Surface-mounting coil component and method of producing the same

• US 20070193022A1
• Filed: 04/19/2007
• Published: 08/23/2007
• Est. Priority Date: 12/22/2003
• Status: Active Grant

• Current Assignee: Katsutoshi Kuroiwa, Koichi Iguchi, Masaki Okamoto, Takahiro Samata, Tomoo Kashiwa
• Original Assignee: Katsutoshi Kuroiwa, Koichi Iguchi, Masaki Okamoto, Takahiro Samata, Tomoo Kashiwa
• Inventors: Iguchi, Koichi, Okamoto, Masaki, Samata, Takahiro, Kuroiwa, Katsutoshi, Kashiwa, Tomoo
• Granted Patent: US 7,310,871 B2
• Time in Patent Office: Days
• US Class Current: 29/602.1
• 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 27/027 specially adapted for combination of signal type inductors or transformers with electronic circuits, e.g. mounting on printed circuit boards
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor
• CPC Class Codes: Y10T 29/49071 by winding or coiling
• CPC Class Codes: Y10T 29/49073 by assembling coil and core

Abstract

A surface-mounting choke coil has a resin coating material with magnetic powder which is filled a space between the upper flange and the lower flange of a drum-type ferrite core, while covering the circumferential of the winding. The resin coating material with magnetic powder has a glass transition temperature Tg of about −20° C. or lower, more preferably about −50° C. or lower in a course of transferring from a glass state to a rubber state during changing of shear modulus with respect to temperature as a physical property when hardening, and the thickness of the upper flange of the drum-type ferrite core is about 0.35 mm or less, and a value of a ratio L2/L1 of an outer diameter L2 of the upper flange to a diameter L1 of the winding core of the drum-type ferrite core is about 1.9 or more.

Claims

1. A method of producing a surface-mounting coil component, comprising:

preparing a drum-type ferrite core in which an upper flange and a lower flange are formed as one body, wherein the lower flange is disposed on the other end of the upper flange facing toward the upper flange;

providing external electrodes that are direct-mounted to the core on the bottom surface of the lower flange;

wrapping a winding around the winding core of the drum-type ferrite core and conductively connecting both ends of the winding to the external electrodes;

filling a paint of a resin coating material with magnetic powder in a space range defined between the upper flange and the lower flange in opposition to this upper flange; and

hardening the paint of the resin coating material with magnetic powder,

wherein the filling of the paint of the resin coating material with magnetic powder uses a paint of the resin coating material with magnetic powder having the glass transition temperature of about −

20°

C. or lower in the course of transferring from the glass state to the rubber state during changing of shear modulus with respect to temperature as the physical property when hardening.

2. The method of producing the surface-mounting coil component as set forth in claim 1, wherein the glass transition temperature is about −

50°

C. or lower.

3. The method of producing the surface-mounting coil component as described in claim 2, wherein the paint of the resin coating material with magnetic powder contains magnetic powder, epoxy resin, and carboxyl group modified propylene glycol.

4. The method of producing the surface-mounting coil component as described in claim 2, wherein the paint of the resin coating material with magnetic powder contains magnetic powder and silicone resin.

5. The method of producing the surface-mounting coil component as described in claim 2, wherein the paint of the resin coating material with magnetic powder contains magnetic powder, polyether amine, and epoxy resin.

6. The method of producing the surface-mounting coil component as described in claim 1, wherein the thickness of the upper flange is about 0.35 mm or less.

7. The method of producing the surface-mounting coil component as described in claim 1, wherein a ratio of L2/L1 is about 1.9 or more, where L2 is an outer diameter of the upper flange and L1 is a diameter of the winding core of the drum-type ferrite core.