不具有 像薄的圓形線構造那樣柔韌之扁平表面。 隨著電子裝置繼續變得愈來愈強大之最近趨勢，亦要求 諸如電感器等磁性元件傳導增加之電流量。因此，通常增 加用於製造線圈之線規格。由於用於製作線圈之線之大小 增加’ €使用圓形線來製作線圏時，通常使端變平至一合 適厚度及寬度以使用（舉例而言）軟焊、焊接或導電黏合劑 等令人滿意地完成至端子夾之機械與電連接。然而，線規 格越大，越難以使線圈之端變平以合適地將其連接至端子 夾。此等困難已導致線圈與端子夾之間的連接不一致，此 可導致使用中之磁性元件之不合意效能問題及變化。減小 此變化已證明極為困難且成本高昂。 自扁平導體而非圓形導體製作線圈對於某些應用而言可 減輕此等問題，但扁平導體往往更具剛性且在第一實例中 更難以形成為線圈且因此引入其他製造問題。使用扁平導 體而非圓形導體亦可改變使用中之元件之效能，有時是不 合意地改變。另外，在某些已知構造中，尤其是包括由扁 平導體製作之線圈之彼等構造，諸如鉤等端接特徵或其他 結構特徵可形成至線圈之端中以促進至端子夾之連接。然 148071.doc 201106391 而，將此等特徵形成至線圈之端中可在製程中引入進一步 的費用。 減小大小但又增加電子裝置之功率及能力之最近趨勢呈 現更進一步之挑戰。隨著電子裝置之大小減小，該等電子 裝置中所利用之電子元件之大小必須相應地減小，且因此 直努力經濟地製造具有相對小（有時為微型化）之結構但 攜载一增加之電流量以給該裝置供電之功率電感器及變壓 器。該等磁芯結構合意地具備相對於電路板之愈來愈低之 輪廓以達成電裝置之纖小且有時極薄之輪廓。滿足此要求 呈現更進一步之困難。對於連接至多相電力系統之元件存 在另外其他困難，其中在一微型化裝置中接納不同相之電 力係困難的。 尋求滿足現代電子裝置之尺寸要求之元件製造商對努力 最佳化磁性7C件之佔用面積及輪廓極感興趣。一電路板上 之每一元件通常可由在平行於該電路板之一平面中量測之 一垂直寬度及深度尺寸界定，該寬度與深度之乘積確定該 元件在j電路板上佔據之表面面積該表面面積有時稱作 該元件之「佔用面積」。另一方面，沿法向於或垂直於該 電路板之-方向量測之該元件之總高度有時稱作該元件之 「輪廓」。兀件之佔用面積部分地確定在一電路板上可安 裝多少疋件，且輪廓部分地確定電子裝置中之並聯電路板 之間所允許之間距。較小之電子裝置通常要求在所存在之 每電路板上女裝較多元件、減小田比鄰電路板之間的間隙 或兩者。 148071.doc 201106391 然而’與磁性it件-同使用之諸多已知端子夾在元件表 面安裝至電路板時具有增加該元件之佔用面積及/或輪 廓之一趨勢。亦即，該等夾往往在元件安裝至一電路板時 延伸凡件之深度、寬度及/或高度且不合意地增加元件之 佔用面積及/或輪廓。尤其對於在芯之頂部、底部或側部 分裝配於磁芯件之外部表面上方之夾，成品元件之佔用面 積及/或輪廓可由端子夾延伸。即使元件輪廓或高度之延 伸相對小，但隨著任一給定電子裝置中元件及電路板之數 目增加結果亦可係實質性的。 II.實例性發明性磁性元件總成及製造方法 現在將論述解決此項技術中之習用磁性元件之一些問題 之磁性兀件總成之實例性實施例。與所闡述裝置相關聯之 製造步驟係部分顯而易見且部分下文具體闡述。此外，與 所闡述方法步驟相關聯之裝置係部分顯而易見且部分下文 明確闡述。亦即，本發明之裝置與方法在下文論述中將未 必分開闡述，但相信在不進一步闡釋之情形下熟習此項技 術者亦能很好地理解。 圖1至圖4係根據本發明之一實例性實施例之一實例性表 面女裝磁性元件100之各種視圖。更具體而言，圖i係表面 安裝磁性元件100之一部分分解圖，圖2係磁性元件1〇〇之 一俯視透視示，¾圖，圖3係磁性元件1 〇 〇之一俯視透視組裝 圖’且圖4係磁性元件1〇〇之一仰視透視組裝圖。 元件100通常包括一磁芯1 〇2、通常含於芯1 〇2中之一線 圈104及端子夾106、1〇8。在圖1至圖4中所示之實例性實 148071.doc -9- 201106391 單個件110，但在另一實施例 於一個芯件，其中在經組裝時 施例中，芯102係製作為— 中，芯102可視情況包括多 芯件實體上彼此間隔開。 芯件11〇可使用（舉例而言）可壓製於線圈1〇4周圍之鐵粉 材料或非晶形芯材料（亦為在此項技術中已知）製作為一整 體件。此等鐵私材料及非晶形芯材料可展現分佈式間隙性 質’此避免對芯結構中之—實體間隙之任何需要。在一個 實例性實施例中，用於元件⑽之單個芯件u〇可由熟習此 項技術者所錢之-磁粉材料製作，且該材料可壓製或壓 縮於一線圈104周圍以形成一整體芯與線圈構造。 在一進一步及/或替代實施例中，芯件n〇可由堆疊及壓 製於線圈104周圍之磁粉材料層或薄片形成。用以製作此 等層或薄片之實例性磁粉粒子可包括鐵氧體粒子、鐵㈣ 粒子、鐵矽鋁（Fe-Si-Al)粒子、MPP(Ni_M〇_Fe)粒子、U.S. Patent Application Serial No. 1 1/519,349. [Prior Art] With the advancement of electronic packaging, it has become possible to make smaller but more powerful electronic devices 148071.doc 201106391. To reduce the overall size of one of these devices, the electronic components used to fabricate such devices have become increasingly miniaturized. Manufacturing electronic components that meet these needs presents a number of difficulties, thus making the process more expensive and undesirably increasing the cost of such electronic components. As with other components, processes for magnetic components such as inductors and transformers have been studied to reduce costs in highly competitive electronics manufacturing businesses. A reduction in manufacturing cost is particularly desirable when the component being manufactured is a low cost mass produced component. In the mass production process of such components and electronic devices utilizing such components, any reduction in manufacturing cost is of course significant. SUMMARY OF THE INVENTION Exemplary embodiments of magnetic component assemblies and methods of making such assemblies are disclosed herein that are advantageously utilized to achieve one or more of the following benefits: more suitable for production at a miniaturized level Component structure; component structure that is easier to assemble in a miniaturized level; component structure that allows elimination of manufacturing steps common to known magnetic structures; component structure with increased reliability by more efficient manufacturing techniques; Compared with the existing magnetic components, the component structure has improved performance in a package size similar to that of the reduced package size; the micro-sized magnetic component has a (4) structure with increased power capability; and has a structure with respect to the known magnetic component. A unique core and coil construction component structure that provides different performance advantages. It is believed that these exemplary component assemblies are particularly advantageous for constructing (for example) inductors and transformers. The assemblies can be reliably provided in a small package size and can include surface mount features that are easy to mount to a circuit board. 14807 丨.d0c 201106391 [Embodiment] An exemplary embodiment of an inventive electronic component design that overcomes many of the difficulties in the art is set forth herein. To the extent that the present invention is to be understood to the fullest extent, the following disclosure is provided in various sections or sections, the first part of which discusses specific problems and difficulties' and the first part sets forth example component constructions and assemblies for overcoming such problems. I. Introduction to the Invention Conventional magnetic components, such as inductors, for circuit board applications typically include a magnetic core and a conductive winding (sometimes referred to as a coil) within the core. The core may be a discrete core member (which is Magnetic material fabrication) in which windings are placed between the core members. Those skilled in the art are familiar with cores and assemblies of various shapes and types, including but not necessarily limited to U-core and I-core assemblies, ER core and core assemblies, ER core and ER core assemblies, and a can core. Match the shape with the τ core assembly and others. The discrete core members can be bonded together by a bond and are typically spaced apart or spaced apart from each other in the body. In some known components, for example, the coil is made of a wire wound around a core or a terminal clip. That is, after the core member has been completely formed, the wire can be wound with a core member (sometimes referred to as a drum core or other spool core). Each free end of the coil can be referred to as a lead and can be used to couple the inductor to a circuit (either by attaching directly to a circuit board or by indirect connection by one of the terminal clips). Especially for small core parts, it is a challenge to wind the coil system in a cost-effective and reliable manner. Hand-wound components tend to be inconsistent in their performance. The shape of the core member is relatively fragile and core breakage is likely to occur when the coil is wound, and variations in the gap between the anger members can result in undesirable variations in component performance. 14807I.doc 201106391 A further difficulty is that the DC resistance ("DCR") can be undesirably changed due to uneven winding and tension during the winding process. Among other known components, coils of known surface mount magnetic components are typically fabricated separately from the core member and later assembled with the core members. That is, the coils are sometimes referred to as pre-formed or pre-wound to avoid problems caused by winding the coil by hand and to simplify assembly of the magnetic components. These pre-formed coils are particularly advantageous for small component sizes. In order to complete the electrical connection to the coil when the surface of the magnetic component is mounted on a circuit board, a conductive terminal or clip is typically provided. The sets are clamped onto the formed core member and electrically connected to the respective ends of the coil. The terminal clips typically include a plurality of generally flat and flat regions that can be electrically connected to conductive traces and pads of a circuit board using, for example, known soldering techniques, when so connected and enabled In the case of a circuit board, current may flow from the circuit board to one of the terminal clips 'flowing through the coil to the other of the terminal clips and flowing back to the circuit board. In the case of an inductor, the current flowing through the coil flows the magnetic field and magnetic energy in the inductive core. More than one coil can be provided. In the case of a transformer, a secondary coil and a secondary coil are provided, wherein current flow through the primary coil induces a current flow in the secondary coil. The manufacture of transformer components presents a similar challenge to inductor components. For increasingly miniaturized components, it is a challenge to provide physically spaced cores. Establishing and maintaining a consistent gap size is difficult to reliably achieve in a cost effective manner. There are also several practical problems in completing the electrical connection between the coil in the miniaturized surface mount magnetic component and the terminal clip. A fairly fragile connection between the wire I4S071, d〇c 201106391 ring and the terminal clamp is usually completed outside the core and the connection is therefore easily broken. In some cases, it is known to wind the end of the coil around a portion of the clip to ensure a reliable mechanical and electrical connection between the coil and the clip. However, this has proven to be cumbersome and will require an easier and faster termination solution from a manufacturing perspective. In addition, coiling the coil ends is impractical for certain types of coils, such as coils having a rectangular cross-section that does not have a flat surface that is as flexible as a thin circular wire configuration. As electronic devices continue to become more powerful and recent trends, magnetic components such as inductors are also required to conduct an increased amount of current. Therefore, the wire size for manufacturing the coil is usually increased. Since the size of the wire used to make the coil is increased by using a circular wire to make the wire, it is usually flattened to a suitable thickness and width to use, for example, solder, solder or conductive adhesive. The mechanical and electrical connection to the terminal clamp is completed satisfactorily. However, the larger the wire gauge, the more difficult it is to flatten the end of the coil to properly connect it to the terminal clamp. These difficulties have led to inconsistent connections between the coil and the terminal clip, which can lead to undesirable performance problems and variations in the magnetic components in use. Reducing this change has proven to be extremely difficult and costly. Fabricating coils from flat conductors rather than circular conductors can alleviate these problems for some applications, but flat conductors tend to be more rigid and more difficult to form into coils in the first example and thus introduce other manufacturing issues. The use of flat conductors rather than circular conductors can also alter the performance of components in use, sometimes undesirably. Additionally, in some known configurations, particularly including configurations 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 these features into the ends of the coils introduces further costs in the process. Recent trends in reducing the size but increasing the power and capabilities of electronic devices present a further challenge. As the size of electronic devices decreases, the size of the electronic components utilized in such electronic devices must be correspondingly reduced, and thus efforts are made to economically manufacture relatively small (and sometimes miniaturized) structures but carry one The amount of current added is the power inductor and transformer that power the device. The core structures desirably have increasingly lower profiles relative to the board to achieve a slim and sometimes extremely thin profile of the electrical device. Meeting this requirement presents further difficulties. There are other difficulties with the components connected to the multiphase power system, where it is difficult to accept different phases of power in a miniaturized device. Component manufacturers seeking to meet the size requirements of modern electronic devices are extremely interested in optimizing the footprint and profile of magnetic 7C components. Each component on a circuit board can generally be defined by a vertical width and depth dimension measured in a plane parallel to the board, the product of the width and depth determining the surface area occupied by the component on the j board. The surface area is sometimes referred to as the "occupied area" of the component. On the other hand, the total height of the component measured along the normal or perpendicular to the direction of the board is sometimes referred to as the "profile" of the component. The footprint of the component determines, in part, how many components can be mounted on a circuit board, and the profile partially determines the allowable spacing between parallel circuit boards in the electronic device. Smaller electronic devices typically require more components to be worn on each circuit board present, to reduce the gap between the adjacent circuit boards, or both. 148071.doc 201106391 However, many known terminal clips used with magnetic components have a tendency to increase the footprint and/or profile of the component when it is mounted to the board. That is, the clips tend to extend the depth, width and/or height of the component when the component is mounted to a circuit board and undesirably increase the footprint and/or profile of the component. Particularly for clips that are mounted over the outer surface of the core member at the top, bottom or side portions of the core, the footprint and/or profile of the finished component can be extended by the terminal clip. Even if the profile or height of the component is relatively small, the result can be substantial as the number of components and boards in any given electronic device increases. II. Exemplary Inventive Magnetic Element Assembly and Method of Manufacture An exemplary embodiment of a magnetic element assembly that addresses some of the problems of conventional magnetic elements in the art will now be discussed. The manufacturing steps associated with the illustrated apparatus are partially apparent and partially set forth below. Moreover, the portion of the apparatus associated with the method steps set forth is obvious and partially hereinafter set forth. That is, the apparatus and method of the present invention will not be separately described in the following discussion, but it is believed that those skilled in the art will be well understood without further elaboration. 1 through 4 are various views of an exemplary surface female 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 100, FIG. 2 is a top perspective view of the magnetic component 1 ,, and FIG. 3 is a top perspective assembly view of the magnetic component 1 ' And Figure 4 is a perspective view of one of the magnetic elements 1 仰. Element 100 typically includes a core 1 〇 2, typically included in one of the cores 1 线 2 of the coil 104 and terminal clips 106, 1 〇 8. In the example embodiment 148071.doc -9- 201106391 single piece 110 shown in Figures 1 to 4, but in another embodiment in a core piece, wherein in the assembled embodiment, the core 102 is made as - The core 102 may optionally include a plurality of core members that are physically spaced apart from one another. The core member 11 can be fabricated as a unitary member using, for example, an iron powder material or an amorphous core material (also known in the art) that can be pressed around the coil 1〇4. These iron-clad materials and amorphous core materials can exhibit distributed interstitial properties' which avoids any need for physical gaps in the core structure. In an exemplary embodiment, a single core member for the component (10) can be fabricated from a magnetic powder material known to those skilled in the art, and the material can be pressed or compressed around a coil 104 to form a unitary core and Coil construction. In a further and/or alternative embodiment, the core member n can be formed from a layer or sheet of magnetic powder material stacked and pressed around the coil 104. Exemplary magnetic particle particles used to form such layers or sheets may include ferrite particles, iron (tetra) particles, iron-bismuth aluminum (Fe-Si-Al) particles, MPP (Ni_M〇_Fe) particles,
HighFluX(Ni-Fe)粒子、合金）粒子以鐵為 主之非晶形粉末粒子、以鈷為主之非晶形粉末粒子或此項 技術中已知之其他等效材料。當此等磁粉粒子與一聚合物 黏結劑材料混合時，所得磁性材料展現分佈式間隙性質， 此避免實體上間隔開或分離不同磁性材料件之任何需要。 因此，有利地避免與建立並維持一致實體間隙大小相關聯 之困難及費用。對於高電流應用，藉由一聚合物黏結劑結 合之一預退火磁性非晶形金屬粉末可係有利的。 最佳見於圖2中，線圈104由一長度之圓形線製作且包括 一第一末端或引線15〇、與該第一端相對之一第二末端或 148071.doc •10- 201106391 引線152及線圈端150與152之間的一繞組部分154，其中該 線係纏繞一線圈軸15 6數匝以達成一合意效應，諸如用於 元件100之一選定最終用途應用之一合意電感值。另外， 該線圈沿軸1 56以一螺旋方式且相對於軸丨56以盤旋形式兩 者纏繞以提供一更緊湊線圈設計，以滿足低剖面要求同時 仍提供一合意電感值。端150、152相對於繞組部分154弯 曲，以使得該等端平行於線圈軸156延伸’以促進線圈端 150、152之端接，如下文所闡釋。 視需要’用以形成線圈1〇4之線可塗佈瓷釉塗層及類似 塗層以改良線圈104之結構及功能方面。如熟習此項技術 者將瞭解，線圈104之一電感值部分取決於線類型、線圈 中線之匝數及線直徑。因此，線圈1 〇4之電感額定值可針 對不同應用而相當大地變化。線圈1〇4可使用已知技術獨 立於芯件110製作且可提供為用於元件1〇〇之組裝之一預纏 繞結構。在一實例性實施例中，線圈1 〇4係以一自動化方 式形成以提供成品線圈之一致電感值，但可視需要替代地 用手纏繞線圈。應理解，若提供多於一個線圈，則同樣可 需要額外端子夾來實現至所有所利用線圈之電連接。 線圈104僅係實例性且應理解，可替代利用其他類型之 線圈。舉例而言，扁平導體可替代圖2中所圖解說明之圓 形線用以製作一線圈。另外，繞組部分丨54可採用各種替 代形狀及組態（包括但不限於螺旋或盤旋組態（但非如圖2中 所示之兩者））及具有替代彎曲區段（例如，蛇形形狀、c形 等）之筆直多邊形區段之繞組部分組態。同樣，可視需要 148071.doc 11 201106391 利用多於一個線圈。 如所圖解說明之實施例中所示，芯件1 1 0形成為一大體 矩形體，該體具有一基底壁114及自基底壁114之橫向邊緣 延伸之複數個大體正交側壁11 6、1 1 8、1 20及122。在圖1 至圓4中所示之實施例中’基底壁〗14有時可稱作一底部 壁。側壁1 1 6及11 8彼此相對且有時可分別稱作一左側一右 側。壁120及122彼此相對且有時可分別稱作一前側一後 側。側壁116、118、120及122在基底壁114上方界定一室 或腔，當組裝該元件時該室或腔通常含有線圈1 04。 亦如圖1中所示，第一芯件110之側壁！ 16亦包括一下陷 表面12 3，且相對側壁1 1 8包括一對應下陷表面12 $。下陷 表面12 3及12 5僅沿各別側壁116及11 8之一長度延伸一部分 距離。下陷表面123及125亦自基底壁114向上延伸小於侧 壁116及118之在垂直於底部表面之一方向上量測之高度之 一距離。因此，下陷表面123及125與側壁116及118之頂部 邊緣分隔開，同時在β比鄰基底壁114延伸之側壁116及118 之長度之一部分上毗連基底壁114之下陷表面126及128。 芯件11 0之基底壁114之外部表面係起伏的且包括分離第 一及第一下陷表面126及128之一非下陷表面124。下陷表 面126及128在非下陷表面124之相對側上延伸β第三及第 四下陷表面130及132亦提供於基底壁114之相對角上。第 五及第/、下陷表面134、136在:件110之剩餘角上與第三 及第四下陷表面13 0及13 2相對。在所圖解說明之實施例 中，第五及第六下陷表面134、136以彼此大體共面之一關 148071.doc -12- 201106391 係且亦以與第三及第四下陷表面13〇及132大體共面之一關 係延伸。因此，基底壁丨丨4係分級為三個表面等級，其中 第一等級係非下陷表面124 ’第二等級係與第一等級分隔 開一第一量之下陷表面126及128，且第三等級係與第—及 第二等級中之每一者分隔開之下陷表面13〇、132、134、 U6。下陷表面12ό、132及134藉由非下陷表面124與下陷 表面128、130及136分隔開及分離。下陷表面13〇與ΐ3ό藉 由下陷表面128分隔開及分離，且下陷表面132與134藉由 下陷表面126分隔開及分離。 圖1中所示之實例性端子夾106及1〇8在構造上大致相同 但當施加至第一芯件丨10時反轉18〇。且因此作為彼此之鏡 像延伸。元件100之端子夾1〇6及1〇8各自分別包括安裝區 段140、大體扁平且平坦之底部區段142及在底部區段142 之與安裝區段140之相對端上延伸之線圈區段144。一立式 定位連接片區段145亦在每一夾1〇6及1〇8中大體垂直於底 部區段142延伸。該等定位連接片區段經成形及尺寸確定 以接納於第一芯件11 〇之側壁1丨6及丨丨8中之下陷表面丨23、 125 中。 在所圖解說明之實施例中，安裝區段14〇以與線圈區段 144大體共面之一關係延伸且自底部區段142之平面偏移或 分隔開。失106、1 〇8組裝至芯件丨1 〇，其中底部區段丨42鄰 接下陷表面126及128 ’線圈區段144鄰接下陷表面130及 132 ’且安裝區段14〇鄰接下陷表面134及136。亦如圖1及 圖2中所示’線圈端15〇及152延伸穿過端子夾1〇6、108之 148071.doc -13 - 201106391 線圈區段144中之通孔146，其中其可軟焊、焊接或以其他 方式附接以確保線圈端1 5 〇、1 52與線圈1 04之間的電連 接。然而，由於線圈端15〇、152係定位於芯件11〇之基底 壁114上之凹陷表面上，其不自芯件u 〇之總外部表面凸出 且在處置元件100時較不易於發生不合意之分離。 端子夾106、108及其所有區段（如所闡述）可藉由自一導 電材料切割、彎曲或以其他方式成形夾1 06及1 〇8來以一相 對簡單方式製造。在一個實例性實施例中，端子係自一經 電鍍銅薄片衝壓且彎曲為最終形式，但可替代利用其他材 料及形成技術。夾106、108可預形成且在一稍後生產階段 組裝至芯件1 1 0。 由於芯件110係壓製於線圈1〇4周圍，因此線圈端15〇、 152與端子夾1〇6、108之間的電連接定位於芯結構外部。 如圖3中所示，當元件1 〇〇安裝至電路板丨8〇時，第一怒件 110之基底壁114面向且鄰接板表面} 84且每一端子夾1〇6、 108之扁平且平坦底部區段142經由軟焊技術或此項技術中 已知之其他技術電連接至板180上之導電跡線182 »每一夾 1 06、108之線圈區段144各自面向電路板1 8〇且線圈端 150、152與夾之線圈區段144之間的電連接大致保護於芯 結構下方。夾106及108促進線圈端15〇及152在一相對簡 單、有效且成本高效之製程中之安全且可靠之電連接。 圖5至圖8係根據本發明之一實例性實施例之另一表面安 裝磁性元件200之各種視圖。圖5係元件200之一部分分解 圖。圖6係元件200之一俯視透視示意圖，且圖7係元件2〇〇 148071.doc •14· 201106391 之一俯視透視組裝圖。圖8係磁性元件2 0 0之一仰視透視組 裝圖。 元件200類似於元件1〇〇，但包括離散芯件11〇及丨12，其 中第二芯件112係組裝至第一芯件，其中線圈1〇4定位於其 之間。芯件110及112可根據已知技術由熟習此項技術者已 知之一合適磁性材料製作’包括但不限於鐵磁材料及亞鐵 磁材料、如上文所闡述之其他材料及此項技術中已知之材 料。 圖9部分圖解說明利用一端接製作層38〇之一端接技術。 端子製作層380可根據已知技術由此項技術中已知之一導 電材料（例如，銅）或導電合金製作》該製作層可經形成以 包括一引線框架382，引線框架382具有連接至引線框架 382之邊緣之相對端子夾384對。雖然顯示兩對端子夾 3 84 ’但可替代提供更多或更少數目個端子夾。間隙或空 間係界定於每一對中之端子夾384中之每一者之間。如下 文所闡釋’磁體可形成於此等間隙或空間中。 如圖10中所示且類似於上文所闡述之端子夾1〇6及1〇8， 每一端子夾384包括一中心部分3 86，中心部分3 86側翼係 在與中心部分386之平面分隔開之一平面中延伸之偏移連 接片或突出部388、390。雖然連接片或突出部388、39〇在 圖1 〇中所示之觀點上看似自中心部分386升起，但當該等 夾翻轉時，連接片或突出部388、390將以與上文所闡述之 夾106及108類似之一方式相對於中心部分386下陷。因 此，可將中心部分3 86視為底部區段142且可將突出部或連 148071.doc -15- 201106391 接片388、390視為上文所闡述之夾1〇6及1〇8中之區段丨⑽ 及 144。 在一實例性實施例中，每一端子夾384中之升起突出部 中之一者388包括一芯柱392且升起突出部中之另一者39〇 包括一端接槽394。各別芯柱392有助於將夾384固定至一 磁體，且端接槽394充當用於一線圈引線之一連接點。雖 然在一個實施例中提供端接槽394，但在另一實施例中可 替代提供通孔以接納線圈引線。如圖9及圖1〇中所示，各 別對端子夾384在一個實例中形成為彼此之鏡像，但在至 少某些實施例中其不需要係鏡像。 圖11圖解說明利用端接製作層380來製造一微型化磁性 元件之製程。如圖11A中所見，端接製作層38〇可插入一模 具400中，且一線圈4〇2可提供於每一對端子夾π#(圖9及 圖1〇)之間。亦如圖11A中所示，每一端子夾384 t之端接 槽394接納線圈端403中之一者。然後，磁性材料（其可係 上文所闡述材料中之任一者）可施加並壓製於料線圈周 圍以在每一線圈402周圍形成磁體4〇4，如圖UB十所示。 端子夹384中之芯柱392(圖1〇)在模製磁冑4〇4時嵌入於磁體 4〇4t。然後可自模具400移除磁體4〇4及包括夾3料之所附 接引線框架。圖11C以俯視圖圖解說明所得總成且圖ud 以仰視圖圖解說明所得總成。 如圖11D及圖UE中所示，彳在一切割線384處修剪讀 斷引線框架382，切割線384位置距磁體4〇4之橫向邊每 預定距離，且每-端子夾384之一部分可繞磁體之一傾 148071.doc •16· 201106391 緣f曲如圖11F中所示。夾384之該部分以大致90。之一 角度#曲且並靠磁體之側壁延伸。由於切割線3 距磁體 404之預定距離相對小，因此夾384之彎曲部分僅延伸至磁 體404之側之一半。亦即，夾384之彎曲部分之一高度小於 磁體404之側壁之高度。 如圖11F中所示之夾384之彎曲部分可大致對應於上文針 對端子夹106及108所闡述之定位區段145。凹陷(類似於以 上實施例中所闡述之凹陷123及125)可模製於磁體之側壁 中以容納端子夾384之彎曲部分而不會負面影響磁性元件 之佔用©積。，線圈端403可經由軟焊過帛、焊接過程或熟 習此項技術者所熟悉之其他技術電連接至夾384，如圖nG 中所不。當使用相對大之線規格來製作 佳的，且當使用相對較小之線規格來製作線圈== 較佳的〇 圖11H圖解說明包括端子夾384之一成品磁性元件。一旦 完成磁性元件420 ’則可經由夾384之中心部分386將其表 面安裝至一電路板，如上文所闡述。 圖12圖解說 〜 只他例，其可類似 於上文所闡述之方法製造。在製造元件45〇時，當修剪引 線框架382時，㈣線410(圖11D)係與磁體—分隔開較 遠。因此，當夾386繞磁體404f曲時，夾之經修剪部分充 分長以延伸磁體404之側壁之整個高声 门及儿進一步以約90。之 一角度彎曲以並靠磁體之頂部壁之一邱八从 。卩分延伸，該磁體可 包括一凹陷以容納該彎曲夾而不會負面影鲤 Θ凡1千之剖面。 148071.doc -17- 201106391 使切割線與磁體404分隔開更遠（如在圖12之實施例中）呈現 降低之污染問題風險且及因在形成磁體404時之模製操作 或其他製造步驟而產生之負面效應。 所闡述之基本方法之諸多變化形式係可行的。舉例而 言，可在修剪引線框架之前及/或在繞磁體之側彎曲夾386 之將線圈前軟焊、焊接或以其他方式連接至線圈端4〇3。 亦即’未必需要如上文所闡述之步驟次序。 另外，可在引線製作層中形成具有類似效應及優點之其 他形狀之端子夹。亦即，在其他替代實施例中，該等夾需 要具有所圖解說明及闡述之精確形狀。 同樣，在某些實施例中，線圈不需要與端子製作層38〇 分開提供而在模製過程中進行組裝。而是，在某些實施例 中，線圈可預附接至該製作層或以其他方式與端子製作層 整體形成。 更進一步，可以各種方式實現將線圈端軟焊、焊接或以 其他方式電連接至夾。舉例而言，夾中之槽394(圖1〇)可視 為可選的且可替代使用通孔或促進線圈引線之嚙合之其他 機械特倣。作為另-實例’《中之通孔及槽在某些實施例 中可視為可選的，且線圈引線4〇3可焊接（舉例而言）至夾之 表面而不利用機械嚙合特徵。更進一步，可如已以引用方 弋併入本文中之2009年4月24曰提出申請之美國申請案第 。/429’856中所闡述在一芯件内部一位置處將端子夾焊接 或二人焊至弓j線之端。此外’線圈引線可軟焊或焊接至夹之 内邛面向表面(即，在成品元件中面向磁體之-表面)以及 14807] .doc 201106391 夾之外部面向表面（即，成品元件中與磁體相對之一表 面）。 圖13係根據一實例性實施例形成之一磁性元件之一芯件 450之一透視圖。 在如圖所示之一實例性實施例中，芯件45〇係由一已知 材料及已知技術（諸如，上文所闡述之彼等材料及技術）預 製作且經提供以在一稍後製造階段與其他元件組裝。如圖 13中所示’芯件450包括—大體平坦且矩形基底部分452及 自基底部分452之平面向上且大體垂直延伸之一圓柱形或 管狀部分454。所示實例性實施例中之基底部分452相對於 圓柱形部分454之直徑在尺寸上實質更長且更寬，且圓柱 形部分454中心大致在矩形基底部分454上。基底部分452 及圓柱形部分454因此界定用於一線圈（諸如線圈402(圖 11A及圖11B))或本文中所闡述之其他線圈之一接納區域。 更具體而言，且如圖14中所示，芯件450之圓柱形部分 454延伸穿過線圈402之一開放中心區域，以使得圓柱形部 分454大致填充線圈402之該開放中心區域。圖14中亦顯示 端接製作層380具有上文所闡述之線圈端接特徵，其中該 總成置於一模具中。當如此組裝時，每一芯件450之圓柱 形部分454延伸穿過且大體佔據每一線圈之中心開口。芯 件450可藉由一固定件固持到位，該固定件亦將端接製作 層380及所附接電感器線圈402固定到位以進行進一步製 程。 一磁體458(顯示於圖15中且亦在圖13中以陰影顯示）因 148071.doc •19· 201106391 此可形成於線圏402及磁芯件450及端接製作層380之若干 部分周圍。在一個實例中，接著可將一電感器體壓縮模製 於經組裝線圏402、端接製作層380之端子夾及芯件450上 方。分開提供之芯件450之圓柱形部分454防止用以形成磁 體458之材料在模製過程期間進入芯之中心區域。尤其在 芯件450與磁體458由具有不同磁性性質之不同材料製作 時’相當多之效能優點可藉由經簡化之製程產生。一整體 或單塊式芯結構可自芯件450與磁體45 8產生，其中該芯結 構之不同部分中具有變化之磁性性質，同時消除用於與習 用磁性兀件構造相關聯之分離芯件之間隔及黏接步驟。 可以與上文關於圖11D至圖11H所闡述之方式類似之一 方式7G成在模製過程完成之後的圖丨5中所示之總成。 III.所揭示之實例性實施例 現在應顯而易見，可以各種組合形式混合及匹配所闡述 之各種特徵。可有利地提供具有不同磁性性質、不同數目 及類型之線圏且具有不同效能特性之各種各樣之磁性元件 總成’以滿足具體應用之需要。 此外，所闡述特徵中之某些特徵可有利地用於具有實體 上彼此間隔開且分隔開之離散芯件之結構中。 在如上文所列舉之在本發明之範疇内之各種可能性中， 相信至少以下實施例相對於習用電感器元件係有利的。 已揭示一種表面安裝磁性元件總成’其包括：—導電線 圈，其具有一繞組部分及自該繞組部分延伸之相對第一及 第二末端；一磁芯，其形成於該繞組部分周圍且包封該繞 148071.doc •20· 201106391 組部分，該磁芯具有一基底壁及自該基底壁延伸之正交側 壁，該第一及第二末端延伸穿過該磁芯之該基底壁；及第 一及第二端子夾’其連接至各別第一及第二末端，該第一 及第二端子夾鄰該磁芯之相對側壁定位於該基底壁上。 視情況，該第一及第二端子爽完全在該磁芯外部延伸。 該第一及第二端子夾可包括經組態以接納該第一及第二末 端中之一者之一開口及一槽中之一者。該第一及第二末端 可延伸穿過該磁芯之該基底壁上之分隔開之凹陷表面。該 等末端可在該等凹陷表面處連接至該第一及第二端子夾。 該第一及第二端子夾中之至少一者可包括嵌入於該芯中之 一柱。邊第一及第二端子夾可提供於一端接製作層上。 該磁性元件總成可進一步包括該磁芯内之一分開製作之 芯件。該繞組部分可具有一開放中心區域，其中該分開製 作之芯件之一部分佔據該開放中心區域。該分開製作之芯 件之該部分可係圓柱形。該分開提供之芯件亦可包括一矩 形基底部分及自該基底部分延伸之—圓柱形部分。該分開 提供之芯件可由不同於該磁芯之一磁性材料製作。 該m元件總成可進—步包括—電路板，其中該基底壁 係搁置於該電路板上。該磁體與線圈可形成—電感器。 亦已揭示-種製造一磁性元件之方法，其包括：在一對 端子夾之曝露表面及與該對端子夾相關聯之至少一個線圈 上方形成一磁體；藉此，該線圈之-繞組部分係完全嵌入 於：磁體中且該線圈之相對末端係附接至該所形成磁體之 一共同壁上之端子夾。 148071.doc •21· 201106391 視情況’該方法可進一步包括：組裝一分開提供之芯件 與該線圈，及在該分開提供之芯件與該線圈之總成上方形 成一磁體。組裝該所提供之芯件與該線圈可包括使該分開 提供之芯件之一部分延伸穿過該線圈之一開放中心區域。 該等端子夾可包括至少一個柱，其中該方法進一步包含在 形成該磁體時將該柱嵌入於該磁體中。該對端子央亦可附 接至一引線框架，其中該方法進一步包含修剪該引線框架 以自該引線框架切斷該等夾。 該方法亦可包括繞該磁體之一側壁彎曲夾之一部分，及 將該端子夾電連接至線圈端《電連接該端子夾可包括將該 線圈端焊接或軟焊至該夹。電連接該端子夾亦可包括將該 線圈端接納於一通孔或端子槽中之一者中，及將該磁體之 底部表面上之一曝露線圈端附接至該夾。 形成該體包含在該至少一個夾上方模製該體。該對端子 夾可由一引線框架接合，其中該對夾之間具有一間隙，且 該磁體係形成於該對端子夾之間的該間隙中。 每一端子夾可包括一中心部分及該中心部分之任一側上 之第-及第：下陷部分，且該方法可進—步包括將該線圈 連接至該等下陷部分中之—者。該方法亦可包括配置該對 端子夾以使其作為彼此之鏡像延伸。 IV.結論 現在，相信自前述實例及實施例顯而易見本發明之益 處。雖#已具體闡述眾多實施例及㈣，但所揭示之實例 性裝置、總成及方法之範疇及精神内可存在其他實例及實 148071.doc •22· 201106391 施例。 此書面說明使用實例來揭示本發明，包括最佳模式，且 亦使得熟習此項技術者能夠實踐本發明，包括製作並使用 任何裝置或系統及執行任何所併入之方法。本發明之專利 範疇由申請專利範圍界定，且可包括熟習此項技術者想到 之其他實例。若此等其他實例具有不與申請專利範圍之書 面語言不同之結構組件，或若其包括具有與申請專利範圍 之書面語言無實質不同之等效結構組件’則此等其他實例 意欲歸屬於申請專利範圍之範疇内。 【圖式簡單說明】 參照以下圖式闡述非限制性及非窮盡性實施例，其中除 非另有規定，各圖式中相同參考編號指代相同部件。 圖1係根據本發明之一實例性實施例之一實例性表面安 裝磁性元件之—部分分解圖。 圖2係圖1中所干 丫所不之磁性70件之一俯視透視示意圖。 圖3係圖1中胼+々& _ 甲所不之磁性兀件之一俯視透視組裝圖。 圖4係圖1中所示之磁性元件之-仰視透視組裝圖。 _系根據本發明之一實例性實施例之另一實例性磁伯 元件之一部分分解圖。 圖6係圖5 Φ π - & 、， _ ^ 不之磁性元件之一俯視透視示意圖。 圖7係圖5中张- 不之磁性元件之一俯視透視組裝圖。 圖8係圖5中# - ,5, 〇_ . 不之磁性元件之一仰視透視組裝圖。 成。 祆據本發明之另一實施例形成之一端子錯 148071.docThe HighFluX (Ni-Fe) particles, alloy particles are mainly amorphous powder particles based on iron, amorphous powder particles mainly composed of cobalt, or other equivalent materials known in the art. When such magnetic powder particles are mixed with a polymeric binder material, the resulting magnetic material exhibits distributed gap properties which avoids any need to physically separate or separate the different magnetic material pieces. Therefore, the difficulties and costs associated with establishing and maintaining a consistent physical gap size are advantageously avoided. For high current applications, it may be advantageous to pre-anneal the magnetic amorphous metal powder by a combination of a polymeric binder. Preferably, as seen in Figure 2, the coil 104 is fabricated from a length of circular wire and includes a first end or lead 15A, a second end opposite the first end, or a 148071.doc •10-201106391 lead 152 and A winding portion 154 between coil ends 150 and 152, wherein the wire is wound around a coil shaft 156 to achieve a desired effect, such as a desirable inductance value for one of the selected end use applications of component 100. In addition, the coils are wound in a spiral pattern along the shaft 1 56 and in a spiral relative to the shaft 56 to provide a more compact coil design to meet low profile requirements while still providing a desirable inductance value. The ends 150, 152 are curved relative to the winding portion 154 such that the ends extend parallel to the coil shaft 156 to facilitate termination of the coil ends 150, 152, as explained below. The enamel coating and the like may be applied as needed to form the coil 1〇4 to improve the structural and functional aspects of the coil 104. As will be appreciated by those skilled in the art, the inductance value of one of the coils 104 depends in part on the type of wire, the number of turns in the coil, and the wire diameter. Therefore, the inductance rating of coil 1 〇 4 can vary considerably for different applications. The coil 1〇4 can be fabricated separately from the core member 110 using known techniques and can be provided as one of the pre-wrap structures for assembly of the component 1〇〇. In an exemplary embodiment, coils 1 〇 4 are formed in an automated manner to provide a consistent inductance value for the finished coil, but alternatively the coil may be wound by hand as needed. It should be understood that if more than one coil is provided, an additional terminal clip may be required to achieve electrical connection to all of the utilized coils. Coil 104 is merely exemplary and it should be understood that other types of coils may be utilized instead. For example, a flat conductor can be used in place of the circular line illustrated in Figure 2 to make a coil. Additionally, the winding portion 丨 54 can take a variety of alternative shapes and configurations (including but not limited to spiral or spiral configurations (but not both shown in FIG. 2)) and have alternative curved segments (eg, serpentine shapes) , c-shaped, etc.) The winding part configuration of the straight polygon section. Again, as needed, 148071.doc 11 201106391 utilizes more than one coil. As shown in the illustrated embodiment, the core member 110 is formed as a generally rectangular body having a base wall 114 and a plurality of generally orthogonal sidewalls 116, 1 extending from the lateral edges of the base wall 114. 1 8, 1 20 and 122. The base wall 14 in the embodiment shown in Figures 1 through 4 can sometimes be referred to as a bottom wall. The side walls 1 16 and 11 8 are opposed to each other and may sometimes be referred to as a left side and a right side, respectively. The walls 120 and 122 are opposite each other and may sometimes be referred to as a front side and a rear side, respectively. The sidewalls 116, 118, 120, and 122 define a chamber or cavity above the base wall 114 that typically contains the coil 104 when the component is assembled. As also shown in Figure 1, the side walls of the first core member 110! 16 also includes a recessed surface 12 3 and the opposing sidewalls 1 18 include a corresponding depressed surface 12 $. The depressed surfaces 12 3 and 12 5 extend only a portion of the length along one of the respective side walls 116 and 181. The depressed surfaces 123 and 125 also extend upwardly from the base wall 114 by a distance less than the height of the side walls 116 and 118 measured in a direction perpendicular to one of the bottom surfaces. Thus, the depressed surfaces 123 and 125 are spaced apart from the top edges of the sidewalls 116 and 118 while adjoining the underlying surfaces 126 and 128 of the base wall 114 at a portion of the length of the sidewalls 116 and 118 from which the adjacent base wall 114 extends. The outer surface of the base wall 114 of the core member 110 is undulating and includes separating one of the first and first depressed surfaces 126 and 128 from the non-sag surface 124. The depressed surfaces 126 and 128 extend on opposite sides of the non-sag surface 124. The third and fourth depressed surfaces 130 and 132 are also provided at opposite corners of the base wall 114. The fifth and/or sunken surfaces 134, 136 are opposite the third and fourth depressed surfaces 13 0 and 13 2 at the remaining corners of the member 110. In the illustrated embodiment, the fifth and sixth depressed surfaces 134, 136 are substantially coplanar with one another 148071.doc -12- 201106391 and also with the third and fourth depressed surfaces 13 and 132 One of the major coplanar relationships extends. Thus, the base wall raft 4 is graded into three surface grades, wherein the first grade is a non-sag surface 124 'the second grade is separated from the first grade by a first amount of undercut surfaces 126 and 128, and a third The hierarchy separates the underlying surfaces 13〇, 132, 134, U6 from each of the first and second levels. The depressed surfaces 12, 132, and 134 are separated and separated from the depressed surfaces 128, 130, and 136 by the non-sag surface 124. The depressed surfaces 13〇 and ΐ3ό are separated and separated by the depressed surface 128, and the depressed surfaces 132 and 134 are separated and separated by the depressed surface 126. The exemplary terminal clips 106 and 1 8 shown in Figure 1 are substantially identical in construction but inverted 18 turns when applied to the first core member 10 . And thus as a mirror image of each other. The terminal clips 1〇6 and 1〇8 of the component 100 each include a mounting section 140, a generally flat and flat bottom section 142, and a coil section extending at an opposite end of the bottom section 142 from the mounting section 140. 144. A vertical positioning tab section 145 also extends generally perpendicular to the bottom section 142 in each of the clips 1〇6 and 1〇8. The positioning tab segments are shaped and sized to be received in the underlying surfaces 丨23, 125 of the sidewalls 1丨6 and 丨丨8 of the first core member 11〇. In the illustrated embodiment, the mounting sections 14b extend in a substantially coplanar relationship with the coil section 144 and are offset or spaced apart from the plane of the bottom section 142. The losses 106, 1 〇 8 are assembled to the core member 〇 1 , wherein the bottom portion 丨 42 abuts the depressed surfaces 126 and 128 ′ the coil portion 144 abuts the depressed surfaces 130 and 132 ′ and the mounting portion 14 〇 abuts the depressed surfaces 134 and 136 . As also shown in Figures 1 and 2, the coil ends 15 and 152 extend through the through holes 146 in the coil section 144 of the terminal clamps 1〇6, 108, which can be soldered. , soldered or otherwise attached to ensure electrical connection between coil ends 1 5 〇, 152 and coil 104. However, since the coil ends 15〇, 152 are positioned on the recessed surface on the base wall 114 of the core member 11〇, they do not protrude from the total outer surface of the core member 且 and are less prone to occur when the component 100 is disposed. Desirable separation. The terminal clips 106, 108 and all of their sections (as illustrated) can be fabricated in a relatively simple manner by cutting, bending or otherwise forming the clips 106 and 1 〇8 from a conductive material. In an exemplary embodiment, the terminals are stamped from an electroplated copper sheet and bent into a final form, but other materials and forming techniques may be utilized instead. The clips 106, 108 can be pre-formed and assembled to the core member 110 in a later production stage. Since the core member 110 is pressed around the coil 1〇4, the electrical connection between the coil ends 15〇, 152 and the terminal clips 1〇6, 108 is positioned outside the core structure. As shown in FIG. 3, when the component 1 is mounted to the board 丨8〇, the base wall 114 of the first anger 110 faces and abuts the board surface 84 and each terminal clip 〇6, 108 is flat and The flat bottom section 142 is electrically coupled to the conductive traces 182 on the board 180 via soldering techniques or other techniques known in the art. The coil sections 144 of each clip 106, 108 each face the board 18 and The electrical connection between the coil ends 150, 152 and the coil section 144 of the clip is substantially protected beneath the core structure. The clips 106 and 108 facilitate secure and reliable electrical connection of the coil ends 15A and 152 in a relatively simple, efficient and cost effective process. 5 through 8 are various views of another surface mount magnetic component 200 in accordance with an exemplary embodiment of the present invention. Figure 5 is a partially exploded view of a component 200. Figure 6 is a top perspective view of one of the elements 200, and Figure 7 is a top perspective assembly view of the element 2〇〇 148071.doc • 14· 201106391. Figure 8 is a perspective view of one of the magnetic elements 200. Element 200 is similar to element 1 but includes discrete core members 11 and 12, wherein second core 112 is assembled to the first core with coil 1〇4 positioned therebetween. The core members 110 and 112 can be fabricated from a suitable magnetic material known to those skilled in the art in accordance with known techniques, including but not limited to ferromagnetic materials and ferrimagnetic materials, other materials as set forth above, and in the art. Know the material. Part 9 of Figure 9 illustrates one of the termination techniques using one end fabrication layer 38. The terminal fabrication layer 380 can be fabricated from a conductive material (e.g., copper) or a conductive alloy known in the art according to known techniques. The fabrication layer can be formed to include a leadframe 382 having a leadframe attached thereto. The edge of the 382 is opposite the terminal clamp 384 pairs. Although two pairs of terminal clips 3 84 ' are shown, a greater or lesser number of terminal clips may be provided instead. A gap or space is defined between each of the terminal clips 384 in each pair. As explained below, the magnets can be formed in such spaces or spaces. As shown in FIG. 10 and similar to the terminal clips 1〇6 and 1〇8 described above, each terminal clip 384 includes a central portion 386 that is flanked by a central portion 386. Offset tabs or tabs 388, 390 extending in one of the planes. Although the tabs or tabs 388, 39 看 appear to rise from the central portion 386 from the point of view shown in FIG. 1 , when the clips are flipped, the tabs or tabs 388 , 390 will One of the illustrated clips 106 and 108 is depressed relative to the central portion 386. Thus, the central portion 386 can be considered as the bottom section 142 and the tabs or 148071.doc -15-201106391 tabs 388, 390 can be considered as being in the clips 1〇6 and 1〇8 described above. Sections 丨 (10) and 144. In an exemplary embodiment, one of the raised projections 388 in each of the terminal clips 384 includes a stem 392 and the other of the raised projections 39A includes an end slot 394. The respective stems 392 help to secure the clip 384 to a magnet, and the termination slot 394 acts as a connection point for a coil lead. Although a termination trench 394 is provided in one embodiment, in another embodiment a via may be provided instead to receive the coil lead. As shown in Figures 9 and 1B, the respective pairs of terminal clips 384 are formed in mirror images of one another in one example, but in at least some embodiments they do not require mirroring. Figure 11 illustrates a process for fabricating a miniaturized magnetic component using termination fabrication layer 380. As seen in Fig. 11A, the termination fabrication layer 38A can be inserted into a mold 400, and a coil 4〇2 can be provided between each pair of terminal clamps π# (Fig. 9 and Fig. 1). As also shown in Figure 11A, the termination slot 394 of each terminal clip 384t receives one of the coil ends 403. Then, a magnetic material (which may be any of the materials set forth above) may be applied and pressed around the coil to form a magnet 4〇4 around each coil 402, as shown in UB10. The stem 392 (Fig. 1A) in the terminal clamp 384 is embedded in the magnet 4〇4t when the magnetic pole 4胄4 is molded. The magnet 4〇4 and the attached lead frame including the clip 3 can then be removed from the mold 400. Figure 11C illustrates the resulting assembly in a top view and Figure ud illustrates the resulting assembly in a bottom view. As shown in FIG. 11D and FIG. UE, the readout lead frame 382 is trimmed at a cutting line 384, the cutting line 384 is positioned at a predetermined distance from the lateral side of the magnet 4〇4, and a portion of each of the terminal clips 384 can be wound. One of the magnets is tilted 148071.doc •16· 201106391 The edge f curve is shown in Figure 11F. This portion of clip 384 is approximately 90. One of the angles # is curved and extends along the side walls of the magnet. Since the predetermined distance of the cutting line 3 from the magnet 404 is relatively small, the curved portion of the clip 384 extends only to one half of the side of the magnet 404. That is, the height of one of the curved portions of the clip 384 is smaller than the height of the side wall of the magnet 404. The curved portion of the clip 384 as shown in Fig. 11F may generally correspond to the positioning section 145 described above for the terminal clips 106 and 108. The recesses (similar to the recesses 123 and 125 as described in the above embodiments) can be molded into the sidewalls of the magnet to accommodate the curved portion of the terminal clip 384 without adversely affecting the occupancy of the magnetic component. The coil end 403 can be electrically connected to the clip 384 via a solder pass, soldering process, or other technique familiar to those skilled in the art, as shown in Figure nG. When used with relatively large wire gauges, and when relatively small wire gauges are used to make the coils == preferred 〇 Figure 11H illustrates one of the finished magnetic components including terminal clips 384. Once the magnetic element 420' is completed, its surface can be mounted to a circuit board via the central portion 386 of the clip 384, as set forth above. Figure 12 illustrates a typical example which can be fabricated similar to the method set forth above. When the component 45 is fabricated, when the lead frame 382 is trimmed, the (four) line 410 (Fig. 11D) is spaced apart from the magnet. Thus, when the clip 386 is bent about the magnet 404f, the trimmed portion of the clip is sufficiently long to extend the entire gimbal of the side wall of the magnet 404 and further to about 90. One angle bends and leans against one of the top walls of the magnet. The enthalpy extension, the magnet may include a recess to accommodate the curved clip without adversely affecting the profile of one thousand. 148071.doc -17- 201106391 Separating the cutting line further away from the magnet 404 (as in the embodiment of Figure 12) presents a reduced risk of contamination problems and due to molding operations or other manufacturing steps in forming the magnet 404 And the negative effects. Many variations of the basic methods described are possible. For example, the coils can be soldered, welded, or otherwise attached to the coil ends 4〇3 prior to trimming the leadframe and/or before bending the coils 386 around the side of the magnet. That is, the order of steps as described above is not necessarily required. In addition, terminal clips of other shapes having similar effects and advantages can be formed in the lead forming layer. That is, in other alternative embodiments, the clips need to have the precise shape illustrated and described. Also, in some embodiments, the coil need not be provided separately from the terminal fabrication layer 38 and assembled during the molding process. Rather, in some embodiments, the coils may be pre-attached to the fabrication layer or otherwise formed integrally with the terminal fabrication layer. Still further, the coil ends can be soldered, soldered or otherwise electrically connected to the clips in a variety of ways. For example, the slot 394 (Fig. 1A) in the clip can be considered as an alternative and can be used in place of other mechanical emulations that use through holes or facilitate the engagement of the coil leads. The vias and slots in another embodiment can be considered optional in some embodiments, and the coil leads 4〇3 can be soldered, for example, to the surface of the clip without the use of mechanical engagement features. Further, the U.S. Application Serial No. 4, filed on Apr. 24, 2009, which is incorporated herein by reference. The terminal clamp is welded or two-person welded to the end of the j-line at a position inside a core member as described in /429'856. In addition, the 'coil leads can be soldered or soldered to the inner surface of the clip facing the surface (ie, facing the magnet-surface in the finished component) and 14807].doc 201106391 The outer facing surface of the clip (ie, the finished component is opposite the magnet) a surface). Figure 13 is a perspective view of one of the core members 450 forming one of the magnetic elements in accordance with an exemplary embodiment. In an exemplary embodiment as shown, the core member 45 is prefabricated from a known material and known techniques, such as those materials and techniques set forth above, and is provided for The post-production phase is assembled with other components. As shown in Fig. 13, the core member 450 includes a generally flat and rectangular base portion 452 and a cylindrical or tubular portion 454 extending upwardly and generally perpendicularly from the plane of the base portion 452. The base portion 452 of the illustrated exemplary embodiment is substantially longer and wider in size relative to the diameter of the cylindrical portion 454, and the cylindrical portion 454 is generally centered on the rectangular base portion 454. Base portion 452 and cylindrical portion 454 thus define a receiving area for a coil, such as coil 402 (Figs. 11A and 11B) or other coils as set forth herein. More specifically, and as shown in Figure 14, the cylindrical portion 454 of the core member 450 extends through one of the open central regions of the coil 402 such that the cylindrical portion 454 substantially fills the open central region of the coil 402. Also shown in Figure 14 is a termination fabrication layer 380 having the coil termination features set forth above, wherein the assembly is placed in a mold. When so assembled, the cylindrical portion 454 of each core member 450 extends through and generally occupies the central opening of each coil. The core member 450 can be held in place by a retaining member that also secures the termination fabrication layer 380 and the attached inductor coil 402 in place for further processing. A magnet 458 (shown in Figure 15 and also shown hatched in Figure 13) can be formed around the turns 402 and the core member 450 and portions of the termination fabrication layer 380 as a result of 148071.doc • 19·201106391. In one example, an inductor body can then be compression molded over the assembled coil 402, the terminal clip of the termination fabrication layer 380, and the core member 450. The cylindrical portion 454 of the core member 450 provided separately prevents the material used to form the magnet 458 from entering the central region of the core during the molding process. Especially when the core member 450 and the magnet 458 are made of different materials having different magnetic properties, a considerable number of performance advantages can be produced by a simplified process. A monolithic or monolithic core structure can be produced from the core member 450 and the magnets 458, wherein the different portions of the core structure have varying magnetic properties while eliminating the separate core members associated with conventional magnetic jaw constructions. Interval and bonding steps. One of the manners 7G can be made to the assembly shown in Fig. 5 after the molding process is completed, in a manner similar to that described above with respect to Figs. 11D to 11H. III. Illustrative Example Illustrated It should now be apparent that the various features set forth can be mixed and matched in various combinations. It is advantageous to provide a wide variety of magnetic component assemblies having different magnetic properties, different numbers and types of turns and having different performance characteristics to meet the needs of a particular application. Moreover, some of the features set forth may be advantageously utilized in structures having discrete core members that are physically spaced apart from each other and spaced apart. Among the various possibilities within the scope of the invention as enumerated above, it is believed that at least the following embodiments are advantageous over conventional inductor elements. A surface mount magnetic component assembly has been disclosed which includes: a conductive coil having a winding portion and opposing first and second ends extending from the winding portion; a magnetic core formed around the winding portion and including Encapsulating the winding 148071.doc • 20· 201106391 group portion, the magnetic core has a base wall and orthogonal sidewalls extending from the base wall, the first and second ends extending through the base wall of the magnetic core; The first and second terminal clips ' are connected to the respective first and second ends, and the first and second terminals are positioned on the base wall adjacent to the opposite sidewalls of the magnetic core. Optionally, the first and second terminals are completely extended outside the core. The first and second terminal clips can include one of an opening and a slot configured to receive one of the first and second ends. The first and second ends extend through the spaced apart recessed surface of the base wall of the core. The ends can be joined to the first and second terminal clips at the recessed surfaces. At least one of the first and second terminal clips can include a post embedded in the core. The first and second terminal clips can be provided on one end of the fabrication layer. The magnetic component assembly can further include a core member that is separately fabricated from the core. The winding portion can have an open central region in which one of the separately fabricated core members partially occupies the open central region. The portion of the separately fabricated core member can be cylindrical. The separately provided core member may also include a rectangular base portion and a cylindrical portion extending from the base portion. The separately provided core member may be made of a magnetic material different from one of the magnetic cores. The m-element assembly can further include a circuit board in which the substrate wall rests on the circuit board. The magnet and the coil can form an inductor. A method of fabricating a magnetic component is also disclosed, comprising: forming a magnet over an exposed surface of a pair of terminal clips and at least one coil associated with the pair of terminal clips; whereby the coil-winding portion is Fully embedded in the magnet and the opposite ends of the coil are attached to the terminal clips on a common wall of one of the formed magnets. 148071.doc • 21· 201106391 Depending on the situation, the method may further comprise: assembling a separately provided core member and the coil, and forming a magnet on the separately provided core member and the assembly of the coil. Assembling the provided core member and the coil can include extending a portion of the separately provided core member through an open central region of the coil. The terminal clips can include at least one post, wherein the method further includes embedding the post in the magnet when the magnet is formed. The pair of terminals can also be attached to a lead frame, wherein the method further includes trimming the lead frame to sever the clip from the lead frame. The method can also include bending a portion of the clip around a sidewall of the magnet and electrically connecting the terminal clip to the coil end. Electrically connecting the terminal clip can include soldering 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 and attaching one of the exposed coil ends on the bottom surface of the magnet to the clip. Forming the body includes molding the body over the at least one clip. The pair of terminal clips are engageable by a lead frame with a gap between the pair of clips and the magnetic system is formed in the gap between the pair of terminal clips. Each of the terminal clips can include a center portion and a first and a: sinker portions on either side of the center portion, and the method can further include connecting the coil to the depressed portions. The method can also include configuring the pair of terminal clips to extend as mirror images of each other. IV. Conclusion It is now believed that the benefits of the present invention are apparent from the foregoing examples and examples. Although numerous embodiments and (4) have been specifically described, other examples and embodiments may be present in the scope and spirit of the disclosed exemplary devices, assemblies and methods. 148071.doc • 22· 201106391 Example. 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 patentable scope of the invention is defined by the scope of the claims, and may include other examples of those skilled in the art. If such other examples have structural components that are not different from the written language of the scope of the patent application, or if they include equivalent structural components that are not substantially different from the written language of the scope of the patent application, these other examples are intended to be Within the scope of the scope. BRIEF DESCRIPTION OF THE DRAWINGS Non-limiting and non-exhaustive embodiments are described with reference to the following drawings, wherein the same reference numerals refer to the same parts throughout the drawings unless otherwise specified. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a partially exploded 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 showing one of the magnetic members 70 of the dry type in Fig. 1. Fig. 3 is a top perspective assembled view of one of the magnetic members of Fig. 1 in which 胼+々& Figure 4 is a bottom perspective assembly view of the magnetic component shown in Figure 1. A partially exploded view of another exemplary magnetic element in accordance with an exemplary embodiment of the present invention. Figure 6 is a top perspective view of one of the magnetic elements of Figure 5 Φ π - &,, _ ^. Figure 7 is a top perspective assembled view of one of the magnetic elements of the sheet of Figure 5. Figure 8 is a perspective view of the assembly of #-, 5, 〇_. to make. According to another embodiment of the present invention, a terminal error is formed 148071.doc
C -23- 201106391 圖1 0係圖9中所示之總成之—部 圖11圖解說明利用圖9及圖中 步驟；其中 分之一放大圖。 所示之端子總成之製造 圖11Α表示一磁性元件之一第—製造階段； 圖11B表示該磁性元件之一第二製造階段； 圖HC圖解說明來自圖11B之所得總成之一俯視圖； 圖11D圖解說明來自圖ι1Β之所得總成之一仰視圖； 圖1 1E表示s玄磁性元件之一第三製造階段； 圖11F表示該磁性元件之一第四製造階段； 圖11G表示該磁性元件之一第五製造階段； 圖11Η顯示成品磁性元件。 圖12圖解說明另一磁性元件。 圖13係根據一實例性實施例形成之一磁性元件之一芯件 之一透視圖。 圖14圖解說明圖13中所示之一芯件在一模製製造階段中 與一端子引線框架組裝。 圖1 5圖解說明在模製過程之後圖14中所示之總成之一部 分。 【主要元件符號說明】 100 表面安裝磁性元件 102 芯 104 線圈 106 端子夾 108 端子夾 148071.doc .24 - 201106391 110 件 112 芯件 114 芯件 116 側壁 118 側壁 120 側壁 122 側壁 123 下陷表面 124 下陷表面 125 下陷表面 126 下陷表面 128 下陷表面 130 下陷表面 132 下陷表面 134 下陷表面 136 下陷表面 140 安裝區段 142 底部區段 144 線圈區段 145 立式定位連接片區段 146 通孔 150 線圈端 152 線圈端 154 繞組部分 148071.doc -25- 線圈軸 電路板 導電跡線 板表面 磁性元件 端子製作層 引線框架 端子爽 中心部分 偏移連接片或突出部 偏移連接片或突出部 芯柱 端接槽 模具 線圈 線圈端 磁體 切割線 磁性元件 磁性元件 基底部分 圓柱形部分 磁體 -26-C -23- 201106391 Fig. 1 0 is a portion of the assembly shown in Fig. 9. Fig. 11 illustrates the steps of using Fig. 9 and Fig. 1; Figure 11A shows a first manufacturing stage of a magnetic element; Figure 11B shows a second manufacturing stage of the magnetic element; Figure HC illustrates a top view of the resulting assembly from Figure 11B; 11D illustrates a bottom view of the resultant assembly from FIG. 1I; FIG. 1E shows a third manufacturing stage of one of the s-magnetic elements; FIG. 11F shows a fourth manufacturing stage of the magnetic element; FIG. 11G shows the magnetic element. A fifth stage of manufacture; Figure 11 shows the finished magnetic component. Figure 12 illustrates another magnetic element. Figure 13 is a perspective view of one of the core members of one of the magnetic members formed in accordance with an exemplary embodiment. Figure 14 illustrates that one of the core members shown in Figure 13 is assembled with a terminal leadframe in a molding manufacturing stage. Figure 15 illustrates a portion of the assembly shown in Figure 14 after the molding process. [Main component symbol description] 100 Surface mount magnetic component 102 Core 104 Coil 106 Terminal clamp 108 Terminal clamp 148071.doc .24 - 201106391 110 Piece 112 Core member 114 Core member 116 Side wall 118 Side wall 120 Side wall 122 Side wall 123 Sink surface 124 Sink surface 125 depressed surface 126 depressed surface 128 depressed surface 130 depressed surface 132 depressed surface 134 depressed surface 136 depressed surface 140 mounting section 142 bottom section 144 coil section 145 vertical positioning tab section 146 through hole 150 coil end 152 coil end 154 Winding Section 148071.doc -25- Coil Shaft Circuit Board Conductor Trace Board Surface Magnetic Element Terminal Fabrication Layer Lead Frame Terminal Cool Center Partial Offset Tab or Tab Offset Tab or Tab Core Post End Slot Mold Coil Coil End magnet cutting line magnetic element magnetic element base part cylindrical part magnet-26-