Coil-embedded dust core and method for manufacturing the same
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Accused Products
Abstract
A coil-embedded dust core and a method for manufacturing the coil-embedded dust core are provided. The coil-embedded dust core comprises a coil formed from a flat conductor wound in a coil configuration, and a green body consisting of insulating material-coated ferromagnetic metal particles. This results in a coil-embedded dust core more compact in size but with larger inductance. A rectangular wire can be used as the flat conductor. In addition, parts of the coil may function as terminal sections. In this case, the terminal sections of the coil may be formed wider than other part of the coil. The coil-embedded dust core is less prone to joint failures between a coil and terminal sections and to insulation failures of the coil and the terminal section with respect to the magnetic powder. The coil-embedded dust core is more compact while achieving larger inductance.
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Citations
17 Claims
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1. -9. (Canceled)
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10. A coil-embedded dust core, comprising;
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a green body in a rectangular solid shape having front and back surfaces that oppose each other across a predetermined space and side surfaces formed around the front and back surfaces;
a coil having a winding section and end sections pulled out from the winding section, the coil having at least the winding section placed inside the green body; and
end section housing chambers, each of which opens to one of the side surfaces of the green body and houses one of the end sections of the coil exposed from the green body. - View Dependent Claims (11)
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12. A coil-embedded dust core, comprising:
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a dust core section molded with magnetic powder formed from ferromagnetic metal particles coated with an insultating material and a coil embedded inside the magnetic powder; and
terminal sections outside the dust core section;
where the coil and the terminal sections are connected to one another outside the dust core section. - View Dependent Claims (13)
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14. (Canceled)
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15. A method for manufacturing a coil-embedded dust core in which a coil is embedded within a green body, the method comprising:
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preparing a preformed body by placing a coil formed from a flat, insulation-coated conductor in a raw material powder containing a soft magnetic metal powder and an insulating material; and
compressing formation of the raw material powder with the coil placed therein. - View Dependent Claims (16)
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17. -23. (Canceled)
Specification