Coil component and manufacturing method therefor

Patent metadata

Field	Value
Publication number	US-12170163-B2
Application number	US-202117504344-A
Country	US
Kind code	B2
Filing date	Oct 18, 2021
Priority date	Oct 23, 2020
Publication date	Dec 17, 2024
Grant date	Dec 17, 2024

Abstract

Disclosed herein is a coil component that includes a coil pattern embedded in a resin body. The resin body includes a winding core area surrounded by the coil pattern and having a first surface and a substantially flat second surface different in the circumferential direction position from the first surface, and a first surrounding area covering the first surface of the winding core area. The coil pattern includes first sections extending along the first surface of the winding core area and second sections extending along the second surface of the winding core area. One ends of the first sections are connected respectively to their corresponding one ends of the second sections. The other ends of the first sections are connected respectively to their corresponding other ends of the second sections.

First claim

What is claimed is:

1. A coil component comprising:
a resin body;
a coil pattern embedded in the resin body and helically wound in a plurality of turns; and
first and second terminal electrodes provided on a surface of the resin body and connected respectively to one and other ends of the coil pattern,
wherein the resin body includes:
a winding core area surrounded by the coil pattern and having a first surface and a substantially flat second surface different in the circumferential direction position from the first surface; and
a first surrounding area covering the first surface of the winding core area,

wherein the coil pattern includes a plurality of first sections extending along the first surface of the winding core area and a plurality of second sections extending along the second surface of the winding core area,
wherein one ends of the plurality of first sections are connected respectively to their corresponding one ends of the plurality of second sections, and
wherein other ends of the plurality of first sections are connected respectively to their corresponding other ends of the plurality of second sections.

2. The coil component as claimed in claim 1 , wherein the first surface of the winding core area has a curved surface in a circumferential direction.

3. The coil component as claimed in claim 1 , wherein the winding core area and the first surrounding area are made of mutually different resin-based insulating materials.

4. The coil component as claimed in claim 3 ,
wherein the first surrounding area is added with filler, and
wherein the winding core area is not added with filler.

5. The coil component as claimed in claim 1 ,
wherein the resin body further includes a second surrounding area that covers the second surface of the winding core area so as to embed the plurality of second sections therein,
wherein the first and second terminal electrodes are provided on the second surrounding area, and
wherein a resin-based insulating material constituting the second surrounding area is lower in relative permittivity than a resin-based insulating material constituting the first surrounding area.

6. The coil component as claimed in claim 1 ,
wherein the resin body further includes a third surrounding area provided between the first surface of the winding core area and the first surrounding area so as to embed the plurality of first sections therein, and
wherein a resin-based insulating material constituting the third surrounding area is lower in relative permittivity than a resin-based insulating material constituting the first surrounding area.

7. The coil component as claimed in claim 1 , wherein the first and second terminal electrodes are arranged along an axial direction of the coil pattern.

8. The coil component as claimed in claim 7 , wherein the first and second terminal electrodes are formed on the surface of the resin body parallel to the axial direction without being formed on another surface thereof perpendicular to the axial direction.

9. A method of manufacturing a coil component, the method comprising:
forming a winding core area made of a resin-based insulating material on a support body;
forming a plurality of first sections of a coil pattern along a first surface of the winding core area;
covering the plurality of first sections and the first surface of the winding core area with a first surrounding area made of a resin-based insulating material;
exposing a second surface of the winding core area and one and other ends of each of the plurality of first sections by removing the support body; and
forming a plurality of second sections of the coil pattern so as to connect the one ends of the plurality of first sections and their corresponding other ends of the plurality of first sections.

10. The method of manufacturing a coil component as claimed in claim 9 , further comprising:
forming, on the second surface of the winding core area, a second peripheral area made of a resin-based insulating material so as to embed the plurality of second sections therein; and
forming, on the second surrounding area, first and second terminal electrodes connected respectively to one and other ends of the coil pattern,
wherein the resin-based insulating material constituting the second surrounding area is lower in relative permittivity than the resin-based insulating material constituting the first surrounding area.

11. The method of manufacturing a coil component as claimed in claim 9 , further comprising forming, on the first surface of the winding core area, a third surrounding area made of a resin-based insulating material so as to embed the plurality of first sections therein after the forming the plurality of first sections of the coil pattern and before the covering,
wherein the resin-based insulating material constituting the third surrounding area is lower in relative permittivity than the resin-based insulating material constituting the first surrounding area.

Assignees

• Tdk Corp

Inventors

• Okuzawa Nobuyuki
• Ito Kazuhiko
• Takaku Munehiro
• Urabe Junichiro

Classifications

• H01F27/292

  Surface mounted devices · CPC title

• H01F27/327

  Encapsulating or impregnating (encapsulating coil and core H01F27/022) · CPC title

• H01F41/127

  Encapsulating or impregnating (encapsulating coil and core H01F41/005) · CPC title

• H01F2017/004

  with the coil helically wound around an axis without a core · CPC title

• H01F2027/348

  Preventing eddy currents · CPC title