COIL COMPONENT AND METHOD OF MANUFACTURING THE SAME

• US 20170092410A1
• Filed: 09/26/2016
• Published: 03/30/2017
• Est. Priority Date: 09/30/2015
• Status: Active Grant

• Current Assignee: Taiyo Yuden Company Limited (Taiyo Yuden Co)
• Original Assignee: Taiyo Yuden Company Limited (Taiyo Yuden Co)
• Inventors: SADO, Atsushi, HAYASHI, Chiharu
• Granted Patent: US 10,366,819 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: H01F 17/043 with two, usually identical or nearly identical parts enclosing completely the coil (pot cores)
• CPC Class Codes: H01F 2017/046 helical coil made of flat wire, e.g. with smaller extension of wire cross section in the direction of the longitudinal axis
• CPC Class Codes: H01F 27/255 made from particles H01F27/26 takes precedence
• CPC Class Codes: H01F 27/2828 Construction of conductive connections, of leads
• 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 41/0206 Manufacturing of magnetic cores by mechanical means magnetic cores per se H01F27/24
• CPC Class Codes: H01F 41/076 Forming taps or terminals while winding, e.g. by wrapping or soldering the wire onto pins, or by directly forming terminals from the wire

Abstract

In an embodiment, an air-core coil 50 includes a winding part 54 formed by winding a coated conductive wire 52, wherein a pair of leader parts 56 and 58 is interposed between a second core 20 and a first core 40 which contain metal magnetic grains. A first gap 72 is provided between a principle face 50A of one end portion of the winding part 54 in the direction of a winding core axis of the winding part 54 and the first core member 40. A second gap 70 is provided between a principle face 50B of the other end portion and the second core member 20. The coil component is a small and high-performance coil component with a high dielectric withstanding voltage.

Claims

1. A coil component comprising:

an air-core coil that is formed of a winding part which winds a coated conductive wire and includes an inner circumferential surface, an outer circumferential surface, and a principle face of one end portion and a principle face of the other end portion in the direction of a winding core axis, and of a pair of leader parts which lead outward from the winding part;

a first core member that includes a shaft part disposed inside the inner circumferential surface, a side wall portion disposed in at least a portion of the outer circumferential surface, and a connection portion which is disposed such that a first gap is formed between the principle face of the one end portion and the connection portion, and through which the shaft part is connected to the side wall portion, and that contains metal magnetic grains; and

a second core member which is disposed such that a second gap is formed between the principle face of the other end portion and the second core member and which contains metal magnetic grains.

2. A coil component according to claim 1, wherein:

a third gap is provided between the shaft part and the second core member, and

a fourth gap is provided between the side wall portion and the second core member, which is larger in distance than the third gap.

3. A coil component according to claim 1, wherein:

a fifth gap is provided between the leader parts and a side surface of the second core member.

4. A coil component according to claim 2, wherein:

a fifth gap is provided between the leader parts and a side surface of the second core member.

5. A coil component according to claim 1, wherein:

the second core member is an E-type or I-type.

6. A coil component according to claim 2, wherein:

the second core member is an E-type or I-type.

7. A coil component according to claim 3, wherein:

the second core member is an E-type or I-type.

8. A coil component according to claim 4, wherein:

the second core member is an E-type or I-type.

9. A method of manufacturing a coil component comprising:

a preparation step of obtaining a first core member of an E-type and a second core member of an E-type or an I-type by forming and heat-treating metal magnetic grains;

another preparation step of obtaining an air-core coil which is formed of a winding part formed by winding a coated conductive wire, and of a pair of leader parts which lead outward from the winding part, and obtaining terminal electrodes electrically connected to the air-core coil;

a step of installing the air-core coil in the second core member;

a step of applying an adhesive to the second core member;

a step of disposing the first core member such that the air-core coil is disposed between the second core member and the first core member; and

a step of curing the adhesive.

10. A method according to claim 9, wherein the terminal electrodes are formed by installing the air-coil in the second core member after bending conductor portions that extend from the leader parts, or after connecting terminal members to the conductor portions via soldering or bending.

11. A method according to claim 10, further comprising forming a first gap between the first core member and the air-core coil in an interposed manner, and forming a second gap between the second core member and the air-core coil in an interposed manner.

12. A method according to according to claim 11, further comprising forming a third gap between the shaft part and the second core member, and forming a fourth gap between the side wall portion and the second core member, which is larger in distance than the third gap.

13. A method according to claim 12, further comprising forming a fifth gap between the second core member and the leader parts.