Coil component

• US 10,490,327 B2
• Filed: 01/24/2019
• Issued: 11/26/2019
• Est. Priority Date: 04/19/2017
• Status: Active Grant

• Current Assignee: Murata Manufacturing Co Limited
• Original Assignee: Murata Manufacturing Co Limited
• Inventors: Ishida, Takuya, Shinohara, Gota
• Primary Examiner(s): Hinson, Ronald
• Application Number:
  US16/256,685
• Publication Number:
  US 20190180895A1
• Time in Patent Office: 306 Days
• Field of Search: 336233
• CPC Class Codes: H01F 1/14766 Fe-Si based alloys
• CPC Class Codes: H01F 1/15308 based on Fe/Ni H01F1/15325 takes precedence
• CPC Class Codes: H01F 1/15333 containing nanocrystallites, e.g. obtained by annealing
• CPC Class Codes: H01F 17/04 with magnetic core
• CPC Class Codes: H01F 17/045 with core of cylindric geometry and coil wound along its longitudinal axis, i.e. rod or drum 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 27/29 Terminals; Tapping arrangements for signal inductances
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 41/02 for manufacturing cores, coils, or magnets H01F41/14 takes precedence; for dynamo-electric machines H02K15/00
• CPC Class Codes: H01F 41/0246 Manufacturing of magnetic circuits by moulding or by pressing powder magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36

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 outer electrodes electrically connected to the coil conductor. The average particle diameter of the metal particles in the magnetic portion is 1 μm or more and 5 μm or less, and the CV value of the metal particles is 50% or more and 90% or less.

Claims

1. A coil component comprising:

a magnetic portion that includes metal particles and a resin material;

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

-winding form; and

outer electrodes electrically connected to the coil conductor,

wherein;

the magnetic portion includes

a magnetic base including a base portion and a protrusion portion disposed on an upper surface of the base portion, the protrusion portion having a portion located in a core portion of the coil conductor and including the metal particles and the resin material, and

a magnetic outer coating, and

a filling factor of the metal particles in the magnetic base is 73% or less, and a filling factor of the metal particles in the magnetic outer coating is from 65% to 80%,

the coil conductor is made of a wire, the wire is a rectangular wire, and a thickness of the rectangular wire is 0.04 mm or more,

a length of the coil component is from 1.8 mm to 2.2 mm, and

a width of the coil component is from 1.0 mm to 1.8 mm.

2. The coil component according to claim 1, wherein

a filling factor of the metal particles in the magnetic base is 66% or more.

3. The coil component according to claim 1, wherein

the thickness of the rectangular wire is 0.08 mm or less.

4. The coil component according to claim 1, wherein

a width of the rectangular wire is 0.15 mm or more.

5. The coil component according to claim 1, wherein

a width of the rectangular wire is 0.19 mm or less.

6. The coil component according to claim 1, wherein a ratio (thickness/width) of the thickness to a width of the rectangular wire is from 0.2 to 0.6.

7. The coil component according to claim 1, wherein

the protrusion portion extends from the base portion and includes an end positioned a spaced distance from the base portion, and the magnetic outer coating covers the end of the protrusion portion.

8. The coil component according to claim 1, wherein

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

9. The coil component according to claim 1, wherein

a protective layer containing Ti is disposed on the magnetic portion.

10. The coil component according to claim 9, wherein

the protective layer further contains resin.

11. The coil component according to claim 1, wherein the magnetic outer coating contains the metal particles being formed of a metal material, the metal material being Fe—

Si alloys.

12. The coil component according to claim 11, wherein the magnetic outer coating further contains the metal particles being formed of a metal material, the metal material being iron.

13. The coil component according to claim 11, wherein

the particles of Fe—

Si alloys are coated with an insulating material containing phosphorus.

14. The coil component according to claim 1, wherein

the magnetic base contains the metal particles being formed of a metal material, the metal material being Fe—

Si—

Cr alloys.

15. The coil component according to claim 14, wherein the particles of Fe—

Si—

Cr alloys are coated with an insulating material containing phosphorus.

16. The coil component according to claim 14, wherein

the particles of Fe—

Si—

Cr alloys are the crystalline particles.

17. The coil component according to claim 14, wherein

the magnetic base further contains the metal particles being formed of a metal material, the metal material being iron.

18. The coil component according to claim 17, wherein

the particles of iron are the crystalline particles.

19. The coil component according to claim 17, wherein

the particles of iron are coated with an insulating material containing Si.