US 11,688,547 B2
Inductor device and method of fabricating the same
Ping-Hung Lin, Taoyuan (TW); Zuei-Chown Jou, Taoyuan (TW); Yung-Ping Wu, Taoyuan (TW); Chi-Ming Huang, Taoyuan (TW); Yao-Tsung Chen, Taoyuan (TW); and Bo-Yu Huang, Taoyuan (TW)
Assigned to DARFON ELECTRONICS CORP., Taoyuan (TW)
Filed by DARFON ELECTRONICS CORP., Taoyuan (TW)
Filed on Sep. 4, 2020, as Appl. No. 17/12,919.
Claims priority of application No. 108134095 (TW), filed on Sep. 20, 2019.
Prior Publication US 2021/0090792 A1, Mar. 25, 2021
Int. Cl. H01F 27/28 (2006.01); H01F 27/32 (2006.01); H01F 27/29 (2006.01); H01F 27/255 (2006.01); H01F 41/02 (2006.01); H01F 41/04 (2006.01); H01F 41/12 (2006.01)
CPC H01F 27/32 (2013.01) [H01F 27/255 (2013.01); H01F 27/29 (2013.01); H01F 41/0246 (2013.01); H01F 41/04 (2013.01); H01F 41/127 (2013.01)] 6 Claims
OG exemplary drawing
 
1. An inductor device, comprising:
a conductive coil, constituted by a circular wire being spirally wound to form multi-layer turns;
an insulating layer, overlaying an outer surface of the circular wire of the conductive coil;
two terminals, respectively electrically connected to one of two ends of the conductive coil;
a pillar, molded from a plurality of first composite material powders by a pressing process, each first composite material powder being composed of a first magnetic material powder coated with a first thermosetting resin, the pillar being placed in a surrounding space formed by the conductive coil; and
a cladding body, molded from a plurality of second composite material powders, each of the second composite material powders being composed of a second magnetic material powder coated with a second thermosetting resin, the cladding body cladding the conductive coil, two portions of the terminals connected with the ends of the conductive coil and the pillar, and the two terminals being exposed outside the cladding body;
wherein a first weight ratio of the first thermosetting resin to the first composite material powders is less than a second weight ratio of the second thermosetting resin to the second composite material powders, the cladding body, the conductive coil and the pillar cladded by the cladding body are heated to a curing temperature such that the plurality of first magnetic material powders are bonded by the cured first thermosetting resin and the plurality of second magnetic material powders are bonded by the cured second thermosetting resin, the first weight ratio is in a range of from 0 to 3.5%.