METHOD OF MANUFACTURING ELECTRONIC COMPONENT, AND ELECTRONIC COMPONENT

• US 20160322160A1
• Filed: 11/17/2014
• Published: 11/03/2016
• Est. Priority Date: 12/27/2013
• Status: Active Grant

• Current Assignee: Murata Manufacturing Co Limited
• Original Assignee: TOKO Incorporated (Murata Manufacturing Co Limited)
• Inventors: KAWACHI, Takao, SATO, Yoshiharu, IDA, Isao, OGAWA, Takahiro
• Granted Patent: US 10,026,549 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: H01F 2017/048 with encapsulating core, e.g. made of resin and magnetic powder
• CPC Class Codes: H01F 27/2871 Pancake coils
• 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 41/04 for manufacturing coils coils for transformer or inductances H01F27/28

Abstract

A method of manufacturing an electronic component includes: a coil forming step of forming a winding coil by a wire-shaped conductor; a press fitting step of embedding the winding coil into a plate-shaped composite magnetic material in a state in which the plate-shaped composite magnetic material is softened, the plate-shaped composite magnetic material being a composite magnetic material that is formed in a plate shape and in which magnetic particles and a resin are mixed; a covering step of covering a part of the winding coil with another plate-shaped composite magnetic material that is softened, the part of the coil being a part remaining uncovered in the press fitting step; a pressurizing step of pressurizing and molding an entirety; and, a hardening step of hardening the composite magnetic material.

Claims

1. A method of manufacturing an electronic component, the method comprising:

a coil forming step of forming a coil by a wire-shaped conductor;

a press fitting step of embedding the coil into a plate-shaped composite magnetic material in a state in which the plate-shaped composite magnetic material is softened, the plate-shaped composite magnetic material being a composite magnetic material that is formed in a plate shape and in which magnetic particles and a resin are mixed;

a covering step of covering a part of the coil with another plate-shaped composite magnetic material that is softened, the part of the coil being a part remaining uncovered in the press fitting step;

a pressurizing step of pressurizing and molding an entirety; and

a hardening step of hardening the composite magnetic material.

2. The method of manufacturing an electronic component according to claim 1, wherein

at least the press fitting step and the steps following the press fitting step are performed to more than one coil at the same time using the plate-shaped composite magnetic material having a size on which a plurality of coils are placeable.

3. The method of manufacturing an electronic component according to claim 1, wherein

the pressurizing step and the hardening step are performed at the same time.

4. An electronic component comprising:

a coil formed by a wire-shaped conductor; and

a magnetic body formed of a composite magnetic material so as to cover the coil excluding a terminal, the composite magnetic material being a material that is hardened and in which magnetic particles and a resin are mixed, wherein

the magnetic body is formed by embedding the coil into a plate-shaped composite magnetic material in a state in which the plate-shaped composite magnetic material is softened, and then hardening the plate-shaped composite magnetic material, the plate-shaped composite magnetic material being a composite magnetic material that is formed in a plate shape.

5. The electronic component according to claim 4,

wherein the electronic component is manufactured based on a method comprising:

a coil forming step of forming the coil by the wire-shaped conductor;

a press fitting step of embedding the coil into the plate-shaped composite magnetic material in a state in which the plate-shaped composite magnetic material is softened, the plate-shaped composite magnetic material being a composite magnetic material that is formed in a plate shape and in which magnetic particles and a resin are mixed;

a covering step of covering a part of the coil with another plate-shaped composite magnetic material that is softened, the part of the coil being a part remaining uncovered in the press fitting step;

a pressurizing step of pressurizing and molding an entirety; and

a hardening step of hardening the composite magnetic material.