COIL COMPONENT AND METHOD OF MANUFACTURING THE SAME

• US 20110309906A1
• Filed: 05/25/2011
• Published: 12/22/2011
• Est. Priority Date: 06/17/2010
• Status: Active Grant

• Current Assignee: Murata Manufacturing Co Limited
• Original Assignee: TOKO Incorporated (Murata Manufacturing Co Limited)
• Inventors: Muneuchi, Keita, Kito, Yusuke, Ohaga, Takeo, Yano, Hisashi
• Granted Patent: US 8,438,720 B2
• Time in Patent Office: Days
• US Class Current: 336/221
• 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 27/327 Encapsulating or impregnating encapsulating coil and core H01F27/022
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor
• CPC Class Codes: Y10T 29/49071 by winding or coiling

Abstract

A coil component, in which a space on an outer periphery of a winding interposed between a pair of flange portion is coated with a resin with magnetic powder, has a problem of long-term reliability that a thermosetting resin expands and contracts due to change in a temperature and the flange portions are fatigued to be broken.

An object of the present invention is to provide the coil component of which core is hardly broken even when the resin with magnetic powder expands and contracts and a method of manufacturing the same.

In order to solve the above-described problem, the method of manufacturing the coil component according to one embodiment of the present invention is a method of manufacturing a coil component including a drum-shaped core including a winding core portion and a pair of flange portions provided on both ends in an axial direction of the winding core portion, and a winding wound around the winding core portion, including applying a mold releasing agent for providing a gap on at least one of opposed surfaces of the pair of flange portions, winding the winding around the winding core portion, applying a resin with magnetic powder formed of a thermosetting resin to a space on an outer periphery of the winding interposed between the pair of flange portions, and thermally curing the resin with magnetic powder.

Claims

1. A method of manufacturing a coil component comprising a drum-shaped core including a winding core portion and a pair of flange portions provided on both ends in an axial direction of the winding core portion, and a winding wound around the winding core portion, comprising:

applying a mold releasing agent for providing a gap on at least one of opposed surfaces of the pair of flange portions;

winding the winding around the winding core portion;

applying a resin with magnetic powder formed of a thermosetting resin to a space on an outer periphery of the winding interposed between the pair of flange portions; and

thermally curing the resin with magnetic powder.

2. The method of manufacturing the coil component according to claim 1, wherein

a temperature at which the resin with magnetic powder is thermally cured is higher than a specification temperature of the coil component.

3. A coil component manufactured by the manufacturing method according to claim 1.

4. A coil component, comprising:

a drum-shaped core including a winding core portion and a pair of flange portions provided on both ends in an axial direction of the winding core portion;

a winding wound around the winding core portion; and

a resin with magnetic powder, which coats a space on an outer periphery of the winding interposed between the pair of flange portions, wherein

a gap is provided between at least one of opposed surfaces of the pair of flange portions and the resin with magnetic powder.