Surface mount inductor and method for manufacturing the same

Abstract

A surface mount inductor includes a coil including a wound portion and a feeder end portion drawn out from the wound portion, a compact that contains a magnetic powder and that encapsulates the coil, and an external terminal disposed on the compact and connected to the coil. The compact has surfaces including two pressed surfaces, opposing each other in a direction of an axis of the wound portion and formed by being pressed in the direction of the axis, and a non-pressed surface, adjacent to the two surfaces and not pressed. The coil is disposed so that the axis of the wound portion is parallel to a mount surface of the compact. The mount surface is included in the non-pressed surface, the feeder end portion is exposed from the mount surface, and the external terminal is formed on only the non-pressed surface and connected to the feeder end portion.

What is claimed is: 
     
         1 . A surface mount inductor, comprising:
 a coil including a wound portion and at least one feeder end portion drawn out from the wound portion;   a compact that contains a magnetic powder and that encapsulates the coil therein, the compact having surfaces including two pressed surfaces, which oppose each other in a direction of an axis of the wound portion and which are formed by being pressed in the direction of the axis, and a non-pressed surface, which is adjacent to the two surfaces and which is not pressed; and   an external terminal disposed on the compact and connected to the coil,   wherein the coil is disposed so that the axis of the wound portion is parallel to a mount surface of the compact, the mount surface being included in the non-pressed surface, the feeder end portion is exposed from the mount surface of the compact, and the external terminal is formed on only the non-pressed surface of the compact and connected to the feeder end portion.   
     
     
         2 . The surface mount inductor according to  claim 1 , wherein the mount surface of the compact includes an irregular interface. 
     
     
         3 . The surface mount inductor according to  claim 2 , wherein
 the coil has two feeder end portions each corresponding to the feeder end portion, and   the irregular interface extends from an exposed portion of one of the feeder end portions exposed from the mount surface to an exposed portion of the other feeder end portion exposed from the mount surface.   
     
     
         4 . The surface mount inductor according to  claim 1 , wherein
 the coil has two feeder end portions each corresponding to the feeder end portion, and   an exposed portion of one of the feeder end portions exposed from the mount surface and an exposed portion of the other feeder end portion exposed from the mount surface extend in opposite directions.   
     
     
         5 . The surface mount inductor according to  claim 4 , wherein the exposed portion of one of the feeder end portions and the exposed portion of the other feeder end portion extend to respective side surfaces included in the non-pressed surface and adjacent to the mount surface. 
     
     
         6 . The surface mount inductor according to  claim 5 , wherein
 the external terminal is formed in a substantially letter L shape extending from the mount surface of the compact to a corresponding one of the side surfaces, and   a portion of the external terminal disposed on the side surface has a height greater than or equal to a quarter of a height of the side surface.   
     
     
         7 . The surface mount inductor according to  claim 1 , wherein
 the coil has two feeder end portions each corresponding to the feeder end portion, and   the two feeder end portions are drawn out of the wound portion so as not to cross each other.   
     
     
         8 . The surface mount inductor according to  claim 2 , wherein
 the coil has two feeder end portions each corresponding to the feeder end portion, and   an exposed portion of one of the feeder end portions exposed from the mount surface and an exposed portion of the other feeder end portion exposed from the mount surface extend in opposite directions.   
     
     
         9 . The surface mount inductor according to  claim 3 , wherein
 the coil has two feeder end portions each corresponding to the feeder end portion, and   an exposed portion of one of the feeder end portions exposed from the mount surface and an exposed portion of the other feeder end portion exposed from the mount surface extend in opposite directions.   
     
     
         10 . The surface mount inductor according to  claim 8 , wherein the exposed portion of one of the feeder end portions and the exposed portion of the other feeder end portion extend to respective side surfaces included in the non-pressed surface and adjacent to the mount surface. 
     
     
         11 . The surface mount inductor according to  claim 9 , wherein the exposed portion of one of the feeder end portions and the exposed portion of the other feeder end portion extend to respective side surfaces included in the non-pressed surface and adjacent to the mount surface. 
     
     
         12 . The surface mount inductor according to  claim 10 , wherein
 the external terminal is formed in a substantially letter L shape extending from the mount surface of the compact to a corresponding one of the side surfaces, and   a portion of the external terminal disposed on the side surface has a height greater than or equal to a quarter of a height of the side surface.   
     
     
         13 . The surface mount inductor according to  claim 2 , wherein
 the coil has two feeder end portions each corresponding to the feeder end portion, and   the two feeder end portions are drawn out of the wound portion so as not to cross each other.   
     
     
         14 . The surface mount inductor according to  claim 3 , wherein
 the coil has two feeder end portions each corresponding to the feeder end portion, and   the two feeder end portions are drawn out of the wound portion so as not to cross each other.   
     
     
         15 . The surface mount inductor according to  claim 4 , wherein
 the coil has two feeder end portions each corresponding to the feeder end portion, and   the two feeder end portions are drawn out of the wound portion so as not to cross each other.   
     
     
         16 . The surface mount inductor according to  claim 5 , wherein
 the coil has two feeder end portions each corresponding to the feeder end portion, and   the two feeder end portions are drawn out of the wound portion so as not to cross each other.   
     
     
         17 . The surface mount inductor according to  claim 6 , wherein
 the coil has two feeder end portions each corresponding to the feeder end portion, and   the two feeder end portions are drawn out of the wound portion so as not to cross each other.   
     
     
         18 . A surface mount inductor, comprising:
 a coil including a wound portion and a feeder end portion drawn out from the wound portion;   a compact that contains a magnetic powder and that encapsulates the coil therein; and   an external terminal disposed on the compact and connected to the coil,   wherein   the coil is disposed so that an axis of the wound portion is parallel to a mount surface of the compact, and the feeder end portion is exposed from the mount surface of the compact and connected to the external terminal, and   the mount surface of the compact includes an irregular interface.   
     
     
         19 . The surface mount inductor according to  claim 18 , wherein
 the coil has two feeder end portions each corresponding to the feeder end portion, and   the irregular interface extends from an exposed portion of one of the feeder end portions exposed from the mount surface to an exposed portion of the other feeder end portion exposed from the mount surface.   
     
     
         20 . A method for manufacturing a surface mount inductor, comprising:
 enclosing a coil in a compact material containing a magnetic powder, and placing the coil in a die set, the coil including a wound portion and a feeder end portion drawn out of the wound portion;   pressing the compact material in a direction of an axis of the wound portion to form a compact that encapsulates the coil therein, and exposing the feeder end portion from a non-pressed surface of the compact; and   forming an external terminal on only the non-pressed surface of the compact and connecting the external terminal to the feeder end portion.