Coil component and method for manufacturing coil component

• US 8,458,890 B2
• Filed: 06/06/2008
• Issued: 06/11/2013
• Est. Priority Date: 08/31/2007
• Status: Expired due to Fees

• Current Assignee: Sumida Corporation
• Original Assignee: Sumida Corporation
• Inventors: Sakamoto, Shinichi
• Primary Examiner(s): Musleh, Mohamad
• Assistant Examiner(s): Chan, Tsz
• Application Number:
  US12/673,632
• Publication Number:
  US 20110006870A1
• Time in Patent Office: 1,831 Days
• Field of Search: 336/83, 336/90
• US Class Current: 29/602.1
• CPC Class Codes: H01F 1/14791 Fe-Si-Al based alloys, e.g. Sendust
• CPC Class Codes: H01F 1/26 by macromolecular organic substances
• CPC Class Codes: H01F 17/043 with two, usually identical or nearly identical parts enclosing completely the coil (pot cores)
• 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: H01F 27/306 Fastening or mounting coils or windings on core, casing or other support
• CPC Class Codes: H01F 3/10 Composite arrangements of magnetic circuits
• CPC Class Codes: H01F 41/005 Impregnating or encapsulating insulating of windings H01F41/12
• 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
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

Abstract

In an inductor including a coil, a drum type core constituted by a soft magnetic metal material and a resin material, and a filling member constituted by a soft magnetic metal material and a resin material in which a magnetic flux excited by aforesaid coil goes through aforesaid drum type core and aforesaid filling member serially, the present invention constitutes an inductor, wherein aforesaid drum type core is constituted by injection molding so as to include a receiving portion, aforesaid coil is arranged in aforesaid receiving portion, and aforesaid filling member is filled therein.

Claims

1. A method of manufacturing a coil component, comprising:

forming a compound magnetic core by molding a mixture including a first soft magnetic metal material and a first resin material in a die, the compound magnetic core having a receiving portion and a longitudinal plane of symmetry, the die including a first die portion for forming one portion of the compound magnetic core and a second die portion for forming another portion of the compound magnetic core, the first die portion and the second die portion being mateable at the longitudinal plane of symmetry to define a parting line on the compound magnetic core, the first die portion and the second die portion including features for forming a recessed groove along portions of the parting line in the receiving portion;

assembling a coil in the receiving portion of the compound magnetic core; and

arranging a compound material including a second soft magnetic metal material and a second resin material in the compound magnetic core so as to coat the coil.

2. The manufacturing method according to claim 1, wherein the mixture has a linear expansion coefficient, the method further comprising:

adjusting the composition of the compound material such that the compound material has a linear expansion coefficient equal to the linear expansion coefficient of the mixture.

3. The manufacturing method according to claim 1, wherein the first soft magnetic material and the second soft magnetic material are the same.