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Coil component and fabrication method of the same

  • US 7,427,909 B2
  • Filed: 06/10/2004
  • Issued: 09/23/2008
  • Est. Priority Date: 06/12/2003
  • Status: Active Grant
First Claim
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1. A coil component comprising:

  • a coil-containing insulator enclosure obtained by enclosing a coil, except for end portions of the coil, with an insulator which comprises a first resin; and

    a magnetic core made of a mixture of a second resin and a powder, the powder comprises magnetic powder having particles, wherein at least one part of the coil-containing insulator enclosure is embedded in the magnetic core, the coil comprising a plurality of turns of a conductor, the turns being stacked along a predetermined direction with each space between neighboring turns being filled with the insulator,wherein the insulator has a first thickness in a radial direction of the coil and a second thickness in an axial direction of the coil; and

    each of the first and the second thicknesses is larger than one-third of an average particle size of the magnetic powder, the insulator further comprises a non-magnetic filler added to the first resin, the coil comprising two coil members each having an axis, the coil members being arranged so that the axes of the coil members are parallel to each other, the insulator comprising a connection portion between the coil members, the connection portion having a third thickness between the coil members in a first direction perpendicular to the axial direction, the connection portion having a fourth thickness in a second direction perpendicular to the axial direction and the first direction, the fourth thickness being equal to or more than the third thickness, the third thickness being one-third or more of an average particle size of the non-magnetic filler.

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