Coil component

• US 8,643,455 B2
• Filed: 11/14/2011
• Issued: 02/04/2014
• Est. Priority Date: 01/21/2011
• Status: Active Grant

• Current Assignee: Taiyo Yuden Company Limited (Taiyo Yuden Co)
• Original Assignee: Taiyo Yuden Company Limited (Taiyo Yuden Co)
• Inventors: Ogawa, Hideki, Yagasaki, Toshiyuki, Matsumoto, Tsuyoshi, Shigemoto, Hiroya, Higuchi, Hiroyuki, Tanaka, Kiyoshi
• Primary Examiner(s): Enad, Elvin G
• Assistant Examiner(s): Hinson, Ronald
• Application Number:
  US13/295,774
• Publication Number:
  US 20120188040A1
• Time in Patent Office: 813 Days
• Field of Search: 336/83, 336/185, 336/192, 336/96, 336/198
• US Class Current: 336/83
• 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 27/266 Fastening or mounting the core on casing or support on coil H01F27/30
• CPC Class Codes: H01F 27/292 Surface mounted devices

Abstract

As an embodiment, a pair of first conductive films 12, 13 are formed from the side face to the bottom face of the sheet part 11a of a magnetic core 11, and one end 14b of the conductive wire of the coil 14 and the other end 14c of the conductive wire are joined to the side faces 12a, 13a of the first conductive films 12, 13, respectively. Also, as an embodiment, the joined parts 14b1, 14c1 are sandwiched by the side faces 12a, 13a of the first conductive films 12, 13 and the part 15a of the magnetic sheath 15 covering the side face of the sheet part 11a of the magnetic core 11, wherein the parts of the magnetic sheath 15 covering the joined parts 14b1, 14c1 are sandwiched by the side faces 12a, 13a of the first conductive films 12, 13 and the side faces 16a, 17a of second conductive films 16, 17 as well as the side faces 18a, 19a of third conductive films 18, 19.

Claims

1. A coil component characterized by comprising:

a magnetic core integrally having a sheet part and a pillar part formed on a top face of the sheet part;

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

a coil integrally having a spiral part where a conductive wire whose cross-section shape is a rectangle having a long side and a short side is spirally wound, and a one end of the conductive wire and an other end of the conductive wire are drawn from the spiral part, wherein the spiral part is placed around the pillar part of the magnetic core, and the long side at the one end of the conductive wire is joined to a surface of the side face of the one first conductive film, while the long side at the other end of the conductive wire is joined to a surface of the side face of the other first conductive film;

a magnetic sheath formed so as to cover each of;

the top face of the pillar part and the side face of the sheet part of the magnetic core,

surfaces of the side faces of the first conductive films, and

surfaces of the spiral part, one end of the conductive wire, the joined part at the one end of the conductive wire, the other end of the conductive wire and the joined part at the other end of the conductive wire, of the coil;

a pair of second conductive films formed from a side face of the magnetic sheath to a bottom face of the sheet part of the magnetic core, via a bottom face of the magnetic sheath, so that the surfaces of the bottom faces of the first conductive films are covered, respectively; and

a pair of third conductive films formed so as to cover surfaces of the respective second conductive films;

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;

wherein the joined part at the one end of the conductive wire and the joined part at the other end of the conductive wire of the coil are sandwiched by the side faces of the first conductive films and a part of the magnetic sheath covering the side face of the sheet part of the magnetic core, respectively; and

wherein the parts of the magnetic sheath covering the surface of the joined part at the one end of the conductive wire and the surface of the joined part at the other end of the conductive wire are sandwiched, with each joined part in between, by the side face of each of the first conductive films and the side face of each of the second conductive films as well as the side face of each of the third conductive films, respectively.

2. A coil component according to claim 1, characterized in that the first conductive films are baked conductive films.

3. A coil component according to claim 1, characterized in that the second conductive films are constituted by metal grains and insulation material present between the metal grains.

4. A coil component according to claim 1, characterized in that the sheet part of the magnetic core has a profile, as viewed from the top, of a rough rectangle and the first conductive films are formed from two opposing side faces to the bottom face of the sheet part, and

the magnetic sheath has a profile, as viewed from the top, of a rough rectangle and the second conductive films have width dimensions roughly the same as those of the two side faces of the magnetic sheath corresponding to the two opposing side faces of the sheet part of the magnetic core.

5. A coil component according to claim 4, characterized in that the side faces and bottom faces of the second conductive films are continued via second side faces present on the other two side faces adjacent to the two side faces of the magnetic sheath, and two wraparound parts are formed on the first external terminal and the second external terminal by the second side faces and the second side faces of the third conductive films covering these side faces.

6. A coil component according to claim 1, characterized in that the magnetic core is constituted by magnetic alloy grains, an oxide film of the magnetic alloy grains is formed on a surface of each magnetic alloy grain, and the oxide film binds adjacent magnetic alloy grains.

7. A coil component according to claim 1, characterized in that the magnetic sheath is constituted by magnetic alloy grains and an insulation material present between the magnetic alloy grains, and the insulation material binds adjacent magnetic alloy grains.

8. A coil component according to claim 1, characterized in that the bottom face of the sheet part of the magnetic core is roughly flush with the bottom face of the magnetic sheath.

9. A coil component according to claim 1, characterized in that, along an outer periphery of the bottom face of the sheet part of the magnetic core, two areas not covered by the first external terminal and the second external terminal are entirely covered by a part extending downward from the part of the magnetic sheath covering the side face of the sheet part of the magnetic core.

10. A coil component according to claim 1, characterized in that, along an outer periphery of the bottom face of the sheet part of the magnetic core, two areas not covered by the first external terminal and the second external terminal are partially covered by a part extending downward from the part of the magnetic sheath covering the side face of the sheet part of the magnetic core.

11. A coil component according to claim 1, characterized in that a concave part is formed that divides each of two areas not covered by the first external terminal and the second external terminal along an outer periphery of the bottom face of the sheet part of the magnetic core.

12. A coil component according to claim 2, characterized in that the second conductive films are constituted by metal grains and insulation material present between the metal grains.

13. A coil component according to claim 2, characterized in that the sheet part of the magnetic core has a profile, as viewed from the top, of a rough rectangle and the first conductive films are formed from two opposing side faces to the bottom face of the sheet part, and

the magnetic sheath has a profile, as viewed from the top, of a rough rectangle and the second conductive films have width dimensions roughly the same as those of the two side faces of the magnetic sheath corresponding to the two opposing side faces of the sheet part of the magnetic core.

14. A coil component according to claim 3, characterized in that the sheet part of the magnetic core has a profile, as viewed from the top, of a rough rectangle and the first conductive films are formed from two opposing side faces to the bottom face of the sheet part, and

the magnetic sheath has a profile, as viewed from the top, of a rough rectangle and the second conductive films have width dimensions roughly the same as those of the two side faces of the magnetic sheath corresponding to the two opposing side faces of the sheet part of the magnetic core.

15. A coil component according to claim 12, characterized in that the sheet part of the magnetic core has a profile, as viewed from the top, of a rough rectangle and the first conductive films are formed from two opposing side faces to the bottom face of the sheet part, and

the magnetic sheath has a profile, as viewed from the top, of a rough rectangle and the second conductive films have width dimensions roughly the same as those of the two side faces of the magnetic sheath corresponding to the two opposing side faces of the sheet part of the magnetic core.

16. A coil component according to claim 13, characterized in that the side faces and bottom faces of the second conductive films are continued via second side faces present on the other two side faces adjacent to the two side faces of the magnetic sheath, and two wraparound parts are formed on the first external terminal and the second external terminal by the second side faces and the second side faces of the third conductive films covering these side faces.

17. A coil component according to claim 14, characterized in that the side faces and bottom faces of the second conductive films are continued via second side faces present on the other two side faces adjacent to the two side faces of the magnetic sheath, and two wraparound parts are formed on the first external terminal and the second external terminal by the second side faces and the second side faces of the third conductive films covering these side faces.

18. A coil component according to claim 15, characterized in that the side faces and bottom faces of the second conductive films are continued via second side faces present on the other two side faces adjacent to the two side faces of the magnetic sheath, and two wraparound parts are formed on the first external terminal and the second external terminal by the second side faces and the second side faces of the third conductive films covering these side faces.