Coil component, powder-compacted inductor and winding method for coil component

• US 9,536,653 B2
• Filed: 07/07/2014
• Issued: 01/03/2017
• Est. Priority Date: 04/25/2011
• Status: Active Grant

• Current Assignee: Sumida Corporation
• Original Assignee: Sumida Corporation
• Inventors: Yamada, Satoru, Hatayama, Yoshiyuki
• Primary Examiner(s): Enad, Elvin G
• Assistant Examiner(s): HOSSAIN, KAZI S
• Application Number:
  US14/324,585
• Publication Number:
  US 20140320250A1
• Time in Patent Office: 911 Days
• Field of Search: 336/192, 336/198, 336/184, 336/232, 336/83, 336/212, 336/221
• US Class Current: 1/1
• CPC Class Codes: H01F 2017/048 with encapsulating core, e.g. made of resin and magnetic powder
• CPC Class Codes: H01F 27/2823 Wires H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/29 Terminals; Tapping arrangements for signal inductances
• CPC Class Codes: H01F 41/064 Winding non-flat conductive wires, e.g. rods, cables or cords
• CPC Class Codes: H01F 41/071 Winding coils of special form winding conductors onto closed formers or cores H01F41/08

Abstract

A coil component includes an air-core winding wire portion wound by a wire with a plurality of wound layers by alignment winding, a spiral shaped wound portion in which the wire wound in a spiral shape from an inner edge of an end surface toward an outer edge thereof along the end surface while in contact with the end surface on one side in the axis direction of the winding wire portion, a first lead portion extended and extracted outward from a winding first end point of the spiral shaped wound portion, and a second lead portion extended and extracted outward from a winding second end point at the outer circumference of the winding wire portion.

Claims

1. A powder-compacted inductor, comprising:

a powder-compacted body that is in a cubic shape having first and second side surfaces and a bottom surface continuously formed with the first and second side surfaces, the first and second side surfaces being opposite to each other;

a first terminal that is formed along the first side surface and that continuously extends to the bottom surface so as to be along the bottom surface;

a second terminal that is formed along the second side surface and that continuously extends to the bottom surface so as to be along the bottom surface; and

a coil component that is embedded in the powder-compacted body, the coil component including

a winding wire portion in which a wire having electrical conductivity is wound into a plurality of wound layers;

a spiral shaped wound portion in which the wire extends from a winding start point at an inner circumference of the winding wire portion and in which the wire is wound in a spiral shape from an inner edge of an end surface toward an outer edge of the end surface along the end surface while the wire is in contact with the end surface, the end surface being located at one side of the winding wire portion in an axis direction of the winding wire portion, the axis direction being perpendicular to the bottoms surface of the powder-compacted body;

a first lead extending outwardly from a winding first end point of the spiral shaped wound portion; and

a second lead extending outwardly from a winding second end point at an outer circumference of the winding wire portion, wherein

the first and second leads are both positioned at the one side of the winding portion in the axis direction,

first and second lead roots of the first and second leads are embedded in the powder-compacted body, respectively,

first and second lead ends of the first and second leads extend outwardly from the first and second side surfaces of the powder-compacted body, respectively, and

the first and second lead ends are connected to first and second terminal ends of the first and second terminals outside of the first and second side surfaces of the powder-compacted body, respectively.

2. The powder-compacted inductor, according to claim 1, wherein

the winding start point at the inner circumference and the winding second end point at the outer circumference of the winding wire portion are both positioned at the one side of the winding wire portion, and

the first and second leads both extend outwardly at the one side of the winding wire portion.

3. The powder-compacted inductor, according to claim 1, wherein

the powder-compacted body includes compression-molded metal magnetic powder.

4. The powder-compacted inductor, according to claim 1, wherein

the winding wire portion is an alignment winding portion and the plurality of wound layers include an inner wound layer and a second layer,

one end of the wire is wound such that the adjacent wires closely contact each other from one end of an axial line to the other end of the axial line to configure the inner wound layer,

the second wound layer is formed around an outer circumference portion of the inner wound layer so that the adjacent wires closely contact each other from the other end of the axial line to the one end of the axial line.

5. The powder-compacted inductor, according to claim 1, wherein

the number of level of the spiral shaped wound portion is one.

6. The powder-compacted inductor, according to claim 1, wherein

the first and second leads are in different but close levels of the plurality of wound layers.

7. The powder-compacted inductor, according to claim 1, wherein

the outermost adjacent windings of the plurality of wound layers are axially spaced apart from each other.

8. The powder-compacted inductor, according to claim 1, wherein

the first and second terminal ends of the first and second terminals are embedded in the powder-compacted body.