Core component, method of manufacturing same, and inductor

Patent metadata

Field	Value
Publication number	US-11581120-B2
Application number	US-201916524879-A
Country	US
Kind code	B2
Filing date	Jul 29, 2019
Priority date	Jan 11, 2019
Publication date	Feb 14, 2023
Grant date	Feb 14, 2023

Abstract

A core component is made of a sintered body of an inorganic powder, in which the core component includes a columnar winding portion and a flange portion integrally formed with the columnar winding portion at both axial ends of the columnar winding portion, in which when observed in a cross section perpendicular to an axial direction, a surface layer portion of the columnar winding portion and a surface layer portion of the flange portion have a void occupancy area smaller than a void occupancy area of an inside of the columnar winding portion and of an inside of the flange portion, respectively.

First claim

What is claimed is:

1. A core component made of a sintered body of an inorganic powder, the core component comprising:
a columnar winding portion having a first axial end and a second axial end;
a flange portion integrally formed with the columnar winding portion at both axial ends of the columnar winding portion,
wherein when observed in a cross section perpendicular to an axial direction, a surface layer portion of the columnar winding portion has a void occupancy area smaller than a void occupancy area of an inside of the columnar winding portion,
the columnar winding portion has a first region and a second region in a cross section orthogonal to the axial center, the first region having a curved outer peripheral surface with a radius of curvature larger than a radius of curvature of the second region, the second region having a curved outer peripheral surface with a radius of curvature smaller than the radius of curvature of the first region.

2. The core component according to claim 1 , wherein the void occupancy area in the surface layer portion of the columnar winding portion is 0.5% to 3%.

3. The core component according to claim 1 , wherein when the flange portion is observed in a cross section perpendicular to the axial direction, a surface layer portion of the flange portion has a void occupancy area smaller than a void occupancy area of an inside of the flange portion.

4. The core component according to claim 3 , wherein the void occupancy area in the surface layer portion of the flange portion is 0.5% to 4%.

5. A method of manufacturing the core component according to claim 1 , the method comprising:
filling and pressure molding an inorganic powder between an upper punch and a lower punch to form a pressure-molded compact, wherein each of the upper punch and lower punch has an arc-shaped pressing surface for forming the columnar winding portion and the flange portion; and
sintering the pressure-molded compact to form a sintered body,
wherein the arc-shaped pressing surface of the upper punch and the arc-shaped pressing surface of the lower punch have different radiuses of curvature at least at a portion forming the columnar winding portion, and
wherein a molding pressure at a time of the pressure molding is 98 MPa or more.

6. The method of manufacturing the core component according to claim 5 , further comprising polishing the sintered body.

7. An inductor comprising the core component according to claim 1 and a conductive wire wound around the columnar winding portion of the core component.

8. A core component made of a sintered body of an inorganic powder, the core component comprising:
a columnar winding portion having a first axial end and a second axial end;
a flange portion integrally formed with the columnar winding portion at both axial ends of the columnar winding portion,
wherein when observed in a cross section perpendicular to an axial direction, a surface layer portion of the columnar winding portion has a void occupancy area smaller than a void occupancy area of an inside of the columnar winding portion,
the columnar winding portion has a first region and a second region in a cross section orthogonal to the axial center, the first region having a curved outer peripheral surface with a radius of curvature larger than a radius of curvature of the second region, the second region having a curved outer peripheral surface with a radius of curvature smaller than the radius of curvature of the first region,
wherein the second region includes a flat portion which is continuous with the second region, the flat portion having an outer peripheral surface connected to the first region via a projection.

Assignees

• Kyocera Corp

Inventors

• Ochiai Hitomi
• Shingu Masamichi
• Kitagawa Yuki
• Mori Hideki
• Takayama Mitsuya

Classifications

• H01F41/0246 Primary

  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

• H01F17/045

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

• H01F41/06

  Coil winding · CPC title

• H01F3/08 Primary

  made from powder (powder coatings on sheets H01F3/02; on strips or ribbons H01F3/04; on wires H01F3/06) · CPC title

• H01F27/255 Primary

  made from particles (H01F27/26 takes precedence) · CPC title