Coil-embedded dust core

• US 7,277,001 B2
• Filed: 08/16/2005
• Issued: 10/02/2007
• Est. Priority Date: 08/20/2004
• Status: Expired due to Fees

• Current Assignee: Alps Alpine Co., Ltd.
• Original Assignee: ALPS Electric Company Limited (Alps Alpine Co., Ltd.)
• Inventors: Naito, Yutaka, Aoki, Kazuo, Mizushima, Takao, Watabe, Satoshi, Kemmotsu, Hidetaka
• Primary Examiner(s): MAI, ANH T
• Application Number:
  US11/206,113
• Publication Number:
  US 20060038651A1
• Time in Patent Office: 777 Days
• Field of Search: 336/83, 336/200, 336/232, 336/223, 336/192
• US Class Current: 336/192
• CPC Class Codes: H01F 17/04 with magnetic core
• 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 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 27/2847 Sheets; Strips H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/292 Surface mounted devices
• 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

Abstract

A coil-embedded dust core of the present invention is provided with a molded coil component including a coil main body having a structure in which a flat type conductor wire is wound edgewise, one end side terminal portion disposed by being lead in the thickness direction of the coil main body, the other end side terminal portion, one end side leading electrode portion disposed by extending the one end side terminal portion, and the other end side leading electrode portion disposed by extending the other end side terminal portion; and a dust core composed of a soft magnetic alloy powder disposed covering the coil main body, the one end side terminal portion, and the other end side terminal portion of the molded coil component.

Claims

1. A coil-embedded dust core comprising:

a molded coil component including a coil main body having an edgewise winding structure in which a flat type conductor wire having a flat portion is wound in such a way that the flat portion is arranged substantially perpendicularly to a winding axis, wherein one end side terminal portion is disposed by leading an end portion of the flat type conductor wire located on the one end side of the coil main body in parallel to the winding axis of the coil main body, the other end side terminal portion disposed by leading an end portion of the flat type conductor wire located on the other end side of the coil main body in parallel to the winding axis of the coil main body, wherein one end side leading electrode portion is disposed by extending the one end side terminal portion, and the other end side leading electrode portion is disposed by extending the other end side terminal portion;

a dust core composed of a soft magnetic alloy powder compact disposed covering the coil main body, the one end side terminal portion, and the other end side terminal portion of the molded coil component;

wherein the one end side terminal portion and the other end side terminal portion are extended to one surface or the other surface of the dust core, the surfaces being perpendicular to the winding axis direction of the coil main body; and

wherein the one end side leading electrode portion that is extended from the one end side terminal portion lead to the one surface or the other surface of the dust core is extended along the dust core surface to a corner portion side of the dust core, and is bent so that the one end side leading electrode portion is exposed.

2. The coil-embedded dust core according to claim 1, wherein the coil main body is low-profile, and the dust core covering the coil main body is low-profile.

3. The coil-embedded dust core according to claim 1, wherein the other end side leading electrode portion that is extended from the other end side terminal portion leads to the one surface or the other surface of the dust core is extended along the dust core surface to a corner portion side of the dust core, and is bent so that the other end side leading electrode portion is exposed.

4. The coil-embedded dust core according to claim 1, wherein both the one end side terminal portion and the other end side terminal portion are extended to one surface of the dust core, the other end side terminal portion being kept a distance from an outer perimeter portion of the coil main body in the inside of the dust core to the one surface, and a part of the soft magnetic alloy powder compact is filled in between the outer perimeter portion of the coil main body and the other end side terminal portion.