Coil component

• US 8,390,415 B2
• Filed: 02/17/2012
• Issued: 03/05/2013
• Est. Priority Date: 04/28/2011
• Status: Active Grant

• Current Assignee: Taiyo Yuden Company Limited (Taiyo Yuden Co)
• Original Assignee: Taiyo Yuden Company Limited (Taiyo Yuden Co)
• Inventors: Ogawa, Hideki, Matsumoto, Tsuyoshi
• Primary Examiner(s): Musleh, Mohamad
• Assistant Examiner(s): Hinson, Ronald
• Application Number:
  US13/399,794
• Publication Number:
  US 20120274429A1
• Time in Patent Office: 382 Days
• Field of Search: 336/83, 336/84.M, 336/96, 336/192, 336/221, 336/233
• US Class Current: 336/83
• CPC Class Codes: H01F 1/24 the particles being insulated
• CPC Class Codes: H01F 1/26 by macromolecular organic substances
• CPC Class Codes: H01F 1/33 mixtures of metallic and non-metallic particles; metallic particles having oxide skin
• CPC Class Codes: H01F 17/04 with magnetic core
• CPC Class Codes: H01F 2003/106 Magnetic circuits using combinations of different magnetic materials
• 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 component 10 includes: a magnetic core made of a magnetic alloy; a coil having a spiral part placed around a pillar part of the magnetic core; a magnetic sheath formed on the magnetic core in a manner covering the coil except for the bottom face of the magnetic core; and a first external terminal and second external terminal formed on the magnetic core and magnetic sheath; wherein the magnetic sheath has numerous voids inside.

Claims

1. A coil component comprising:

a magnetic core integrally having a sheet part and a pillar part formed on top of the sheet part, and made of a magnetic alloy;

a pair of first conductive films separately formed from respective side faces to a bottom face of the sheet part of the magnetic core;

a coil integrally having a spiral part where a conductive wire is spirally wound, and one end of the conductive wire and other end of the conductive wire drawn from the spiral part, where the spiral part is placed around the pillar part of the magnetic core, and the one end of the conductive wire is joined to the one first conductive film, while the other end of the conductive wire is joined to the other first conductive film;

a magnetic sheath formed wherein the magnetic sheath covers a top face of the pillar part and the side faces of the sheet part of the magnetic core, surfaces of side parts of the one and other first conductive films, and surfaces of the spiral part, one end of the conductive wire and joined part at the one end of the conductive wire, as well as other end of the conductive wire and joined part at the other end of the conductive wire, of the coil;

a pair of second conductive films separately formed from respective side faces of the magnetic sheath to the bottom face of the sheet part of the magnetic core, via a bottom face of the magnetic sheath, wherein the surfaces of bottom parts of the one and other first conductive films are covered by the pair of second conductive films, respectively; and

a pair of third conductive films separately formed wherein the pair of third conductive films cover the surfaces of the one and other second conductive films, respectively;

wherein the one first conductive film, one second conductive film and one third conductive film constitute a first external terminal, while the other first conductive film, other second conductive film and other third conductive film constitute a second external terminal; and

wherein the magnetic sheath has numerous closed voids inside.

2. A coil component according to claim 1, wherein the magnetic core is constituted by magnetic alloy grains having an oxide film formed on their surface and bonding with one another via the oxide film.

3. A coil component according to claim 1, wherein the magnetic sheath is constituted by magnetic alloy grains and an insulation material, wherein gaps between adjacent magnetic alloy grains are substantially filled with the insulation material except for the closed voids.

4. A coil component according to claim 3, wherein a proportion by weight of the insulation material is 5% to 15% relative to the weight of the magnetic sheath.

5. A coil component according to claim 3, wherein the magnetic alloy grains forming the magnetic sheath are Fe—

Cr—

Si alloy grains, and the insulation material is an epoxy resin.

6. A coil component according to claim 2, wherein the magnetic sheath is constituted by magnetic alloy grains and an insulation material, and the magnetic alloy grains forming the magnetic core and the magnetic alloy grains forming the magnetic sheath are made of the same alloy and have substantially the same median diameter.

7. A coil component according to claim 1, wherein the number of the closed voids is 100 to 1,000/mm² as measured when counting the number of closed voids having a cross sectional size of 3 μ

m to 50 μ

m observed on a cross section appearing when cutting the magnetic sheath.