Taiyo Yuden Co., Ltd.

Kenji Otake

Hitoshi Matsuura

Takayuki Arai

Shinsuke Takeoka

Masahiro Hachiya

Tomomi Kobayashi

Akiko Yamaguchi

Atsushi Tanada

Kenichiro Nogi

Hidemi Iwao

Kazuhiko Oyama

Kiyoshi Tanaka

Yoshikazu Okino

Ryuichi Kondou

Takashi Nakajima

Yoko Orimo

Hirotaro Seino

Tetsuyuki Suzuki

Hideki Ogawa

Minoru Ryu

Yoshiki Iwazaki

Xinyu Li

Masanori Nagano

Natsuko Sato

Keiko Shiroki

Mika Tamanoi

Takuya Ishida

Chengli He

A magnetic material includes a grain compact in which metal grains having oxide films are compacted, wherein the metal grains are constituted by Fe—Si-M soft magnetic alloy (where M represents a metal element that oxidizes more easily than iron), the metal grains in the grain compact are mutually bonded with adjacent metal grains by inter-bonding of their oxide films, and at least some of this bonding of oxide films takes the form of bonding of crystalline oxides, or preferably at least some of the bonding of oxides is based on continuous lattice bond. A coil component has a coil on an interior or surface of an element body wherein the element body uses the magnetic material.

Magnetic material and coil component

A coil component that can be made thinner while ensuring sufficient magnetic characteristics includes a magnetic part, a conductor part, and multiple insulator parts. The magnetic part is constituted by magnetic alloy grains. The conductor part has multiple winding parts and is wound around one axis inside the magnetic part. The multiple insulator parts are each placed between the multiple winding parts, each having a winding shape that includes two joining surfaces that are respectively joined to two winding parts facing each other at least partially in the direction of the one axis, and are each constituted by electrically insulating grains.

Coil component and method for manufacturing the same

A coil component has a magnetic body of rectangular solid shape, a coil with N turns (N is a positive number of 2 or greater) provided inside the magnetic body, an insulating intermediate part, and external electrodes. The coil has a first conductor layer, a second conductor layer, and an inter-layer connection part. The first conductor layer has a first multiple winding part which is wound around one axis with a first spacing. The second conductor layer has a second multiple winding part which is wound around the one axis with the first spacing and faces the first conductor layer. The insulating intermediate part is provided inside the magnetic body and forms, between the first conductor layer and second conductor layer, a second spacing corresponding to a thickness equal to or less than the product of the first spacing and (N&#x2212;1).

Coil component

A magnetic material has: multiple soft magnetic alloy grains that contain Fe, element L (where element L is Si, Zr, or Ti), and element M (where element M is not Si, Zr, or Ti, and oxidizes more easily than Fe); a first oxide film that contains element L and covers each of the multiple soft magnetic alloy grains; a second oxide film that contains element M and covers the first oxide film; a third oxide film that contains element L and covers the second oxide film; a fourth oxide film that contains Fe and covers the third oxide film; and bonds that are constituted by parts of the fourth oxide film and that bond the multiple soft magnetic alloy grains together.

Magnetic material and electronic component

In an embodiment, a coil component includes a magnetic body, and an internal conductorhaving a center axis and formed in a spiral shape; wherein the internal conductoris embedded in the magnetic body; in a cross sectional view of a plane that includes the center axis extending in the vertical direction, wherein a conductor region partpositioned between the adjacent windings of the spiral shape has a higher oxygen content than that of a core partincluding the center axis and positioned on the inner side of the windings of the spiral shape. the magnetic body is constituted by iron-based soft magnetic grains and oxide film of at least one type of element that oxidizes more easily than iron, which oxide film bonds at least partly the iron-based soft magnetic grains.

In an embodiment, a magnetic body includes soft magnetic alloy grainscontaining Fe, element L, and element M (where element L is Si or Zr and element M is a metal element other than Si or Zr that oxidizes more easily than Fe), as well as oxide film produced from oxidization of part of these grains; wherein at least some of the bonds between adjacent soft magnetic alloy grainsare by way of the oxide film; the oxide film has an inner film, and an outer filmpositioned on the outer side of the inner film; and the inner filmcontains more of element L than element M, while the outer filmcontains more of element M than element L.

Magnetic body and electronic component comprising the same

One object is to provide a laminated inductor having a reduced thickness without reduction in the magnetic characteristic and the insulation quality. The laminated inductor includes a first magnetic layer, an internal conductor, second magnetic layers, third magnetic layers, and a pair of external electrodes. The first magnetic layer includes three or more magnetic alloy particles arranged in the thickness direction and an oxide film binding the magnetic alloy particles together and containing Cr. The three or more magnetic alloy particles have an average particle diameter of 4 &#x3bc;m or smaller. The internal conductor includes a plurality of conductive patterned portions electrically connected to each other via the first magnetic layer. The second magnetic layers are composed of magnetic alloy particles and disposed around the conductive patterned portions. The third magnetic layers are composed of magnetic alloy particles and disposed so as to be opposed to each other in thickness direction.

Laminated inductor

One object is to provide a laminated inductor having a reduced thickness without reduction in the magnetic characteristic and the insulation quality. The laminated inductor includes a first magnetic layer, an internal conductor, second magnetic layers, third magnetic layers, and a pair of external electrodes. The first magnetic layer has a thickness of 4 to 19 &#x3bc;m, and includes three or more magnetic alloy particles arranged in the thickness direction and an oxide film binding the magnetic alloy particles together and containing Cr. The internal conductor includes a plurality of conductive patterned portions electrically connected to each other via the first magnetic layer. The second magnetic layers are composed of magnetic alloy particles and disposed around the conductive patterned portions. The third magnetic layers are composed of magnetic alloy particles and disposed so as to be opposed to each other in thickness direction.

A coil component is of the type where a helical coil is directly contacting a magnetic body where such coil component still meets the demand for electrical current amplification. The coil component is structured in such a way that a helical coil is covered with a magnetic body. The magnetic body is mainly constituted by magnetic alloy grains and contains substantially no glass component, and each of the magnetic alloy grains has an oxide film of the grain on its surface.

A method for manufacturing a magnetic grain compact, includes: providing multiple metal grains constituted by soft magnetic alloy containing Fe, Si, and a metal element M that oxidizes more easily than Fe; compacting the metal grains; and forming oxide film formed on a surface of the metal grains, and forming first bonding parts where adjacent metal grains are directly contacted and bonded together, and second bonding parts where adjacent metal grains are bonded together via the oxide film formed around the entire surface of said adjacent metal grains other than the first bonding parts, by applying heat treatment to the compacted metal grains, thereby obtaining a magnetic grain compact.

Method for manufacturing magnetic grain compact

A coil component is of the type where a helical coil is directly contacting a magnetic body where such coil component still meets the demand for electrical current amplification. The coil component is structured in such a way that a helical coil is covered with a magnetic body. The magnetic body is mainly constituted by magnetic alloy grains and does not contain glass component, and each of the magnetic alloy grains has an oxide film of the grain on its surface.

A magnetic material constituted by a grain compactobtained by shaping metal grainsand then heat-treating them in an oxidizing ambience, wherein the metal grainsare made of a Fe&#x2014;Cr&#x2014;Si alloy and their Fe/(Fe+Fe) ratio as measured before shaping by XPS, with respect to the sum of integral values at the peaks of 709.6 eV, 710.7 eV and 710.9 eV, or Fe, and peak integral value at 706.9 eV, or Fe, is 0.2 or more.

Magnetic material and coil component using the same

An object is to provide a magnetic material and coil component offering improved magnetic permeability and insulation resistance, while also offering improved high-temperature load, moisture resistance, water absorbency, and other reliability characteristics at the same time. A magnetic material that has multiple metal grains constituted by Fe&#x2014;Si-M soft magnetic alloy (where M is a metal element that oxidizes more easily than Fe), as well as oxide film constituted by an oxide of the soft magnetic alloy and formed on the surface of the metal grains, wherein the magnetic material has bonding parts where adjacent metal grains are bonded together via the oxide film formed on their surface, as well as bonding parts where metal grains are directly bonded together in areas having no oxide film, and resin material is filled in at least some of the voids generating as a result of accumulation of the metal grains.

A magnetic material contains multiple metal grains constituted by soft magnetic alloy and oxide film formed on a surface of the metal grains, which soft magnetic alloy includes Fe and a metal element that oxidizes more easily than Fe, wherein the magnetic material forms a grain compact having first bonding parts where adjacent metal grains are contacted and directly bonded together, second bonding parts where adjacent metal grains are bonded together via the oxide film formed around the entire surface of said adjacent metal grains other than the first bonding parts, and voids formed in an area other than the first and second bonding parts and surrounded by the oxide film.

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Takasaki, Japan

Kenji Otake