Coil component magnetic base

• US 10,210,973 B2
• Filed: 11/30/2017
• Issued: 02/19/2019
• Est. Priority Date: 04/19/2017
• Status: Active Grant

• Current Assignee: Murata Manufacturing Co Limited
• Original Assignee: Murata Manufacturing Co Limited
• Inventors: Shinohara, Gota, Ishida, Takuya
• Primary Examiner(s): Enad, Elvin G
• Assistant Examiner(s): Barnes, Malcolm
• Application Number:
  US15/828,150
• Publication Number:
  US 20180308609A1
• Time in Patent Office: 446 Days
• CPC Class Codes: B22F 1/08 Metallic powder characterised by particles having an amorphous microstructure
• CPC Class Codes: B22F 1/10 Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
• CPC Class Codes: B22F 1/102 Metallic powder coated with organic material
• CPC Class Codes: B22F 1/16 Metallic particles coated with a non-metal coated with lubricating or binding agents or with organic material B22F1/10
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 3/02 Compacting only
• CPC Class Codes: B22F 3/10 Sintering only
• CPC Class Codes: B22F 5/106 Tube or ring forms
• CPC Class Codes: B22F 9/002 amorphous or microcrystalline
• CPC Class Codes: C22C 1/05 Mixtures of metal powder with non-metallic powder C22C1/08 takes precedence
• CPC Class Codes: C22C 2202/02 Magnetic
• CPC Class Codes: C22C 33/0257 characterised by the range of the alloying elements
• CPC Class Codes: H01F 1/14733 in the form of particles
• CPC Class Codes: H01F 1/15333 containing nanocrystallites, e.g. obtained by annealing
• CPC Class Codes: H01F 1/15375 using polymers
• CPC Class Codes: H01F 1/26 by macromolecular organic substances
• CPC Class Codes: H01F 1/33 mixtures of metallic and non-metallic particles; metallic particles having oxide skin
• CPC Class Codes: H01F 17/0013 with stacked layers
• CPC Class Codes: H01F 17/04 with magnetic core
• CPC Class Codes: H01F 2017/048 : with encapsulating core, e.g. made of resin and magnetic powder
• CPC Class Codes: H01F 27/255 : made from particles H01F27/26 takes precedence
• CPC Class Codes: H01F 27/2852 : Construction of conductive connections, of leads
• CPC Class Codes: H01F 27/292 : Surface mounted devices
• CPC Class Codes: H01F 41/042 : by thin film techniques
• CPC Class Codes: H01F 41/10 : Connecting leads to windings making electric connections in general H01R43/00

Abstract

A coil component includes a magnetic portion that includes metal particles and a resin material, a coil conductor embedded in the magnetic portion and having a core portion, and outer electrodes electrically connected to the coil conductor. The magnetic portion includes a magnetic outer coating and a magnetic base having a protrusion portion. The coil conductor is disposed on the magnetic base such that the protrusion portion is located in the core portion. The magnetic outer coating is disposed so as to cover the coil conductor, and the bottom surface of the magnetic base includes a recessed portion in an area opposite to the protrusion portion.

Claims

1. A coil component comprising:

a magnetic portion that includes metal particles and a resin material, the metal particles being formed of a metal material, the metal material being at least one material selected from iron, Fe—

Si alloys, Fe—

Si—

Cr alloys, and Fe—

Si—

Al alloys;

a coil conductor embedded in the magnetic portion and having a core portion, the coil conductor being wound in an α

-winding form; and

outer electrodes electrically connected to the coil conductor,

wherein the magnetic portion includes a magnetic base having a protrusion portion, the protrusion portion extending from the magnetic base and including an end positioned a spaced distance from the magnetic base, and a magnetic outer coating,

a protective layer containing Ti and resin is disposed on the magnetic portion,

a filling factor of the metal particles in the magnetic base is 65% or more, and a filling factor of the metal particles in the magnetic outer coating is 50% or more,

the coil conductor is disposed on the magnetic base such that the protrusion portion is located in the core portion,

the magnetic outer coating covers the coil conductor, the magnetic base, and the end of the protrusion portion,

the bottom surface of the magnetic base includes a recessed portion in an area opposite to the protrusion portion,

a length (L) of the coil component is about 0.9 mm or more and 2.2 mm or less, and

a width (W) of the coil component is about 0.6 mm or more and 1.8 mm or less.

2. The coil component according to claim 1, wherein the depth of the recessed portion is from 0.01 to 0.08 mm.

3. The coil component according to claim 1, wherein the depth of the recessed portion is from 0.02 to 0.05 mm.

4. The coil component according to claim 1, wherein the width of the recessed portion is from 0.3 to 0.8 mm.

5. The coil component according to claim 1, wherein the angle formed by a wall surface and a bottom surface of the recessed portion is from 110°

to 130°

.

6. The coil component according to claim 1, wherein the bottom surface of the magnetic base further includes grooves, and end portions of the coil conductor extend into the grooves.

7. The coil component according to claim 6, wherein the magnetic portion is located between the end portions of the coil conductor that extend into the grooves located in the bottom surface of the magnetic portion and respective peripheral surfaces of the coil component.

8. The coil component according to claim 1, wherein the outer electrodes are disposed on at least the end portions of the coil conductor.

9. The coil component according to claim 1, wherein the outer electrodes extend beyond the end portions of the coil conductor to respective peripheral end surfaces of the magnetic portion.

10. The coil component according to claim 1, wherein the coil conductor is disposed adjacent to a surface of the magnetic base from which the protrusion portion extends and a vertical height of the surface increases with increasing distance along the surface from the protrusion.

11. The coil component according to claim 10, wherein the height increases linearly with the increasing distance.

12. The coil component according to claim 1, wherein

the filling factor of the metal particles in the magnetic base is higher than the filling factor of the metal particles in the outer coating.

13. The coil component according to claim 12, wherein the protrusion portion is in a shape of an elliptic cylinder.

14. The coil component according to claim 1, wherein the protrusion portion is substantially aligned with the recessed portion.

15. The coil component according to claim 1, wherein the metal particles comprise at least two of crystalline particles, amorphous particles, and nanocrystal particles.

17. The coil component according to claim 1, wherein the length (L) of the coil component is about 0.9 mm or more and 1.8 mm or less.

18. The coil component according to claim 1, wherein the width (W) of the coil component is about 0.6 mm or more and 1.0 mm or less.

16. A coil component comprising:

a magnetic portion that includes metal particles and a resin material, the metal particles being formed of a metal material, the metal material being at least one material selected from iron, Fe—

Si alloys, Fe—

Si—

Cr alloys, and Fe—

Si—

Al alloys;

a coil conductor made of a wire, embedded in the magnetic portion, and having a core portion, the core portion being a cavity surrounded by the wire, the coil conductor being wound in an α

-winding form; and

outer electrodes electrically connected to the coil conductor,

wherein the magnetic portion includes a magnetic base having a protrusion portion, the protrusion portion extending from the magnetic base and including an end positioned a spaced distance from the magnetic base, and a magnetic outer coating,

a protective layer containing Ti and resin is disposed on the magnetic portion,

a filling factor of the metal particles in the magnetic base is 65% or more, and a filling factor of the metal particles in the magnetic outer coating is 50% or more,

the coil conductor is disposed on the magnetic base such that the protrusion portion is located in the core portion,

the magnetic outer coating is disposed so as to cover the coil conductor, and the end of the protrusion portion,

the bottom surface of the magnetic base includes a recessed portion in an area opposite to the protrusion portion,

the filling factor of the metal particles in the magnetic base is higher than the filling factor of the metal particles in the outer coating,

the filling factor of the metal particles in the magnetic base is from 65% to 85%,

the filling factor of the metal particles in the outer coating is from 50% to 75%,

a length (L) of the coil component is about 0.9 mm or more and 2.2 mm or less,

a width (W) of the coil component is about 0.6 mm or more and 1.8 mm or less,

the protrusion portion is in a shape of an elliptic cylinder having a major axis and a minor axis, and

a ratio of the major axis to the minor axis is in a range of 1.2 and 1.7.

19. The coil component according to claim 16, wherein the length (L) of the coil component is about 0.9 mm or more and 1.8 mm or less.

20. The coil component according to claim 16, wherein the width (W) of the coil component is about 0.6 mm or more and 1.0 mm or less.