Coil Component And Method For Manufacturing Coil Component

• US 20110006870A1
• Filed: 06/06/2008
• Published: 01/13/2011
• Est. Priority Date: 08/31/2007
• Status: Active Grant

• Current Assignee: Sumida Corporation
• Original Assignee: Sumida Corporation
• Inventors: Sakamoto, Shinichi
• Granted Patent: US 8,458,890 B2
• Time in Patent Office: Days
• US Class Current: 336/221
• CPC Class Codes: H01F 1/14791 Fe-Si-Al based alloys, e.g. Sendust
• CPC Class Codes: H01F 1/26 by macromolecular organic substances
• CPC Class Codes: H01F 17/043 with two, usually identical or nearly identical parts enclosing completely the coil (pot cores)
• 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: H01F 27/306 Fastening or mounting coils or windings on core, casing or other support
• CPC Class Codes: H01F 3/10 Composite arrangements of magnetic circuits
• CPC Class Codes: H01F 41/005 Impregnating or encapsulating insulating of windings H01F41/12
• 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
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

Abstract

In an inductor including a coil, a drum type core constituted by a soft magnetic metal material and a resin material, and a filling member constituted by a soft magnetic metal material and a resin material in which a magnetic flux excited by aforesaid coil goes through aforesaid drum type core and aforesaid filling member serially, the present invention constitutes an inductor, wherein aforesaid drum type core is constituted by injection molding so as to include a receiving portion, aforesaid coil is arranged in aforesaid receiving portion, and aforesaid filling member is filled therein.

Claims

1. In a coil component characterized by comprising:

a coil;

a compound magnetic core constituted by a soft magnetic metal material and a resin material; and

a compound magnetic resin constituted by a soft magnetic metal material and a resin material, in which

it is constituted such that magnetic flux excited by said coil serially goes through said compound magnetic core and said compound magnetic resin, wherein

said compound magnetic core is constituted by injection molding so as to include a receiving portion, and

said coil is arranged in said receiving portion and said compound magnetic resin is filled therein.

2. The coil component according to claim 1 characterized in that

said compound magnetic core is constituted by a soft magnetic metal material and a thermo-setting resin material or a thermoplastic resin material.

3. A manufacturing method characterized by comprising:

a process of molding a core by injection-molding a compound material constituted by a soft magnetic metal material and resin material;

a process of housing a coil in said molded core; and

a process of coating said coil with a compound material constituted by a soft magnetic metal material and a resin material after housing said coil in said core.