Patent ID: 7884696
Filing Date: 2011-02-08
Classification: H01F

Abstract:
1. A lead frame-based discrete power inductor comprising: a top lead frame including a first side and a second side, the first side being disposed opposite the second side, the first side having a first set of leads and the second side having a second set of leads, each of the leads of the first set of leads and of the second set of leads having an inner contact section and an outer contact section; a bottom lead frame including a first side and a second side, the first side being disposed opposite the second side, the first side having a first set of leads and the second side having a second set of leads, the first set of leads having a first terminal lead having an inner contact section and a terminal section, each of the remaining leads of the first set of leads having an inner contact section and an outer contact section, the second set of leads having a second terminal lead having an outer contact section and a terminal section, each of the remaining leads of the second set of leads having an inner contact section and an outer contact section; a routing lead having an outer contact section disposed on the first side of the top lead frame and an inner contact section disposed on the second side of the top lead frame; a magnetic core having a window formed through a center thereof, the magnetic core being disposed between the top lead frame and the bottom lead frame such that the first side of the top lead frame is aligned with the first side of the bottom lead frame, the inner contact section of first terminal lead and the inner contact sections of the remaining leads of the bottom lead frame first set of leads are coupled to respective inner contact sections of the top lead frame first set of leads through the window, the outer contact sections of the top lead frame first set of leads are coupled to respective outer contact sections of the remaining leads of the bottom lead frame first set of leads and to the outer contact section of the routing lead, the inner contact section of the routing lead and the inner contact sections of the remaining leads of the bottom lead frame second set of leads are coupled to respective inner contact sections of the top lead frame second set of leads through the window, and the outer contact sections of the top lead frame second set of leads are coupled to respective outer contact sections of the remaining leads of the bottom lead frame second set of leads and to the outer contact section of the second terminal lead to provide a coil about the magnetic core; and wherein the magnetic core is disposed relative to the bottom lead frame without a dielectric layer covering a bottom or a top surface of the magnetic core material, and wherein the top lead frame is spaced relative to the magnetic core and does not rest on the magnetic core, and further comprising a molding material filling in the space between the to lead frame and the magnetic core, and further encapsulating the lead frame-based discrete power inductor.