Patent ID: 7523542
Filing Date: 2009-04-28
Classification: H01F,Y10T

Abstract:
1. A method of manufacturing a magnetic element, comprising the steps of: (a) forming a coil; said coil having end portions; (b) molding and sintering a ferrite core; said ferrite core having a bottom portion and a side wall; said side wall having cut-out portions corresponding to the number of end portions of said coil and wherein said cut-out portions do not extend the height of said side wall; (c) polishing said ferrite core after said sintering step; (d) forming terminal electrodes outside of said ferrite core; (e) placing said coil into said ferrite core with said end portions extending through said cut-out portions, (f) mixing magnetic metal powder and resin to form a paste; (g) forming a dam frame on said cut-out portion of said ferrite core to prevent said mixing paste from contacting with said terminal electrodes; (h) filling said paste into said ferrite core to cover said coil so that an upper surface of said ferrite core and an upper surface of said paste form a flat surface and (i) curing said mixing paste.