公开(公告)号：US11183320B2

公开(公告)日：2021-11-23

申请号：US16663514

申请日：2019-10-25

Applicant: TDK CORPORATION

Inventor： Kyohei Tonoyama ,  Ken Satoh ,  Kentaro Saito ,  Miyuki Asai ,  Hitoshi Ohkubo

IPC: H01F1/20 ,  B22F1/00 ,  B22F1/02 ,  H01F1/24 ,  C22C38/08 ,  C22C38/16 ,  C22C38/00 ,  C22C38/12

Abstract: A magnetic core includes a metal magnetic powder, which has a large size powder, an intermediate size powder, and a small size powder. A particle size of the large size powder is 10 μm or more and 60 μm or less. A particle size of the intermediate size powder is 2.0 μm or more and less than 10 μm. A particle size of the small size powder is 0.1 μm or more and less than 2.0 μm. The large size powder, the intermediate size powder, and the small size powder have an insulation coating. When A1 represents an average insulation coating thickness of the large size powder, A2 represents an average insulation coating thickness of the intermediate size powder, A3 represents an average insulation coating thickness of the small size powder, A3 is 30 nm or more and 100 nm or less, A3/A1≥1.3, and A3/A2≥1.0.

公开(公告)号：US10943719B2

公开(公告)日：2021-03-09

申请号：US16877944

申请日：2020-05-19

Applicant: TDK CORPORATION

Inventor： Miyuki Asai ,  Hokuto Eda ,  Masazumi Arata ,  Hitoshi Ohkubo

IPC: H01F5/06 ,  H01F17/00

Abstract: In a coil component, an insulation layer covers an upper surface of a conductor pattern. Accordingly, insulating properties between the conductor pattern and a magnetic body are enhanced, and insulating properties between the conductor patterns are enhanced. In addition, in the coil component, the magnetic body enters a space between resin walls such that the insulation layer is covered. Therefore, a volume of the magnetic body above the conductor pattern is increased, and high coil characteristics are realized.

公开(公告)号：US10559417B2

公开(公告)日：2020-02-11

申请号：US15166519

申请日：2016-05-27

Applicant: TDK CORPORATION

Inventor： Hitoshi Ohkubo ,  Masazumi Arata ,  Manabu Ohta ,  Yuuya Kaname ,  Yoshihiro Maeda ,  Takahiro Kawahara ,  Hokuto Eda ,  Shigeki Sato

IPC: H01F5/00 ,  H01F27/32

Abstract: A coil component in which a change in thicknesses of the winding part is prevented is provided. According to the coil component, since each of a pair of neighboring resin walls and a seed part between the pair of resin walls are separated by a predetermined distance, a plating part grown on the seed part is easy to grow uniformly between the pair of neighboring resin walls. For this reason, the winding part whose surface is gentle and in which a change in thickness is prevented is obtained by plating growth.

公开(公告)号：US10210974B2

公开(公告)日：2019-02-19

申请号：US14952028

申请日：2015-11-25

Applicant: TDK CORPORATION

Inventor： Hitoshi Ohkubo ,  Masazumi Arata ,  Manabu Ohta ,  Shou Kawadahara ,  Yoshihiro Maeda ,  Takahiro Kawahara ,  Hokuto Eda ,  Shigeki Sato

IPC: H01F1/24 ,  H01F17/00 ,  H01F17/04 ,  H01F27/29

Abstract: In a coil component (planar coil element), at least part of a third metal magnetic powder constituting a metal magnetic powder and having a minimum average grain diameter is uncoated, which suppresses a reduction in magnetic permeability. On the other hand, the remaining metal powders are coated with glass, which improves the insulating properties of a metal magnetic powder-containing resin and reduces core loss.

公开(公告)号：US20250111968A1

公开(公告)日：2025-04-03

申请号：US18899295

申请日：2024-09-27

Applicant: TDK Corporation

Inventor： Kazuhiro YOSHIDOME ,  Hiroyuki Matsumoto ,  Shota Otsuka ,  Masashi Ito ,  Hitoshi Ohkubo

IPC: H01F3/08 ,  H01F1/20 ,  H01F41/02

Abstract: A soft magnetic metal powder includes soft magnetic metal particles with a particle size of 5.0 μm or more. (y95/y50−y90/y50)/(0.95−0.90) is 20.0 or less, where y95 (μm) denotes D95, y90 (μm) denotes D90, and y50 (μm) denotes D50 of a particle size distribution of the soft magnetic metal particles with a particle size of 5.0 μm or more. A magnetic core includes soft magnetic metal particles with a Heywood diameter of 5.0 μm or more in a section of the magnetic core. (Y95/Y50−Y90/Y50)/(0.95−0.90) is 20.0 or less, where Y95 (μm) denotes D95, Y90 (μm) denotes D90, and Y50 (μm) denotes D50 of a particle size distribution of the soft magnetic metal particles with a Heywood diameter of 5.0 μm or more.

公开(公告)号：USD1053135S1

公开(公告)日：2024-12-03

申请号：US29821080

申请日：2021-12-27

Applicant: TDK CORPORATION

Designer： Hokuto Eda ,  Hitoshi Ohkubo ,  Masazumi Arata ,  Masataro Saito ,  Kohei Takahashi ,  Takamasa Iwasaki

公开(公告)号：US11894174B2

公开(公告)日：2024-02-06

申请号：US17093808

申请日：2020-11-10

Applicant: TDK CORPORATION

Inventor： Hitoshi Ohkubo ,  Manabu Ohta ,  Ryo Fukuoka ,  Hironori Kimata

IPC: H01F27/28 ,  H01F17/04

CPC classification number: H01F17/04 ,  H01F27/2804 ,  H01F2017/048

Abstract: In a coil component, a height h1 of a pedestal portion of a resin wall corresponds to the height position of a step portion. In addition, a height of a seed portion corresponds to the plating start position at a time when a winding portion of a coil is plated and grown. The plating start position and the step portion are designed to be close to each other by the height h1 of the pedestal portion and the height h2 of the seed portion satisfying 0.3≤h1/h2≤10. Accordingly, although the coil component has a configuration in which the resin wall has the step portion, the inside of the step portion is sufficiently filled with a coil conductor, and thus deterioration of characteristics is suppressed.

公开(公告)号：US11680307B2

公开(公告)日：2023-06-20

申请号：US17502323

申请日：2021-10-15

Applicant: TDK CORPORATION

Inventor： Kyohei Tonoyama ,  Ken Satoh ,  Kentaro Saito ,  Miyuki Asai ,  Hitoshi Ohkubo

IPC: C22C38/12 ,  H01F1/20 ,  C22C38/16 ,  C22C38/00 ,  H01F1/24 ,  C22C38/08 ,  B22F1/05 ,  B22F1/16 ,  B22F1/052 ,  B22F1/07

CPC classification number: C22C38/12 ,  B22F1/05 ,  B22F1/052 ,  B22F1/07 ,  B22F1/16 ,  C22C38/002 ,  C22C38/005 ,  C22C38/08 ,  C22C38/16 ,  H01F1/20 ,  H01F1/24 ,  B22F2301/355 ,  B22F2304/10

Abstract: A magnetic core includes a metal magnetic powder, which has a large size powder, an intermediate size powder, and a small size powder. A particle size of the large size powder is 10 μm or more and 60 μm or less. A particle size of the intermediate size powder is 2.0 μm or more and less than 10 μm. A particle size of the small size powder is 0.1 μm or more and less than 2.0 μm. The large size powder, the intermediate size powder, and the small size powder have an insulation coating. When A1 represents an average insulation coating thickness of the large size powder, A2 represents an average insulation coating thickness of the intermediate size powder, A3 represents an average insulation coating thickness of the small size powder, A3 is 30 nm or more and 100 nm or less, A3/A1≥1.3, and A3/A2≥1.0.

公开(公告)号：US11049641B2

公开(公告)日：2021-06-29

申请号：US15363938

申请日：2016-11-29

Applicant: TDK Corporation

Inventor： Hitoshi Ohkubo ,  Kyohei Tonoyama ,  Shigeki Sato

IPC: H01F5/00 ,  H01F27/255 ,  H01F17/00 ,  H01F17/04 ,  H01F27/02 ,  H01F27/28 ,  H01F27/29 ,  H01F27/32 ,  H01F27/42

Abstract: A coil device comprising a coil, and a magnetic metal powder containing resin covering said coil. Said magnetic metal powder comprises at least two types of magnetic metal powders with different D50. The magnetic metal powder having larger D50 is defined as a large diameter powder, and the magnetic metal powder having smaller D50 is defined as a small diameter powder among the two types of said magnetic metal powder. Said large diameter powder is made of iron or iron based alloy. Said small diameter powder is made of Ni—Fe alloy. Said small diameter powder has D50 of 0.5 to 1.5 μm. Said large diameter powder and said small diameter powder respectively comprises an insulation coating layer.

公开(公告)号：US11043329B2

公开(公告)日：2021-06-22

申请号：US16027742

申请日：2018-07-05

Applicant: TDK CORPORATION

Inventor： Hitoshi Ohkubo ,  Masazumi Arata ,  Takahiro Kawahara ,  Hokuto Eda ,  Hiroki Tsujiai

IPC: H01F27/28 ,  H01F27/32 ,  H01F41/04 ,  H01F27/29 ,  H01F17/04 ,  H01F17/00 ,  H05K1/16 ,  H05K1/18

Abstract: In a planar coil element, a dead space in a non-overlapping region is reduced by designing a total width of a first resin wall and a first turn located in the non-overlapping region to be narrow, more specifically, by designing the total width to be narrower than a total width of a second turn outside the first turn and a second resin wall located inside the turn and also than a total width of a third turn on the outer side and a third resin wall located inside the turn. As a result, a volume of a magnetic element body in a magnetic core portion of a coil can be increased, and an, inductance value, which is a magnetic characteristic, can also be improved.