公开(公告)号：US10804026B2

公开(公告)日：2020-10-13

申请号：US15848567

申请日：2017-12-20

申请人： TDK CORPORATION

发明人： Yasuhide Yamashita ,  Katsushi Yasuhara ,  Chiomi Sato

IPC分类号： H01F27/02 ,  H01F27/255 ,  H01F41/04 ,  H01F3/08 ,  H01F17/04 ,  B29C43/14 ,  H01F41/02 ,  B29C43/18 ,  H01F1/36 ,  H01F3/14 ,  B29K101/10 ,  B29K705/00 ,  B29K505/00

摘要： A method of manufacturing an inductor element includes preparing an insert member including a winding portion where a conductor is wound in a coil shape. A plurality of preliminary green compacts is obtained by conducting a preliminary compression molding of a granule containing a magnetic powder and a resin at a pressure of 2.5×102 to 1×103 MPa. The insert member and the plurality of preliminary green compacts are integrated so that a joint interface of the plurality of preliminary green compacts is formed intermittently.

公开(公告)号：US10984941B2

公开(公告)日：2021-04-20

申请号：US15968036

申请日：2018-05-01

申请人： TDK CORPORATION

发明人： Yasuhide Yamashita ,  Katsushi Yasuhara ,  Chiomi Sato ,  Syota Goto

IPC分类号： H01F27/255 ,  H01F17/00 ,  B29C43/18 ,  H01F27/02 ,  H01F41/04 ,  B29C43/14 ,  H01F17/04 ,  H01F1/36 ,  B29L31/34 ,  B29K705/00

摘要： An inductor element includes a wire-winding portion and a core portion. In the wire-winding portion, a conductor is wound in a coil shape. The core portion surrounds the wire-winding portion and contains a magnetic powder and a resin. An inner-core central region is a region of the core portion within a distance from a winding axis center of the wire-winding portion toward an existing region of the wire-winding portion in an outward direction perpendicular to the winding axis center. A top-plate central region is a region of the core portion within a distance from the winding axis center toward a no-existing region of the wire-winding portion in the outward direction. Sα−Sβ≥−2% is satisfied, where Sα (%) and Sβ (%) are respectively an area ratio of the magnetic powder in the inner-core central region and the top-plate central region.

公开(公告)号：US10886056B2

公开(公告)日：2021-01-05

申请号：US15967769

申请日：2018-05-01

申请人： TDK CORPORATION

发明人： Yasuhide Yamashita ,  Katsushi Yasuhara ,  Chiomi Sato

IPC分类号： H01F27/255 ,  H01F3/08 ,  H01F27/28 ,  H01F3/10 ,  H01F17/04 ,  H01F27/02

摘要： An inductor element includes a wire-winding portion and a core portion. In the wire-winding portion, a conductor is wound in a coil shape. The core portion surrounds the wire-winding portion and contains a magnetic powder and a resin. The wire-winding portion includes an inner circumferential surface. A winding-wire inner circumferential neighboring region is a region of the core portion within a distance from the inner circumferential surface toward a winding axis of the wire-winding portion. An inner-core central region is a region of the core portion within a distance from the winding axis center toward an existing region of the wire-winding portion in an outward direction perpendicular to the winding axis center. Sα−Sβ1≥5.0% is satisfied, where Sα(%) and Sβ1(%) are respectively an area ratio of a magnetic powder in the inner-core central region and the winding-wire inner circumferential neighboring region.

公开(公告)号：US11043320B2

公开(公告)日：2021-06-22

申请号：US15915901

申请日：2018-03-08

申请人： TDK CORPORATION

发明人： Masahiro Kamiya ,  Yasuhide Yamashita ,  Chiomi Sato ,  Yousuke Futamata ,  Ryoma Nakazawa ,  Takeshi Takahashi ,  Hiroyuki Ono

IPC分类号： H01F1/24 ,  H01F1/33 ,  H01F3/08 ,  B22F1/02 ,  H01F41/02 ,  C22C38/02 ,  H01F1/26

摘要： A dust core includes a metal magnetic material, a resin, and an insulation film. The insulation film contacts with a surface of the metal magnetic material and covers the metal magnetic material. The insulation film includes a first film and a second film. The first film contacts with the surface of the metal magnetic material. The second film contacts with a surface of the first film. A density of the first film is higher than a density of the second film.

公开(公告)号：US11783988B2

公开(公告)日：2023-10-10

申请号：US17017987

申请日：2020-09-11

申请人： TDK CORPORATION

发明人： Yasuhide Yamashita ,  Katsushi Yasuhara ,  Chiomi Sato

IPC分类号： H01F41/04 ,  H01F41/02 ,  H01F3/04 ,  H01L21/56 ,  H01F27/255 ,  H01F27/02 ,  H01F3/08 ,  H01F17/04 ,  B29C43/14 ,  B29C43/18 ,  H01F1/36 ,  H01F3/14 ,  B29K101/10 ,  B29K705/00 ,  B29K505/00

CPC分类号： H01F27/255 ,  B29C43/14 ,  H01F3/08 ,  H01F17/043 ,  H01F27/02 ,  H01F41/0246 ,  H01F41/04 ,  B29C43/18 ,  B29C2043/182 ,  B29K2101/10 ,  B29K2505/00 ,  B29K2705/00 ,  B29K2995/0008 ,  H01F1/36 ,  H01F3/14 ,  H01F2017/046 ,  H01F2017/048 ,  H01L21/56

摘要： A method of manufacturing an inductor element includes preparing an insert member including a winding portion where a conductor is wound in a coil shape. A plurality of preliminary green compacts is obtained by conducting a preliminary compression molding of a granule containing a magnetic powder and a resin at a pressure of 2.5×102 to 1×103 MPa. The insert member and the plurality of preliminary green compacts are integrated so that a joint interface of the plurality of preliminary green compacts is formed intermittently.

公开(公告)号：US11605490B2

公开(公告)日：2023-03-14

申请号：US16841951

申请日：2020-04-07

申请人： TDK CORPORATION

发明人： Yasuhide Yamashita ,  Chiomi Sato

IPC分类号： H01F27/255 ,  H01F27/02 ,  H01F17/04 ,  H01F3/08 ,  B29C43/18 ,  H01F41/04

摘要： The present invention is an inductor element having a conductor wound in a coil form, and a core part surrounding the coil and including a magnetic powder and a resin. The core part includes a top board part and a bottom board part respectively covering both ends of the coil, and an outer circumference part positioned at an outer circumference side of the coil, and a resin content of the outer circumference part is larger than a resin content of the top board part and also larger than a resin content of the bottom board part.