Coil component and production method thereof

Patent metadata

Field	Value
Publication number	US-2023352231-A1
Application number	US-202318307442-A
Country	US
Kind code	A1
Filing date	Apr 26, 2023
Priority date	Apr 28, 2022
Publication date	Nov 2, 2023
Grant date	—

Abstract

A coil component including a core part and a coil part formed by winding a conductor in a coil form, in which the coil part is inside of the core part. The core part has a center pole part positioned in an area surrounded by an inner diameter of the coil part. The center pole part includes a first center pole part and a second center pole part each having different predetermined configurations, or the center pole part includes soft magnetic metal particles having predetermined deflection angles and aspect ratios.

First claim

What is claimed is:

1 . A coil component comprising a core part and a coil part formed by winding a conductor in a coil form, wherein
the coil part is inside of the core part; the core part comprises a center pole part positioned in an area surrounded by an inner diameter of the coil part; the center pole part comprises a first center pole part including first soft magnetic metal particles, and a second center pole part including second soft magnetic metal particles and being arranged around the first center pole part; the first center pole part comprises at least two opposing faces opposing each other; the two opposing faces are parallel to a winding axis direction; and an average deflection angle of the first soft magnetic metal particles against the winding axis direction of the coil part and an average deflection angle of the second soft magnetic metal particles against the winding axis direction of the coil part are different.

2 . The coil component according to claim 1 , wherein a shape of the first center pole part is a quadrangular prism shape.

3 . The coil component according to claim 1 , wherein
an average value of cos 2θα is larger than an average value of cos 2θβ, in which θα represents deflection angles of the first soft magnetic metal particles against the winding axis direction of the coil part and θβ represents deflection angles of the second soft magnetic metal particles against the winding axis direction of the coil part.

4 . The coil component according to claim 1 , wherein
an average value of cos 2θα is larger than an average value of cos 2θγ, in which θα represents deflection angles of the first soft magnetic metal particles against the winding axis direction of the coil part and θγrepresents deflection angles of third soft magnetic metal particles included in an area outside of the coil part against the winding axis direction of the coil part.

5 . The coil component according to claim 1 , wherein
an average value of cos 2θα is 0.1 or larger, in which θα represents deflection angles of the first soft magnetic metal particles against the winding axis direction of the coil part.

6 . The coil component according to claim 1 , wherein an average aspect ratio of the first soft magnetic metal particles included in the first center pole part is 1.1 or larger and 5.0 or smaller.

7 . A coil component comprising a core part and a coil part formed by winding a conductor in a coil form, wherein
the coil part is inside of the core part; the core part comprises a center pole part positioned in an area surrounded by an inner diameter of the coil part; the center pole part comprises a first center pole part including first soft magnetic metal particles, and a second center pole part including second soft magnetic metal particles and being arranged around the first center pole part; the first center pole part comprises at least two opposing faces opposing each other; and the two opposing faces are parallel to a winding axis direction.

8 . A coil component comprising a core part including soft magnetic metal particles, and a coil part formed by winding a conductor in a coil form, wherein
the coil part is inside of the core part; the core part comprises a center pole part positioned in an area surrounded by an inner diameter of the coil part; an average value of cos 2θ of the soft magnetic metal particles included in the center pole part is 0.1 or larger, in which θ represents deflection angles of the soft magnetic metal particles against the winding axis direction of the coil part; and an average aspect ratio of the soft magnetic metal particles included in the center pole part is 1.1 or larger.

9 . The coil component according to claim 8 , wherein the average aspect ratio of the soft magnetic metal particles included in the center pole part is 1.1 or larger and 5.0 or smaller.

10 . The coil component according to claim 8 , wherein the core part comprises a dust core including the soft magnetic metal particles and a resin.

11 . A production method of the coil component according to claim 8 comprising the core part including the soft magnetic metal particles and the coil part formed by winding the conductor in a coil form, in which the coil part is inside the core part; wherein
the production method of the coil component comprises
preparing a center core by pressing; and
arranging the center core so that a pressure applied direction of the center core while pressing and a winding axis direction of the coil part are perpendicular to each other.

12 . The production method according to claim 11 comprising:
preparing a coil, a base core, and cover core;
arranging the center core, the coil, and the cover core on the base core; and
integrally pressing the base core, the center core, and the cover core.

Assignees

• Tdk Corp

Inventors

• Yasuhara Katsushi
• Sezai Yuji
• Nakazawa Ryoma
• Furukawa Hironobu

Classifications

• H01F27/2823 Primary

  Wires (H01F27/2866 takes precedence) · 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

• H01F27/255

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

• H01F3/10 Primary

  Composite arrangements of magnetic circuits · CPC title

• H01F2017/048

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