Patent ID: 8695209
Filing Date: 2014-04-15
Classification: H01F,Y10T

Abstract:
1. A method of producing a surface-mount inductor by encapsulating a coil with an encapsulation material containing a resin and a filler using a mold die assembly, said method comprises the steps of: preparing a first tablet by preforming a part of the encapsulation material, the first tablet is prepared such that it has a flat portion formed such that it has a plate shape and a convex portion formed such that it has a pillar shape on a peripheral of the flat portion; preparing the coil by winding conductive wire having a rectangular cross-section to form an air-core coil; placing the air-core coil on the flat portion of the first tablet to allow both ends of the air-core coil to extend along an outer side surface of the convex portion of the first tablet, and disposing the air-core coil and the first tablet in the mold die assembly such that the both ends of the air-core coil are clamped between an inner wall surface of the mold die assembly and the outer side surface of the convex portion of the first tablet; loading a second tablet prepared with the rest of the encapsulation material into the mold die assembly; integrating the first tablet, the air-core coil and the second tablet together by using a resin molding process or a powder molding process while clamping the both ends of the air-core coil between the inner wall surface of the mold die assembly and the outer side surface of the convex portion of the first tablet, to form a molded body such that at least portions of the ends of the air-core coil are exposed to the surface of the molded body; and forming external electrodes on a surface of or around an outer periphery of the molded body in such a manner that the external electrodes are electrically connected to the both ends of the coil at least a portion of which is exposed to the surface of the molded body.