Coil element

• US 6,181,232 B1
• Filed: 07/23/1998
• Issued: 01/30/2001
• Est. Priority Date: 08/04/1997
• Status: Expired due to Term

• Current Assignee: Murata Manufacturing Co Limited
• Original Assignee: Murata Manufacturing Co Limited
• Inventors: Kitamura, Hidekazu
• Primary Examiner(s): Gellner, Michael L.
• Assistant Examiner(s): MAI, ANH T
• Application Number:
  US09/121,245
• Time in Patent Office: 922 Days
• Field of Search: 336/200, 336/212, 336/83, 336/223
• US Class Current: 336/200
• CPC Class Codes: H01F 17/04 with magnetic core

Abstract

A coil element includes a composite member located on a first magnetic substrate, a second magnetic substrate disposed on the composite member and an adhesive layer located therebetween. The composite member includes coil patterns and insulating layers. The adhesive layer is composed of a material having a relative magnetic permeability of more than about 1.0. Alternatively, the insulating layers, excluding a portion which surrounds an overlapping region of coil patterns, are composed of a material having a relative magnetic permeability of more than about 1.0. Alternatively, the insulating layers are provided with holes in the approximate central regions of the insulating layers surrounded by the coil patterns, and the holes are filled with the material of the adhesive layer.

Claims

1. A coil element, comprising:

a first magnetic substrate;

a composite member disposed on the first magnetic substrate, said composite member including coil patterns and insulating layers being alternately arranged, each of the insulating layers including at least one of a plurality of holes disposed at an approximate central portion thereof and a plurality of cutout portions disposed at peripheral edges thereof;

a second magnetic substrate disposed on the composite member;

an adhesive material extending between the first magnetic substrate and the second magnetic substrate and located within the at least one of the plurality of holes disposed at an approximate central portion of each of the insulating layers and the cutout portions disposed at peripheral edges of each of the insulating layers, the adhesive material being arranged to completely fill the at least one of the plurality of holes of the insulating layers such that only the adhesive material is located in the at least one of the plurality of holes of the insulating layers.

2. The coil element according to claim 1, wherein the material of the adhesive layer comprises a magnetic material.

3. The coil element according to claim 1, wherein the material of the adhesive layer comprises an insulating material which contains magnetic particles.

4. A coil element according to claim 3, wherein the magnetic particles comprise a ferrite.

5. A coil element according to claim 4, wherein the ferrite magnetic particles comprise Ni—

Zn-based or Mn—

Zn-based ferrite magnetic particles.

6. A coil element according to claim 1, wherein the first magnetic substrate, the composite member, the second magnetic substrate and the adhesive layer are arranged to define a common mode choke coil.

7. A coil element according to claim 1, wherein the first magnetic substrate, the composite member, the second magnetic substrate and the adhesive layer are arranged to define a transformer.

8. A coil element according to claim 1, wherein the adhesive layer comprises a material having a relative magnetic permeability of about 1.5.

9. A coil element according to claim 1, further comprising an adhesive layer disposed between the composite member and the second magnetic substrate, wherein the adhesive layer comprises a material having a relative magnetic permeability of more than 1.0.

10. A coil element according to claim 1, wherein the adhesive material disposed between the first magnetic substrate and the second magnetic substrate a relative magnetic permeability of more than 1.0.

11. A coil element, comprising:

a first magnetic substrate;

a composite member disposed on the first magnetic substrate, said composite member including coil patterns and insulating layers being alternately arranged, each of the insulating layers including a hole formed therein;

a second magnetic substrate disposed on the composite member; and

an adhesive material extending between the first magnetic substrate and the second magnetic substrate and arranged so as to surround each of the coil patterns such that only the adhesive material is disposed in the hole of each of the insulating layers.

12. The coil element according to claim 11, wherein the material having a relative magnetic permeability of more than about 1.0 comprises a magnetic material.

13. A coil element according to claim 11, wherein the first magnetic substrate, the composite member, the second magnetic substrate and the adhesive layer are arranged to define a common mode choke coil.

14. A coil element according to claim 11, wherein the first magnetic substrate, the composite member, the second magnetic substrate and the adhesive layer are arranged to define a transformer.

15. A coil element according to claim 11, wherein the adhesive layer comprises a material having a relative magnetic permeability of about 1.5.

16. A coil element according to claim 11, further comprising an adhesive layer disposed between the composite member and the second magnetic substrate, wherein the adhesive layer comprises a material having a relative magnetic permeability of more than 1.0, and said insulating layers, excluding a portion which surrounds a region where the coil patterns overlap each other, comprise a material having a relative magnetic permeability of more than 1.0.

17. A coil element according to claim 11, wherein the adhesive material disposed between the first magnetic substrate and the second magnetic substrate a relative magnetic permeability of more than 1.0.

18. The coil element according to claim 11, wherein the material having a relative magnetic permeability of more than about 1.0 comprises an insulating material which contains magnetic particles.

19. A coil element according to claim 18, wherein the magnetic particles comprise a ferrite.

20. A coil element according to claim 19, wherein the ferrite magnetic particles comprise Ni—

Zn-based or Mn—

Zn-based ferrite magnetic particles.

21. A coil element, comprising:

a first magnetic substrate;

a composite member disposed on the first magnetic substrate, said composite member including coil patterns and insulating layers being alternately arranged, each of the insulating layers including a hole disposed at an approximate central portion thereof and a plurality of cutout portions disposed at peripheral edges thereof;

a second magnetic substrate disposed on the composite member;

an adhesive material extending between the first magnetic substrate and the second magnetic substrate and located within the hole disposed at an approximate central portion of each of the insulating layers, the adhesive material being arranged so as to surround each of the coil patterns and such that only the adhesive material is located in the hole and the cutout portions of each of the insulating layers.

22. The coil element according to claim 21, wherein the material of the adhesive layer comprises a magnetic material.

23. A coil element according to claim 21, wherein said insulating layers comprise cut-outs formed at end portions of the insulating layers, said cut-outs being filled with the material of the adhesive layer.

24. A coil element according to claim 21, further comprising an adhesive layer disposed between the composite member and the second magnetic substrate, wherein the adhesive layer comprises a material having a relative magnetic permeability of more than 1.0.

25. A coil element according to claim 21, wherein the adhesive material disposed between the first magnetic substrate and the second magnetic substrate a relative magnetic permeability of more than 1.0.

26. The coil element according to claim 21, wherein the material of the adhesive layer comprises an insulating material which contains magnetic particles.

27. The coil element according to claim 26, wherein the magnetic particles comprise a ferrite including Ni—

Zn-based or Mn—

Zn-based ferrite magnetic particles.

28. A coil element, comprising:

a first magnetic substrate;

a composite member disposed on the first magnetic substrate, said composite member including coil patterns and insulating layers being alternately arranged;

a second magnetic substrate disposed on the composite member;

wherein each of the insulating layers has a hole connecting the first magnetic substrate and the second magnetic substrate, the hole is disposed at a portion enclosed by the coil patterns, an adhesive comprising a magnetic material having a relative magnetic permeability of more than 1.0 is arranged to fill the hole of each of the insulating layers such that only the adhesive is located in the hole of each of the insulating layers, and the first magnetic substrate and the second magnetic substrate are bonded by the adhesive.