Surface-mounting coil component and method of producing the same

• US 7,209,022 B2
• Filed: 12/22/2004
• Issued: 04/24/2007
• Est. Priority Date: 12/22/2003
• Status: Active Grant

• Current Assignee: Taiyo Yuden Company Limited (Taiyo Yuden Co)
• Original Assignee: Taiyo Yuden Company Limited (Taiyo Yuden Co)
• Inventors: Iguchi, Koichi, Samata, Takahiro, Okamoto, Masaki, Kuroiwa, Katsutoshi, Kashiwa, Tomoo
• Primary Examiner(s): Mai; Anh
• Application Number:
  US11/022,110
• Publication Number:
  US 20050212643A1
• Time in Patent Office: 853 Days
• Field of Search: 336/83, 336/200, 336/232
• US Class Current: 336/83
• 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 27/027 specially adapted for combination of signal type inductors or transformers with electronic circuits, e.g. mounting on printed circuit boards
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor
• CPC Class Codes: Y10T 29/49071 by winding or coiling
• CPC Class Codes: Y10T 29/49073 by assembling coil and core

Abstract

A surface-mounting choke coil has a resin coating material with magnetic powder which is filled a space between the upper flange and the lower flange of a drum-type ferrite core, while covering the circumferential of the winding. The resin coating material with magnetic powder has a glass transition temperature Tg of about −20° C. or lower, more preferably about −50° C. or lower in a course of transferring from a glass state to a rubber state during changing of shear modulus with respect to temperature as a physical property when hardening, and the thickness of the upper flange of the drum-type ferrite core is about 0.35 mm or less, and a value of a ratio L2/L1 of an outer diameter L2 of the upper flange to a diameter L1 of the winding core of the drum-type ferrite core is about 1.9 or more.

Claims

1. A surface-mounting coil component, comprising:

a drum-type ferrite core comprising a winding core, and upper and lower flanges provided on each ends of the winding core;

external electrodes provided on a surface of either of the flanges; and

a winding wound around the winding core of the drum-type ferrite core and conductively connected to the external electrodes on both ends,

wherein the surface-mounting coil component has a resin coating material with magnetic powder that fills a space between the upper flange and the lower flange of the drum-type ferrite core, covering the winding between the upper flange and the lower flange,

and wherein the physical property of the resin coating material with magnetic powder upon hardening is, regarding changes of modulus in torsion to temperature, that a glass transition temperature of about −

20°

C. or lower in a course of transferring from a glass state to a rubber state.

2. The surface-mounting coil component as described in claim 1, wherein the glass transition temperature is about −

50°

C. or lower.

3. The surface-mounting coil component as described in claim 2, wherein the resin coating material with magnetic powder is a hardened paint that contains magnetic powder, epoxy resin, and carboxyl group modified propylene glycol.

4. The surface-mounting coil component as described in claim 2, wherein the resin coating material with magnetic powder is a hardened paint that contains magnetic powder and silicone resin.

5. The surface-mounting coil component as described in claim 2, wherein the resin coating material with magnetic powder is a hardened paint that contains magnetic powder, polyether amine, and epoxy resin.

6. The surface-mounting coil component as described in claim 1, wherein the thickness of the upper flange of the drum-type ferrite core is about 0.35 mm or less, and

wherein a ratio between L2 and L1, where L2 is an outer diameter of the upper flange and L1 is a diameter of the winding core of the drum-type ferrite core, is about 1.9 or more.

7. The surface-mounting coil component as described in claim 6, wherein the drum-type ferrite core has a upper flange with maximum overhang size of about 1.0 mm or more in the diameter direction from the outer circumference of the winding core.

8. The surface-mounting coil component as described in claim 6, wherein the drum-type ferrite core is unified by using a dry forming press and baked thereafter.

9. The surface-mounting coil component as described in claim 6, wherein the drum-type ferrite core is produced by obtaining a plate shaped ferrite body, and grinding and baking it.

10. The surface-mounting coil component as described in claim 6, wherein the drum-type ferrite core has guide grooves on the bottom surface of the lower flange for ends of a winding.

11. The surface-mounting coil component as described in claim 6, wherein at least one pair or two pairs of external electrodes are arranged on the bottom surface of the lower flange.

12. The surface-mounting coil component as described in claim 11, wherein the external electrodes are formed by coating and baking a paste of an Ag electrode material.

13. The surface-mounting coil component as described in claim 11, wherein the external electrodes are applied Ni plating, Tin plating, or Cu plating on the surface of Ag baked electrodes.