Patent ID: 7392581
Filing Date: 2008-07-01
Classification: H01F,Y10T

Abstract:
1. A magnetic element manufacturing method comprising the steps of: die-cutting a metal member of a plate shape to form a plate member including a frame portion, a mounting terminal portion and plural terminal joint portions and having a winding number adjustment means capable of selecting a joint position of an end from the plural terminal joint portions in accordance with a winding number of a coil; winding a flat wire to form the coil of which ends are jointed with the terminal joint portions; setting the coil formed by said winding step while the terminal joint portions and the ends are in a contacting state; jointing the ends and the terminal joint portions to secure a positional relationship of the ends and the terminal joint portions; powder pressing to press the coils, the terminal joint portions and granulated powders while the coils and the terminal joint portions are coated with the granulated powders composed of a magnetic material and a thermosetting resin to thereby form a green compact in which the mounting terminal portion is in an exposed state by the pressing; heating the green compact formed by said powder pressing step to thermoset the granulated powders; and forming a terminal to form a PCB joint portion to be jointed with an external PCB by cutting the mounting terminal portion after said heating step at a middle portion of the mounting terminal portion and bending the cut mounting terminal portion.