Coil component

Patent metadata

Field	Value
Publication number	US-9685263-B2
Application number	US-201514839799-A
Country	US
Kind code	B2
Filing date	Aug 28, 2015
Priority date	Aug 30, 2014
Publication date	Jun 20, 2017
Grant date	Jun 20, 2017

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 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 alloy grains and resin and also by a coil, which composite magnetic material is substantially non-compressed,
wherein an oxygen atom concentration in a surface of the alloy grains is 50 percent or less and at least about 30 percent as measured by secondary ion mass spectrometry, and
the alloy grains have a size of at least 1 μm and are composed of amorphous alloy grains containing 77 to 79.5 percent by weight of Fe and/or crystalline alloy grains containing 92.5 to 95.5 percent by weight of Fe.

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

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

4. A coil component according to claim 1 , wherein an average grain size of the alloy grains is 2 to 20 μm.

5. A coil component according to claim 4 , wherein the alloy grains have a grain size distribution which shows two peaks.

6. A coil component according to claim 1 , wherein the amorphous alloy grains further contains 5 to 10 percent by weight of at least one metal selected from the group consisting of Si, Al, Cr, Ni, Mo, and Co.

7. A coil component according to claim 1 , wherein the crystalline alloy grains further contains 5 to 10 percent by weight of at least one metal selected from the group consisting of Si, Al, Cr, Ni, Mo, and Co.

8. A coil component according to claim 1 , wherein the alloy grains having an oxygen atom concentration of 50% or less 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.

9. A coil component according to claim 1 , wherein the alloy grains contain at least amorphous alloy grains.

10. A coil component according to claim 1 , wherein the oxygen atom concentration is 30 to 40 percent.

11. A coil component according to claim 10 , wherein the coil is embedded in the composite magnetic material.

12. A coil component according to claim 10 , wherein the coil is formed inside the composite magnetic material.

13. A coil component according to claim 10 , 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

• H01F17/04 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

• 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