Small electronic component, electronic circuit board, and method of manufacturing small electronic component

Patent metadata

Field	Value
Publication number	US-10617006-B2
Application number	US-201615208906-A
Country	US
Kind code	B2
Filing date	Jul 13, 2016
Priority date	Jul 29, 2015
Publication date	Apr 7, 2020
Grant date	Apr 7, 2020

Abstract

Provided are a small electronic component including: a magnetic core including at least a columnar core part; a winding coil arranged so as to surround an outer peripheral surface side of the columnar core part and formed by winding a winding wire; and a magnetic cover part formed so as to cover at least part of the magnetic core and the winding coil while following at least part of shapes of the magnetic core and the winding coil through use of a magnetic material containing a mixture of a phosphoric acid ester-based surfactant, magnetic powder, and a resin, an electronic circuit board using the small electronic component, and a method of manufacturing a small electronic component.

First claim

What is claimed is:

1. A small electronic component, comprising:
a magnetic core comprising at least a columnar core part;
a winding coil arranged so as to surround an outer peripheral surface side of the columnar core part and formed by winding a winding wire; and
a magnetic cover part formed so as to cover at least part of the magnetic core and the winding coil while following at least part of shapes of the magnetic core and the winding coil through use of a magnetic material containing a mixture of a phosphoric acid ester-based surfactant, magnetic powder, and a resin,
wherein the magnetic material satisfies the following expressions (1) and (2A) to (5A):
D+M+R= 100  Expression (1)

M≥ 90.5  Expression (2A)

R≥ 3.5  Expression (3A)

R≤−M+ 99.95  Expression (4A)

R≥−M+ 96.5  Expression (5A)

where D represents the content (mass %) of the phosphoric acid ester-based surfactant in the magnetic material, M represents the content (mass %) of the magnetic powder in the magnetic material, and R represents the content (mass %) of the resin in the magnetic material.

2. A small electronic component according to claim 1 , wherein the magnetic cover part has a minimum thickness of 0.8 mm or less.

3. A small electronic component according to claim 1 , wherein the magnetic cover part has a minimum thickness of 0.5 mm or less.

4. A small electronic component according to claim 1 , wherein a surface of the magnetic cover part has a surface roughness Ra of 6.3 μm or less.

5. A small electronic component according to claim 1 , wherein a surface of the magnetic cover part has a surface roughness Ra of 1.6 μm or less.

6. A small electronic component according to claim 1 , wherein the magnetic cover part is molded so as to cover the entire winding coil and part of the magnetic core including the columnar core part while following a shape of the entire winding coil and a shape of part of the magnetic core.

7. A small electronic component according to claim 1 , wherein the magnetic core comprises the columnar core part and a flange part extending in a direction orthogonal to an axial direction of the columnar core part.

8. A small electronic component according to claim 1 , wherein the phosphoric acid-ester-based surfactant is selected from a group consisting of a polyoxyethylene alkyl ether phosphoric acid ester, a salt of the polyoxyethylene alkyl ether phosphoric acid ester, and an alkyl phosphate.

9. A small electronic component according to claim 1 , comprising an electronic component for surface mounting selected from the group consisting of an inductor, a transformer and a filter.

10. An electronic circuit board, comprising at least a wiring board having wiring patterned thereon and a small electronic component,
wherein the small electronic component comprises:
a magnetic core comprising at least a columnar core part;
a winding coil arranged so as to surround an outer peripheral surface side of the columnar core part and formed by winding a winding wire; and
a magnetic cover part formed so as to cover at least part of the magnetic core and the winding coil while following at least part of shapes of the magnetic core and the winding coil through use of a magnetic material containing a mixture of a phosphoric acid ester-based surfactant, magnetic powder, and a resin,
wherein the magnetic material satisfies the following expressions (1) and (2A) to (5A):
D+M+R= 100  Expression (1)

M≥ 90.5  Expression (2A)

R≥ 3.5  Expression (3A)

R≤−M+ 99.95  Expression (4A)

R≥−M+ 96.5  Expression (5A)

where D represents the content (mass %) of the phosphoric acid ester-based surfactant in the magnetic material, M represents the content (mass %) of the magnetic powder in the magnetic material, and R represents the content (mass %) of the resin in the magnetic material.

11. An electronic circuit board according to claim 10 , wherein the wiring further has another electronic component connected thereto.

Assignees

• Sumida Corp

Inventors

• Uchikoba Fumio
• Otsuka Tsutomu
• Kawarai Mitsugu
• Takahashi Motomi

Classifications

• H01F41/0206

  Manufacturing of magnetic cores by mechanical means (magnetic cores per se H01F27/24) · CPC title

• H01F41/0246

  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 title

• H01F27/022

  Encapsulation · CPC title

• H01F27/02

  Casings · CPC title

• H01F27/30

  Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other support · CPC title