INDUCTOR USING DRUM CORE AND METHOD FOR PRODUCING THE SAME

• US 20080055034A1
• Filed: 08/22/2007
• Published: 03/06/2008
• Est. Priority Date: 08/25/2006
• Status: Active Grant

• Current Assignee: Taiyo Yuden Company Limited (Taiyo Yuden Co)
• Original Assignee: Taiyo Yuden Company Limited (Taiyo Yuden Co)
• Inventors: Ogawa, Hideki, Aoki, Hidenori, Okino, Yoshikazu, Okada, Hideki, Tsunemi, Masayoshi
• Granted Patent: US 7,495,538 B2
• Time in Patent Office: Days
• US Class Current: 336/83
• 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 27/324 Insulation between coil and core, between different winding sections, around the coil; Other insulation structures
• CPC Class Codes: H01F 3/10 Composite arrangements of magnetic circuits
• CPC Class Codes: H01F 3/12 Magnetic shunt paths
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

Abstract

An inductor comprises a drum core which comprises a sintered magnetic material and has a winding axis and a pair of collars in a plate shape provided on both ends of the winding axis. The inductor further comprises a coil conductor wound on the winding axis of the drum core, the coil conductor is covered on an outer periphery thereof with a composite magnetic material in a sheet form containing a resin and magnetic powder, and the composite magnetic material in a sheet form is adhered to the outer periphery of the coil conductor except at least for inner surfaces of the pair of collars of the drum core facing each other.

Claims

1. An inductor comprising:

a drum core comprising a sintered magnetic material and having a winding axis and a pair of collars in a plate shape provided on both ends of the winding axis; and

a coil conductor wound on the winding axis of the drum core, the coil conductor being covered on an outer periphery thereof with a composite magnetic material in a sheet form comprising a resin and magnetic powder, the composite magnetic material in a sheet form being adhered to the outer periphery of the coil conductor except at least for inner surfaces of the pair of collars of the drum core facing each other.

2. The inductor of claim 1, wherein the inductor further comprises an adhesive layer on one of major surfaces of the composite magnetic material in a sheet form, and the composite magnetic material in a sheet form is adhered to the outer periphery of the coil conductor by the adhesive layer.

3. The inductor of claim 1, wherein the adhesive layer and the composite magnetic material in a sheet form are of the same width.

4. The inductor of claim 1, wherein the adhesive layer is narrower than the composite magnetic material in a sheet form.

5. The inductor of claim 1, wherein the composite magnetic material has no direct contact with the collars.

6. The inductor of claim 1, wherein the composite magnetic material is in direct contact with the collars, and wherein the adhesive layer is in no direct contact with the collars.

7. A method of producing an inductor comprising:

preparing a drum core comprising a sintered magnetic material and having a winding axis and a pair of collars in a plate shape provided on both ends of the winding axis;

winding a coil conductor on the winding axis of the drum core; and

adhering a composite magnetic material in a sheet form on an outer periphery of the coil conductor, while preventing the composite magnetic material in a sheet form from being in contact with inner surfaces of the pair of collars of the drum core facing each other.

8. A method of producing an inductor comprising:

preparing a drum core comprising a sintered magnetic material and having a winding axis and a pair of collars in a plate shape provided on both ends of the winding axis;

winding a coil conductor on the winding axis of the drum core; and

adhering a composite magnetic material in a sheet form on an outer periphery of the coil conductor, the composite magnetic material in a sheet form comprising an adhesive layer formed in advance on a selected area of one of major surfaces thereof except at least for an area where the composite magnetic material in a sheet form is in contact with inner surfaces of the pair of collars of the drum core facing each other.

9. An inductor comprising:

a drum core comprising magnetic material and having a winding axis and a pair of collars in a plate shape provided on both ends of the winding axis; and

a coil conductor wound on the winding axis of the drum core, the coil conductor being covered on an outer periphery thereof with a composite magnetic material comprising a resin and magnetic powder,

wherein there is no substantial region of contact between the composite magnetic material and the collars.

10. A method of producing an inductor comprising:

winding a coil conductor around a drum core; and

wrapping a sheet of composite magnetic material on an outer periphery of the coil conductor, the composite magnetic material comprising a resin and magnetic powder.