Coil component

Patent metadata

Field	Value
Publication number	US-10748694-B2
Application number	US-201715595575-A
Country	US
Kind code	B2
Filing date	May 15, 2017
Priority date	Aug 30, 2014
Publication date	Aug 18, 2020
Grant date	Aug 18, 2020

Abstract

A coil component is constituted by a composite magnetic material containing alloy grains whose oxygen atom concentration in their surfaces is 50 percent or less, and resin, and also by a coil. The alloy grains are comprised of first alloy grains and second alloy grains which have different compositions and different average grain sizes. The coil component using the composite magnetic material does not require high pressure when formed.

First claim

I claim:

1. A coil component constituted by a composite magnetic material containing magnetic alloy grains and resin and also by a coil, wherein a maximum oxygen atom concentration within an exposed outermost region, referred to as a surface layer, of the magnetic alloy grains which is a part of the magnetic alloy grains is more than 0 percent but 50 percent or less, and an oxygen atom concentration at a surface of the surface layer is lower than the maximum oxygen atom concentration and more than 0 percent but 25 percent or less, said magnetic alloy grains comprised of first alloy grains and second alloy grains which have different compositions and different average grain sizes wherein the first and second alloy grains constitute a grain size distribution which shows two peaks.

2. A coil component according to claim 1 , wherein at least the first alloy grains are amorphous alloy grains.

3. A coil component according to claim 2 , wherein the amorphous alloy grains contain 77 to 79.5 percent by weight of Fe.

4. A coil component according to claim 3 , wherein the amorphous alloy grains further contain 5 to 10 percent by weight of at least one metal selected from the group consisting of Si, Al, Cr, Ni, Mo, and Co.

5. A coil component according to claim 1 , wherein the first alloy grains have a smaller average grain size than the second alloy grains, and account for 10 to 40 percent by volume among all the alloy grains.

6. A coil component according to claim 1 , wherein all the alloy grains have a size of at least 1 μm.

7. A coil component according to claim 1 , wherein the oxygen atom concentration is measured by secondary ion mass spectrometry.

8. A coil component according to claim 1 , wherein the coil is embedded in the composite magnetic material.

9. A coil component according to claim 1 , wherein the coil is formed inside the composite magnetic material.

10. A coil component according to claim 1 , wherein an average grain size of the first and second alloy grains is in a range of from 2 to 20 μm.

11. A coil component according to claim 1 , wherein at least the second alloy grains are crystalline alloy grains containing 92.5 to 95.5 percent by weight of Fe.

12. A coil component according to claim 11 , wherein the crystalline alloy grains further contain 5 to 10 percent by weight of at least one metal selected from the group consisting of Si, Al, Cr, Ni, Mo, and Co.

13. A coil component according to claim 1 , wherein the alloy grains having an oxygen atom concentration of 50% or less in their surface layers account for 80 percent by volume or more in equivalent volume percentage, among all of the alloy grains contained in the composite magnetic material.

14. A coil component according to claim 1 , wherein the composite magnetic material is shaped by curing of the resin without distortion or deformation of the alloy grains.

15. A coil component constituted by a composite magnetic material containing magnetic alloy grains and resin and also by a coil, wherein a maximum oxygen atom concentration within an exposed outermost region, referred to as a surface, of the magnetic alloy grains which is a part of the magnetic alloy grains is 50 percent or less, said magnetic alloy grains comprised of first alloy grains and second alloy grains which have different compositions and different average grain sizes wherein the first and second alloy grains constitute a grain size distribution which shows two peaks, wherein the oxygen atom concentration is 30 to 40 percent.

16. A coil component according to claim 15 , wherein the alloy grains having an oxygen atom concentration of 30% to 40% in their surfaces account for 80 percent by volume or more in equivalent volume percentage, among all of the alloy grains contained in the composite magnetic material.

Assignees

• Taiyo Yuden Kk

Inventors

• Ogawa Hideki

Classifications

• H01F17/045

  with core of cylindric geometry and coil wound along its longitudinal axis, i.e. rod or drum core · CPC title

• H01F1/15375

  using polymers · CPC title

• H01F2017/048

  with encapsulating core, e.g. made of resin and magnetic powder · CPC title

• H01F17/04 Primary

  with magnetic core · CPC title

• H01F1/14708

  Fe-Ni based alloys (pure Fe or Ni H01F1/14, H01F1/16 or H01F1/20) · CPC title