Coil component and method of manufacturing the same

• US 10,366,819 B2
• Filed: 09/26/2016
• Issued: 07/30/2019
• Est. Priority Date: 09/30/2015
• Status: Active Grant

• Current Assignee: Taiyo Yuden Company Limited (Taiyo Yuden Co)
• Original Assignee: Taiyo Yuden Company Limited (Taiyo Yuden Co)
• Inventors: Sado, Atsushi, Hayashi, Chiharu
• Primary Examiner(s): Chan, Tszfung J
• Application Number:
  US15/276,669
• Publication Number:
  US 20170092410A1
• Time in Patent Office: 1,037 Days
• Field of Search: 336 83, 336178, 336196, 336198, 336212, 336221
• CPC Class Codes: H01F 17/043 with two, usually identical or nearly identical parts enclosing completely the coil (pot cores)
• CPC Class Codes: H01F 2017/046 helical coil made of flat wire, e.g. with smaller extension of wire cross section in the direction of the longitudinal axis
• CPC Class Codes: H01F 27/255 made from particles H01F27/26 takes precedence
• CPC Class Codes: H01F 27/2828 Construction of conductive connections, of leads
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 27/306 Fastening or mounting coils or windings on core, casing or other support
• CPC Class Codes: H01F 41/0206 Manufacturing of magnetic cores by mechanical means magnetic cores per se H01F27/24
• CPC Class Codes: H01F 41/076 Forming taps or terminals while winding, e.g. by wrapping or soldering the wire onto pins, or by directly forming terminals from the wire

Abstract

In an embodiment, an air-core coil 50 includes a winding part 54 formed by winding a coated conductive wire 52, wherein a pair of leader parts 56 and 58 is interposed between a second core 20 and a first core 40 which contain metal magnetic grains. A first gap 72 is provided between a principle face 50A of one end portion of the winding part 54 in the direction of a winding core axis of the winding part 54 and the first core member 40. A second gap 70 is provided between a principle face 50B of the other end portion and the second core member 20. The coil component is a small and high-performance coil component with a high dielectric withstanding voltage.

Claims

1. A coil component comprising:

a preformed coil that is formed of a winding part which winds a coated conductive wire continuously and spirally in an axial direction and includes an inner circumferential surface, an outer circumferential surface, and a principle face of one end portion and a principle face of the other end portion in the axial direction, and of a pair of leader parts which extends outwardly from the winding part;

a first core member that includes a shaft part disposed inside the inner circumferential surface, a side wall portion disposed in at least a portion of the outer circumferential surface, and a connection portion which is disposed such that a first gap is formed between the principle face of the one end portion and the connection portion, and through which the shaft part is connected to the side wall portion, and that contains metal magnetic grains; and

a second core member which is disposed such that a second gap is formed between the principle face of the other end portion and the second core member which contains metal magnetic grains and is provided with an adhesive, wherein;

the pair of leader parts are disposed in a portion where the side wall portion of the first core member is not formed on the outer circumferential surface of the winding part, and the pair of leader parts are not covered by the side wall portion,

the coil component further comprises a pair of terminal electrodes formed at respective ends of the leader parts in a manner extending in a same direction and facing the principle face of the other end portion of the winding part, wherein a peripheral portion of the second core member including a portion of the second gap provided with the adhesive is in direct contact with and fitted between the principle face of the other end portion of the winding part and the pair of terminal electrodes,

the second core member is of an E-type wherein the second core member includes a second shaft part facing and axially aligned with the shaft part of the first core member, a second side wall portion facing and axially aligned with the side wall portion of the first core member, and a second connection portion connecting the second shaft part and the second side wall portion, and

the first gap formed between the principle face of the one end portion of the winding part and the connection portion of the first core member is constituted by a void.

2. A coil component according to claim 1, wherein:

a third gap is provided between the shaft part and the second core member, and

a fourth gap is provided between the side wall portion and the second core member, which is larger in distance than the third gap.

3. A coil component according to claim 1, wherein:

a fifth gap is provided between the leader parts and a side surface of the second core member.

4. A coil component according to claim 2, wherein:

a fifth gap is provided between the leader parts and a side surface of the second core member.

5. A coil component according to claim 1, wherein the second core member has a tapered surface toward a bottom surface where the peripheral portion of the second core member including the portion of the second gap provided with the adhesive is in contact with and fitted between the principle face of the other end portion of the winding part and the pair of terminal electrodes.

6. A coil component according to claim 1, wherein the principle face of the other end portion of the winding part is fitted in a groove of the second core member via the adhesive, wherein the groove is formed between the second shaft part and the second side wall portion.

7. A coil component according to claim 1, wherein the outer circumferential surface of the winding part protrudes from the first and second core members between the pair of leader parts on a side of the first and second core members where the pair of leader parts are disposed and no side wall portion of the first core member is formed, as viewed in the axial direction.

8. A coil component according to claim 1, wherein a height of the shaft part of the first core member is larger than that of the second core member.