Coil component and method of manufacturing the coil component

Patent metadata

Field	Value
Publication number	US-11615903-B2
Application number	US-201815967062-A
Country	US
Kind code	B2
Filing date	Apr 30, 2018
Priority date	Feb 1, 2016
Publication date	Mar 28, 2023
Grant date	Mar 28, 2023

Abstract

A coil component includes a body that is made of a composite material containing a resin material and metal powder, a coil conductor which is provided in the body and an end portion of which is exposed on an end face of the body, and a metal film that is provided on an outer surface of the body and that is electrically connected to the coil conductor on the end face in the outer surface. The outer surface of the body has a contact area that is in contact with the metal film. Multiple particles of the metal powder escape from the resin material and are in contact with each other in the contact area of the body.

First claim

What is claimed is:

1. A coil component comprising:
a body made of a composite material containing a resin material and metal powder, the body having an outer surface including a contact area, and particles of the metal powder in the contact area are exposed from the resin material and in contact with each other;
a coil conductor provided in the body and having an end portion exposed from the body; and
a metal film provided on the outer surface of the body in contact with the contact area and electrically connected to the coil conductor, wherein
a percentage of contact of the particles of the metal powder in the body per unit cross-section area is lower than a percentage of contact of the particles of the metal powder in the contact area on the outer surface of the body per unit cross-section area, and
the particles of the metal powder in the contact area that are bonded to each other are bonded through melting.

2. The coil component according to claim 1 , wherein:
the outer surface of the body has an end face and a side face adjacent to the end face, the contact area is provided on the end face and part of the side face, and the metal film is continuously provided on the end face and part of the side face.

3. The coil component according to claim 2 , further comprising:
an insulating film that covers a portion of the metal film, which is positioned on the end face.

4. The coil component according to claim 1 , wherein
a sphericity of the particles of the metal powder in the body is greater than a sphericity of the particles of the metal powder in the contact area on the outer surface of the body.

5. The coil component according to claim 1 , wherein
the particles of the metal powder that are in contact with each other exist in an area up to a depth corresponding to twice of a maximum peak position in a particle size distribution of the metal powder from the outer surface of the body, and the particles of the metal powder that are in an area greater than the depth corresponding to twice of a maximum peak position in a particle size distribution of the metal powder from the outer surface of the body are not in contact with each other.

Assignees

• Murata Manufacturing Co

Inventors

• Tomohiro Takashi
• Shimizu Noriko
• Araki Kenichi
• Iso Eiji
• Muneuchi Keita
• Ida Isao

Classifications

• H01F1/14766

  Fe-Si based alloys · CPC title

• B22F2999/00

  Aspects linked to processes or compositions used in powder metallurgy · CPC title

• B22F3/24 Primary

  After-treatment of workpieces or articles {(B22F3/1146 takes precedence)} · CPC title

• B22F1/16

  Metallic particles coated with a non-metal (coated with lubricating or binding agents or with organic material B22F1/10) · CPC title

• H01F1/20 Primary

  in the form of particles, e.g. powder (H01F1/147 takes precedence) · CPC title