METHOD OF MANUFACTURING MAGNETIC ELEMENT AND MAGNETIC ELEMENT

• US 20130328656A1
• Filed: 05/30/2013
• Published: 12/12/2013
• Est. Priority Date: 06/08/2012
• Status: Abandoned Application

• Current Assignee: Sumida Corporation
• Original Assignee: Sumida Corporation
• Inventors: SAKAMOTO, Shinichi
• Application Number:
  US13/905,778
• Publication Number:
  US 20130328656A1
• Time in Patent Office: Days
• US Class Current: 336/221
• CPC Class Codes: H01F 17/043 with two, usually identical or nearly identical parts enclosing completely the coil (pot cores)
• CPC Class Codes: H01F 2017/048 with encapsulating core, e.g. made of resin and magnetic powder
• 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: Y10T 29/49073 by assembling coil and core

Abstract

The magnetic element has a first core member, a winding part, and a second core member, and is manufactured by way of at least a winding part placement step of placing the winding part on the face of the first core member on the side on which the core part is provided, such that the core part is positioned within the inner periphery of the winding part, and an injection molding step of injection molding so as to surround the first core member and the winding part with resin material, and in the winding part placement step, the winding part is placed on the face of the first core member on the side on which the core part is provided, with at least a portion of the inner peripheral face of the winding part distanced from the outer peripheral face of the core part.

Claims

1. A method of manufacturing a magnetic element having:

a first core member made from a resin material in which a magnetic powder is dispersed, and having an substantially plate-like base and a core part protruding from the approximate center of one face of the base;

a winding part formed as a tube by winding a conductive wire, which is placed on the base such that the core part is positioned within an inner periphery of the tube; and

,

a second core member made from a resin material in which a magnetic powder has been dispersed, which is provided so as to surround a side of the first core member on which the core part is provided and the winding part,

the method comprising at least;

a winding part placement step of placing the winding part on the face of the first core member on the side on which the core part is provided, such that the core part is positioned within the inner periphery of the winding part; and

an injection molding step of injection molding so as to surround the side of the first core member on which the core part is provided and the winding part with the resin material in which the magnetic powder has been dispersed,

wherein, in the winding part placement step, the winding part is placed on the face of the first core member on the side on which the core part is provided, with at least a portion of an inner peripheral face of the winding part distanced from an outer peripheral face of the core part.

2. The method of manufacturing a magnetic element according to claim 1,

wherein, in the winding part placement step, the winding part is placed on the face of the first core member on the side on which the core part is provided, with at least substantially the entire surface of the inner peripheral face of the winding part, other than in the vicinity of a base side thereof, distanced from the outer peripheral face of the core part.

3. The method of manufacturing a magnetic element according to claim 2,

wherein an outer peripheral profile shape of the core part and an inner peripheral profile shape of the winding part are similar, and

in the winding part placement step, the winding part is placed on the face of the first core member on the side on which the core part is provided, such that a central axis of the core part and a central axis of the winding part approximately coincide.

4. The method of manufacturing a magnetic element according to claim 2,

further comprising providing a step on the face of the base on the side on which the core part is provided, on at least a portion of a line corresponding to at least one diameter selected from the inner diameter and the outer diameter of the winding part, at which a central axis of the core part and a central axis of the winding part are assumed to approximately coincide.

5. The method of manufacturing a magnetic element according to claim 2,

wherein, the shape of the core part is any one shape selected from an approximately conical shape, a base-plane side of which is oriented toward the base, and an approximately frustum shape, a base-plane side of which is oriented toward the base, and

in the winding part placement step, at least a portion of the outer peripheral face of the core part on the base side thereof, and at least a portion of the inner peripheral face of the winding part make contact.

6. The method of manufacturing a magnetic element according to claim 1,

wherein, in the winding part placement step, the winding part is placed on the face of the first core member on the side on which the core part is provided, such that a portion of the inner peripheral face of the winding part and a portion of the outer peripheral face of the core part make contact, extending in the direction of a central axis of the core part.

7. The method of manufacturing a magnetic element according to claim 6,

wherein there are two or more contact parts where a portion of the inner peripheral face of the winding part and a portion of the outer peripheral face of the core part make contact, extending in the direction of the central axis of the core part.

8. The method of manufacturing a magnetic element according to claim 7,

wherein the two or more contact parts are arranged at approximately point symmetric positions with respect to the central axis of the core part.

9. The method of manufacturing a magnetic element according to claim 8, wherein a combination of an outer peripheral profile shape of the core part and an inner peripheral profile shape of the winding part is at least one combination selected from:

(A) a combination of an approximately circular shape and an approximately triangular shape;

(B) a combination of an approximately circular shape and an approximately quadrangular shape;

(C) a combination of an approximately triangular shape and an approximately circular shape;

(D) a combination of an approximately quadrangular shape and an approximately circular shape;

(E) a combination of an approximately cruciform shape and an approximately circular shape; and

(F) a combination of an approximately cruciform shape and an approximately quadrangular shape.

10. A magnetic element comprising:

a first core member made from a resin material in which a magnetic powder is dispersed, and having a substantially plate-like base and a core part protruding from the approximate center of one face of the base;

a winding part, formed as a tube by winding a conductive wire, which is placed on the base such that the core part is positioned within an inner periphery of the tube; and

a second core member made from a resin material in which a magnetic powder has been dispersed, which is provided so as to surround a side of the first core member on which the core part is provided and the winding part,

the magnetic element being manufactured by way of at least;

a winding part placement step of placing the winding part such that the core part is positioned within the inner periphery of the winding part; and

an injection molding step of injection molding using the resin material in which the magnetic powder has been dispersed, so as to surround the side of the first core member on which the core part is provided and the winding part,

wherein, in the winding part placement step, the winding part is placed on the face of the first core member on the side on which the core part is provided, with at least a portion of an inner peripheral face of the winding part distanced from an outer peripheral face of the core part.