Abstract:
Multiple methods are provided to paint a body of an inductor so that there is no residual glue remained in the lead that may cause extra cleaning work and soldering issues when the lead is soldered with an external circuit.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application No. 62/331,991 filed on May 5, 2016, which is hereby incorporated by reference herein and made a part of specification. 
     
    
     BACKGROUND OF THE INVENTION 
     I. Field of the Invention 
       [0002]    The present invention relates to an inductor, and in particularly, to spray paint on a body of an inductor. 
       II. Description of the Prior Art 
       [0003]    Conventional way to spray paint on all side surfaces of the body of an inductor uses an adhesive tape to cover the leads of the inductor, which will cause extra cleaning work to remove the glue after the tape is removed. 
         [0004]    Please refer to  FIG. 1 , which illustrates views of conventional steps to form a paint-coating layer on the magnetic body of an inductor, wherein a view  101  shows the inductors are made and are arranged on a frame before spraying paint on all surfaces of the magnetic body of each inductor; a view  102  shows the leads of inductors on the frame are covered by a tape, wherein the tape is adhered to the leads by using a tape that has adhesive material on its bottom surface; and then spraying paint on the magnetic body to encapsulate all surfaces of the magnetic body of the inductor; and after the magnetic body is coated with the paint, the tape will be removed; a view  103  shows the inductors arranged on a frame after the magnetic body is coated with the paint for baking so that the paint can be heated and stayed on the magnetic body of each inductor. However, this conventional method uses sticky tape, and there is a need to remove the glue after the sticky tape is removed, so it might cause structural damage to body or the leads of the inductor. By doing so, it will cost more time and more cost to clean the residual glue on the leads of the inductor. 
         [0005]    Accordingly, the present invention proposes a better way to coat the paint on the body of the inductor to overcome the above-mentioned problems. 
       SUMMARY OF THE INVENTION 
       [0006]    One objective of the present invention is to provide a method to paint a body of an inductor so that there is no residual glue remained in the lead that may cause extra cleaning work and soldering issues when the lead is soldered with an external circuit. 
         [0007]    One objective of the present invention is to provide a method to paint a body of an inductor so that the lead of the inductor will not have any paint stains that may cause soldering issues when the lead is soldered with an external circuit. 
         [0008]    One embodiment of the present invention is to provide a method to paint a body of an inductor, wherein a first lead extends out from a first side surface of the body, the method comprising: spraying paint on all surfaces of the body of the inductor and on the first lead; and covering the first lead with a mask to define a first area of a first surface of the first lead; and removing the paint on the first area of the first surface of the first lead by a laser beam. 
         [0009]    In one embodiment, a second lead extends out from a second side surface of the body of the inductor, wherein the first lead and the second lead extends outside of the body from two opposite side surfaces of the body, wherein at least one portion of the second lead is covered by the paint, further comprising: covering the second lead with the mask to define a first area of a first surface of the second lead; and removing the paint on the first area of the first surface of the second lead by the laser beam. 
         [0010]    In one embodiment, the body is a magnetic body, and a coil is embedded inside the magnetic body and electrically connected to the first lead and the second lead. 
         [0011]    In one embodiment, the body is a magnetic body, and a metal strip is embedded inside the magnetic body and electrically connected to the first lead. 
         [0012]    In one embodiment, the body is a magnetic body, and a metal strip is embedded inside the magnetic body and electrically connected to the first lead and the second lead. 
         [0013]    One embodiment of the present invention is to provide a method to paint a body of an inductor, wherein a first lead extends out from a first side surface of the body, the method comprising: covering the first lead with a first object, wherein said first object is not adhered to the first lead; spraying paint on all surfaces of the body of the inductor; and removing said first object to expose the first lead. 
         [0014]    In one embodiment, said object is a non-adhesive tape; 
         [0015]    In one embodiment, said object is a non-adhesive fixture; 
         [0016]    In one embodiment, the inductor further comprises a second lead extending outside the body of the inductor, wherein the first lead and the second lead extends outside of the body from two opposite side surfaces of the body, the method further comprising covering the second lead with a second object, wherein the second object is not adhered to the second lead; and removing said second object to expose the second lead. 
         [0017]    In one embodiment, said first object and said second object are integrally formed in one piece. 
         [0018]    In one embodiment, said first object is a non-adhesive tape. 
         [0019]    In one embodiment, said first object is a non-adhesive fixture. 
         [0020]    In one embodiment, the body is a magnetic body, and a coil is embedded inside the magnetic body and electrically connected to the first lead and the second lead. 
         [0021]    In one embodiment, the body is a magnetic body, and a metal strip is embedded inside the magnetic body and electrically connected to the first lead. 
         [0022]    In one embodiment, the body is a magnetic body, and a metal strip is embedded inside the magnetic body and electrically connected to the first lead and the second lead. 
         [0023]    One embodiment of the present invention is to provide a method to paint a body of an inductor, wherein a first lead extends out from a first side surface of the body, the method comprising: using an ultrasonic equipment to spray paint on all surfaces of the body of the inductor, wherein the lead is not covered while spraying the paint using the ultrasonic equipment. 
         [0024]    In one embodiment, a second lead extends out from a second side surface of the body of the inductor, wherein the first lead and the second lead extends outside of the body from two opposite side surfaces of the body, wherein at least one portion of the second lead is covered by the paint, further comprising: covering the second lead with the mask to define a first area of a first surface of the second lead; and removing the paint on the first area of the first surface of the second lead by the laser beam. 
         [0025]    In one embodiment, the body is a magnetic body, and a coil is embedded inside the magnetic body and electrically connected to the first lead and the second lead. 
         [0026]    In one embodiment, the body is a magnetic body, and a metal strip is embedded inside the magnetic body and electrically connected to the first lead. 
         [0027]    In one embodiment, the body is a magnetic body, and a metal strip is embedded inside the magnetic body and electrically connected to the first lead and the second lead. 
         [0028]    The detailed technology and above preferred embodiments implemented for the present invention are described in the following paragraphs accompanying the appended drawings for people skilled in the art to well appreciate the features of the claimed invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0029]    The foregoing aspects and many of the accompanying advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description when taken in conjunction with the accompanying drawings, wherein: 
           [0030]      FIG. 1  illustrates views of conventional steps of forming a paint-coating layer on the magnetic body of an inductor using an adhesive tape to cover the leads of an inductor; 
           [0031]      FIG. 2  illustrates views of steps of forming a paint-coating layer on the magnetic body of an inductor using a non-adhesive tape to cover the leads of an inductor according to an embodiment of the present invention; 
           [0032]      FIG. 3  illustrates views of steps of forming a paint-coating layer on the magnetic body of an inductor using a fixture to cover the leads of an inductor according to an embodiment of the present invention; 
           [0033]      FIG. 4  illustrates views of steps of forming a paint-coating layer on the magnetic body of an inductor using an ultrasonic equipment according to an embodiment of the present invention; 
           [0034]      FIG. 5  illustrates views of steps of forming a paint-coating layer on the magnetic body of an inductor using a laser beam to remove the paint on the leads according to an embodiment of the present invention; and 
           [0035]      FIGS. 6-8  show different flow charts to form a paint-coating layer on the magnetic body of an inductor. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0036]    The detailed explanation of the present invention is described as follows. The described preferred embodiments are presented for purposes of illustrations and descriptions, and they are not intended to limit the scope of the present invention. 
         [0037]    The present invention discloses different methods to form a paint-coating layer on a magnetic body of an inductor by spraying paint on the magnetic body to encapsulate all surfaces of the magnetic body of the inductor as well as an inductor that has the paint-coating layer. 
         [0038]    The following embodiments discloses different methods to form a paint-coating layer on a magnetic body of an inductor by spraying paint on the magnetic body to encapsulate all surfaces of the magnetic body of the inductor as well as an inductor that has the paint-coating layer. 
       First Embodiment 
       [0039]    The method described in this embodiment is intended to improve the drawbacks of using an adhesive tape to stick on leads of inductors so that the leads can be protected while performing spraying paint on six-sided surfaces of a magnetic body of an inductor, wherein the material of the paint can be polymer and adhesive material, such as resin. The method described in this embodiment can be applied to various sizes or shape of the leads or the magnetic body of an inductor or a choke. 
         [0040]    Please refer to  FIG. 2 , which illustrates views of steps of forming a paint-coating layer on the magnetic body of an inductor using a non-adhesive tape to cover the leads of an inductor, wherein a view  201  shows the inductors  250  are made and are arranged on a frame before spraying paint on all surfaces of the magnetic body of each inductor  250 ; a view  202  shows the leads of inductors  250  on the frame are covered by a tape  260 , wherein the tape  260  is not adhered to the leads by using the tape  260  that has no adhesive material on its bottom surface; and then spraying paint on the magnetic body to encapsulate all surfaces of the magnetic body of the inductor; and after the magnetic body is coated with the paint, the tape  260  can be easily removed because the tape  260  is not adhered to the leads; a view  203  shows the inductors  270  arranged on a frame after the magnetic body is coated with the paint for baking so that the paint can be heated and stayed on the magnetic body of each inductor. Because this method uses the non-sticky tape, unlike conventional technology using a sticky tape, there is no need to remove the glue after the non-sticky tape is removed, so it will not cause any structural damage to the inductor or choke body or the leads of the inductor. By doing so, it can save time and cost while having a much cleaner lead for connecting with an external circuit, because there is no glue attached on the leads for the whole process. 
         [0041]    In one embodiment, a coil is embedded inside the magnetic body, and the coil is electrically connected to the first lead. In one embodiment, a coil is embedded inside the magnetic body, and the coil is electrically connected to the first lead and the second lead. In one embodiment, a metal strip is embedded inside the magnetic body and electrically connected to the first lead. In one embodiment, a metal strip is embedded inside the magnetic body and electrically connected to the first lead and the second lead. 
       Second Embodiment 
       [0042]    This embodiment discloses a method to form a paint-coating layer on a magnetic body of an inductor, the method comprising: painting a body of an inductor having a first lead, wherein the first lead extends outside of the body of the inductor, covering the first lead with a fixture, wherein the fixture is not adhered to the first lead, spraying paint on all surfaces of the body of the inductor and removing said fixture to expose the first lead. 
         [0043]    Please refer to  FIG. 3 , which illustrates views of steps of forming a paint-coating layer on the magnetic body of an inductor using a fixture to cover the leads of an inductor, wherein a view  301  shows the inductors are made and are arranged on a frame before spraying paint on all surfaces of the magnetic body of each inductor; a view  302  shows the leads of inductors on the frame are covered by a fixture, wherein the fixture is not adhered to the leads by using a fixture  360  that has no adhesive material on its bottom surface; and then spraying paint on the magnetic body to encapsulate all surfaces of the magnetic body of the inductor; and after the magnetic body is coated with the paint, the fixture  360  can be easily removed because the fixture  360  is not adhered to the leads; a view  303  shows the inductors arranged on a frame after the magnetic body is coated with the paint for baking so that the paint can be heated and stayed on the magnetic body of each inductor. Because this method uses the non-sticky fixture  360 , unlike conventional technology using a sticky tape, there is no glue remained on the leads after the non-sticky fixture  360  is removed, so it will not cause any structural damage to the inductor or choke body or the leads of the inductor. The non-sticky fixture  360  can be more precise to define the area of the leads without being sprayed with paint, and the gap between the lead and the magnetic body can hence be narrowed, as a result, it will not cause solder-resistance issue when the lead is soldered with an external pad. By doing so, it can save time and cost while having a much cleaner lead for connecting with an external circuit, because there is no glue attached on the leads for the whole process. 
         [0044]    In one embodiment, a coil is embedded inside the magnetic body, and the coil is electrically connected to the first lead. In one embodiment, a coil is embedded inside the magnetic body, and the coil is electrically connected to the first lead and the second lead. In one embodiment, a metal strip is embedded inside the magnetic body and electrically connected to the first lead. In one embodiment, a metal strip is embedded inside the magnetic body and electrically connected to the first lead and the second lead. 
       Third Embodiment 
       [0045]    This embodiment discloses a method to form a paint-coating layer on a magnetic body of an inductor, wherein a lead extends out from a side surface of the body of the inductor, the method comprising: using an ultrasonic equipment to spray paint on all surfaces of the body of the inductor, wherein the lead is not covered while spraying the paint using the ultrasonic equipment. 
         [0046]    Please refer to  FIG. 4 , which illustrates views of steps of forming a paint-coating layer on the magnetic body of an inductor, wherein a view  401  shows the inductors are made and are arranged on a frame before spraying paint on all surfaces of the magnetic body of each inductor; a view  402  shows the leads of inductors on the frame are not covered by any object; and then spraying paint  450  on the magnetic body to encapsulate all surfaces of the magnetic body of the inductor by using an ultrasonic equipment, ultrasonic equipment can generate a gas wall to control the range of paint spraying so that the leads will not be painted. The paint can be an anti-rust or insulating paint material, and the ultrasonic equipment can spray the paint directly onto the magnetic body of the inductor or choke. There is no need to cover the leads of the inductors when using the ultrasonic equipment to spraying the paint, and therefore, there is no need to have a supply material or any cleaning job of covering mask compared with the first and second embodiments described above. By doing so, it can save time and cost while having a much cleaner lead for connecting with an external circuit, because there is no glue attached on the leads for the whole process. This method is intended to improve the disadvantages of the second embodiment described above and it is suitable for various sizes of an inductor or a choke. 
         [0047]    In one embodiment, a coil is embedded inside the magnetic body, and the coil is electrically connected to the first lead. In one embodiment, a coil is embedded inside the magnetic body, and the coil is electrically connected to the first lead and the second lead. In one embodiment, a metal strip is embedded inside the magnetic body and electrically connected to the first lead. In one embodiment, a metal strip is embedded inside the magnetic body and electrically connected to the first lead and the second lead. 
       Fourth Embodiment 
       [0048]    Please refer to  FIG. 5 , which illustrates views of steps to form a paint-coating layer on the magnetic body of an inductor, wherein a view  501  shows that the inductors are made and are arranged on a frame before spraying paint on all surfaces of the magnetic body of each inductor; and then spraying paint on the magnetic body to encapsulate all surfaces of the magnetic body of the inductor; a view  502  shows that the leads of inductors on the frame are coated with the paint; a view  503  shows the inductors are separated so that each inductor is separated from the others; a view  504  shows that the separated inductors are arranged on a frame; a view  505  shows that the leads are covered with a mask  530  to define a first area of a first surface of each lead for removing the paint on said first area; and a view  506  shows the paint on the first area of the first surface of each lead are removed by a laser beam  550 . There is no cleaning job of the covering mask  530  because the laser beam  550  is very precise and the mask  530  will not get any stains of the paint, and hence the mask  530  can be reused without cleaning. The laser beam  550  can remove the paint very precisely according to the mask  530 , and the gap between the lead and the magnetic body can hence be narrowed, as a result, it will not cause solder-resistance issue when the lead is soldered with an external pad. By doing so, it can save time and cost while have a much cleaner leads for connecting with an external circuit, because there is no glue attached on the leads for the whole process. 
         [0049]    In one embodiment, a coil is embedded inside the magnetic body, and the coil is electrically connected to the first lead. In one embodiment, a coil is embedded inside the magnetic body, and the coil is electrically connected to the first lead and the second lead. In one embodiment, a metal strip is embedded inside the magnetic body and electrically connected to the first lead. In one embodiment, a metal strip is embedded inside the magnetic body and electrically connected to the first lead and the second lead. 
         [0050]      FIG. 6  shows a flow chart to perform a method to paint a body of an inductor, wherein a first lead extends out from a first side surface the body, in a step  601 , spraying paint on all surfaces of the body of the inductor and on the first lead of the inductor; in a step  602 , covering the first lead with a mask to define a first area of a first surface of the first lead; and in a step  603 , removing the paint on the first area of the first surface of the first lead by laser beam. 
         [0051]    In one embodiment, a coil is embedded inside the magnetic body, and the coil is electrically connected to the first lead. In one embodiment, a coil is embedded inside the magnetic body, and the coil is electrically connected to the first lead and the second lead. In one embodiment, a metal strip is embedded inside the magnetic body and electrically connected to the first lead. In one embodiment, a metal strip is embedded inside the magnetic body and electrically connected to the first lead and the second lead. 
         [0052]      FIG. 7  shows a flow chart to perform a method to paint a body of an inductor, wherein a first lead extends outside from a first side surface of the body, in a step  701 , covering the first lead of the inductor with a first object, wherein said first object is not adhered to the first lead; in a step  702 , spraying paint on all surfaces of the body of the inductor; and in a step  703 , removing said first object to expose the first lead. 
         [0053]    In one embodiment, a coil is embedded inside the magnetic body, and the coil is electrically connected to the first lead. In one embodiment, a coil is embedded inside the magnetic body, and the coil is electrically connected to the first lead and the second lead. In one embodiment, a metal strip is embedded inside the magnetic body and electrically connected to the first lead. In one embodiment, a metal strip is embedded inside the magnetic body and electrically connected to the first lead and the second lead. 
         [0054]      FIG. 8  shows a flow chart to perform a method to paint a body of an inductor, wherein a first lead extends outside from a first side surface of the body, in a step  801 , positioning an ultra sound equipment over the body of the inductor; in a step  802 , using an ultrasonic equipment to spray paint on all surfaces of the body of the inductor, wherein the lead is not covered while spraying the paint using the ultrasonic equipment. 
         [0055]    In one embodiment, a coil is embedded inside the magnetic body, and the coil is electrically connected to the first lead. In one embodiment, a coil is embedded inside the magnetic body, and the coil is electrically connected to the first lead and the second lead. In one embodiment, a metal strip is embedded inside the magnetic body and electrically connected to the first lead. In one embodiment, a metal strip is embedded inside the magnetic body and electrically connected to the first lead and the second lead. 
         [0056]    In one embodiment, an inductor is disclosed, the inductor comprising: a magnetic body, wherein a first lead extends outside of the body from a first side surface; and a paint-coating layer, formed by spraying paint on the magnetic body to encapsulate all surfaces of the magnetic body of the inductor, wherein the paint-coating layer extends from the first side surface of the magnetic body to a first area of a first surface of the first lead, and a second area of the first surface of the first lead is not covered by the paint-coating layer for electrically connecting with an external circuit. 
         [0057]    In one embodiment, a second lead extends out from a second side surface the magnetic body of the inductor, wherein the first lead and the second lead extends outside of the magnetic body from two opposite side surfaces of the magnetic body, wherein the paint-coating layer extends from the second side surface to a first area of a second surface of the second lead, and a second area of the second surface of the second lead is not covered by the paint-coating layer for electrically connecting with an external circuit. 
         [0058]    In one embodiment, a coil is embedded inside the magnetic body, and the coil is electrically connected to the first lead. In one embodiment, a coil is embedded inside the magnetic body, and the coil is electrically connected to the first lead and the second lead. In one embodiment, a metal strip is embedded inside the magnetic body and electrically connected to the first lead. In one embodiment, a metal strip is embedded inside the magnetic body and electrically connected to the first lead and the second lead. 
         [0059]    The above disclosure is related to the detailed technical contents and inventive features thereof. People skilled in the art may proceed with a variety of modifications and replacements based on the disclosures and suggestions of the invention as described without departing from the characteristics thereof. Nevertheless, although such modifications and replacements are not fully disclosed in the above descriptions, they have substantially been covered in the following claims as appended.