Inductor and manufacturing method therefor
First Claim
1. A method for manufacturing an inductor, comprising the steps of:
- coating a surface of a metal wire having an insulating film thereon with a thermal melting resin to form a coated metal wire;
winding the coated metal wire to form a solenoid-type coil conductor;
performing a heat treatment on the coil conductor to soften the thermal melting resin so that portions of the coil conductor that are adjacent to each other are bonded together by the thermal melting resin;
molding a resin containing magnetic powder into an encapsulating molded body having a predetermined shape so as to encapsulate the coil conductor; and
providing external terminal electrodes on surfaces of the encapsulating molded body so as to be electrically connected with the ends of the coil conductor.
1 Assignment
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Accused Products
Abstract
An inductor which has a superior shape retaining property of a coil conductor, is superior in mass-productivity, and can be applied to an automated manufacturing line, and a manufacturing method therefor are provided. The surface of a metal wire provided with an insulating film thereon is coated with a thermal melting resin. The thickness of the thermal melting resin is, for example, approximately 1 μm. As the thermal melting resin, a thermoplastic resin or a thermosetting resin, such as a polyimide resin or an epoxy resin, containing 85 wt % of a powdered ferrite is used. This coated metal wire is densely wound to form a solenoid-type coil conductor. Next, the thermal melting resin is softened by a heat treatment at, for example, 180° C. and is then solidified by spontaneous cooling. Accordingly, the portions of the coil conductor adjacent to each other are bonded together by the thermal melting resin.
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Citations
19 Claims
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1. A method for manufacturing an inductor, comprising the steps of:
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coating a surface of a metal wire having an insulating film thereon with a thermal melting resin to form a coated metal wire;
winding the coated metal wire to form a solenoid-type coil conductor;
performing a heat treatment on the coil conductor to soften the thermal melting resin so that portions of the coil conductor that are adjacent to each other are bonded together by the thermal melting resin;
molding a resin containing magnetic powder into an encapsulating molded body having a predetermined shape so as to encapsulate the coil conductor; and
providing external terminal electrodes on surfaces of the encapsulating molded body so as to be electrically connected with the ends of the coil conductor. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19)
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14. An inductor comprising:
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an encapsulating molded body including a resin containing magnetic powder;
a solenoid-type coil conductor encapsulated in the encapsulating molded body; and
external terminal electrodes provided on surfaces of the encapsulating molded body and which are electrically connected to ends of the coil conductor;
wherein the coil conductor is coated with a thermal melting resin and adjacent portions of the coil conductor are bonded together by the thermal melting resin, and the inside and the outside of the solenoid portion of the coil conductor are filled with the resin containing the magnetic powder.
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Specification