COIL-TYPE ELECTRONIC COMPONENT AND ITS MANUFACTURING METHOD

• US 20110267167A1
• Filed: 04/22/2011
• Published: 11/03/2011
• Est. Priority Date: 04/30/2010
• Status: Active Grant

• Current Assignee: Taiyo Yuden Company Limited (Taiyo Yuden Co)
• Original Assignee: Taiyo Yuden Company Limited (Taiyo Yuden Co)
• Inventors: OGAWA, Hideki, KISHI, Hiroshi, TANADA, Atsushi, MATSUURA, Hitoshi, TANAKA, Kiyoshi, KAWANO, Kenji
• Granted Patent: US 8,813,346 B2
• Time in Patent Office: Days
• US Class Current: 336/221
• CPC Class Codes: B22F 2998/00 Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: C22C 1/02 by melting C22C1/1036 takes precedence
• CPC Class Codes: C22C 2202/02 Magnetic
• CPC Class Codes: C22C 33/0278 with at least one alloying element having a minimum content above 5%
• CPC Class Codes: H01F 1/12 of soft-magnetic materials
• CPC Class Codes: H01F 1/14766 Fe-Si based alloys
• CPC Class Codes: H01F 1/22 pressed, sintered, or bound together
• CPC Class Codes: H01F 1/24 the particles being insulated
• CPC Class Codes: H01F 1/26 by macromolecular organic substances
• CPC Class Codes: H01F 1/33 mixtures of metallic and non-metallic particles; metallic particles having oxide skin
• CPC Class Codes: H01F 41/02 for manufacturing cores, coils, or magnets H01F41/14 takes precedence; for dynamo-electric machines H02K15/00
• 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: H01F 41/098 Mandrels; Formers
• CPC Class Codes: H01F 41/10 Connecting leads to windings making electric connections in general H01R43/00
• CPC Class Codes: H01F 41/125 Other insulating structures; Insulating between coil and core, between different winding sections, around the coil
• CPC Class Codes: H01F 5/02 wound on non-magnetic supports, e.g. formers
• CPC Class Codes: H01F 5/06 Insulation of windings
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor
• CPC Class Codes: Y10T 29/49069 Data storage inductor or core
• CPC Class Codes: Y10T 29/49071 by winding or coiling
• CPC Class Codes: Y10T 29/49073 : by assembling coil and core
• CPC Class Codes: Y10T 29/49144 : by metal fusion

Abstract

A coil-type electronic component has a coil inside or on the surface of its base material and is characterized in that: the base material is constituted by a group of grains of a soft magnetic alloy containing iron, silicon and other element that oxidizes more easily than iron; the surface of each soft magnetic alloy grain has an oxide layer formed on its surface as a result of oxidization of the grain; this oxide layer contains the other element that oxidizes more easily than iron by a quantity larger than that in the soft magnetic alloy grain; and grains are bonded with one another via this oxide layer.

Claims

1. A coil-type electronic component comprising a base material for a coil and a coil provided inside or on the surface of the base material, wherein:

the base material is constituted by a group of grains of a soft magnetic alloy containing iron, silicon and other element that oxidizes more easily than iron;

the entire surface of each soft magnetic alloy grain whose cross-section outline can be fully observed has an oxide layer formed on its surface as a result of oxidization of the grain, said oxide layer having a single phase;

this oxide layer contains the other element that oxidizes more easily than iron in a quantity larger than that in the soft magnetic alloy grain; and

the grains whose cross-section outline can be fully observed are bonded with one another via this oxide layer.

2. A coil-type electronic component according to claim 1, wherein the oxide layer via which the soft magnetic alloy grains are bonded with one another is thicker than an oxide layer other than the bonding oxide layer on the surface of the soft magnetic alloy grains.

3. A coil-type electronic component according to claim 1, wherein the oxide layer via which the soft magnetic alloy grains are bonded with one another is thinner than an oxide layer other than the bonding oxide layer on the surface of the soft magnetic alloy grains.

4. A coil-type electronic component according to claim 1, wherein at least some of the soft magnetic grains are grains on which the oxide layer has a thickness of at least 50 nanometers.

6. A coil-type electronic component according to claim 1, wherein the element that oxidizes more easily than iron is chromium.

7. A coil-type electronic component according to claim 1, wherein the element that oxidizes more easily than iron is aluminum.

8. A coil-type electronic component according to claim 6, wherein the soft magnetic alloy has a composition of 2 to 8 percent by weight of chromium, 1.5 to 7 percent by weight of silicon, and 88 to 96.5 percent by weight of iron.

9. A coil-type electronic component according to claim 7, wherein the soft magnetic alloy has a composition of 2 to 8 percent by weight of aluminum, 1.5 to 12 percent by weight of silicon, and 80 to 96.5 percent by weight of iron.

10. A coil-type electronic component according to claim 1, wherein the average size of the soft magnetic grain based on arithmetic mean is 30 micrometers or less.

11. A coil-type electronic component according to claim 1, wherein the oxide layer includes in this order a first oxide layer where the content of the iron component decreases while the content of the element that oxidizes easily increases, and a second oxide layer where the content of the iron component increases and the content of the element that oxidizes easily decreases, as viewed outwardly from the alloy grain.

12. A coil-type electronic component according to claim 11, wherein the first oxide layer, as viewed outwardly from the alloy grain, has an inflection point with respect to the content of the element that oxidizes easily.

13. A coil-type electronic component according to claim 1, wherein the peak strength ratio of the element that oxidizes more easily than iron, relative to iron, in the oxide layer is higher than the peak strength ratio of the element that oxidizes more easily than iron, relative to iron, in the grain, based on calculation by the ZAF method through energy diffusion X-ray analysis using a scanning electron microscope.

14. A coil-type electronic component according to claim 1, wherein the coil has its end electrically connected to a conductive film formed on the surface of the base material.

22. A coil-type electronic component according to claim 12, wherein the element that oxidizes easily is chromium.

5. (canceled)

15. A coil-type electronic component having a coil and a base material, wherein:

its base material is constituted by a group of grains of a soft magnetic alloy;

the entire surface of each soft magnetic alloy grain whose cross-section outline can be fully observed has an oxide layer formed on its surface as a result of oxidization of the grain, said oxide layer having a single phase;

this oxide layer contains a quantity of a metal that oxidizes more easily than iron, which quantity is larger than that in the alloy grains;

the grains whose cross-section outline can be fully observed are bonded with one another via this oxide layer; and

a coil conductor is formed inside this base material.

16. A coil-type electronic component according to claim 15, wherein the coil conductor forms conductive patterns and is sintered simultaneously with the base material.

17. A coil-type electronic component according to claim 15, wherein the metal that oxidizes more easily than iron in the oxide layer is chromium.

18. A coil-type electronic component according to claim 15, wherein the metal that oxidizes more easily than iron in the oxide layer is aluminum.

19. (canceled)

20. (canceled)

21. (canceled)