Tdk Corporation

Junetsu Tamura

Tsuneo Suzuki

Hideharu Moro

Tsutomu Chou

Kazuhiko Shibata

Yasuhiko Kitajima

Takashi Nagasaka

Sadaki Satoh

A method for manufacturing a coil-embedded dust core with a small variation in inductance value with efficiency includes a step (a) of charging soft magnetic metal powder including an insulating material, composing a green body, so as to cover a coil, and (b) compacting the soft magnetic metal powder covering the coilin an axial direction of the coil. In the step (b), the soft magnetic metal powder is compacted while an amount of the soft metal powder charged into the part corresponding to the winding section is kept smaller than an amount of the soft magnetic metal powder charged into the other part that are not corresponding to the winding section, with an upper surface or a lower surface of the winding section as a reference.

Method for manufacturing inductor having coil embedded dust core

A coil-embedded dust core and a method for manufacturing the coil-embedded dust core are provided. The coil-embedded dust core comprises a coil formed from a flat conductor wound in a coil configuration, and a green body consisting of insulating material-coated ferromagnetic metal particles. This results in a coil-embedded dust core more compact in size but with larger inductance. A rectangular wire can be used as the flat conductor. In addition, parts of the coil may function as terminal sections. In this case, the terminal sections of the coil may be formed wider than other part of the coil. The coil-embedded dust core is less prone to joint failures between a coil and terminal sections and to insulation failures of the coil and the terminal section with respect to the magnetic powder. The coil-embedded dust core is more compact while achieving larger inductance.

Coil-embedded dust core and method for manufacturing the same

Growing community of inventors

Akita-ken, Japan

Junetsu Tamura