Claims
- 1. An inductor component comprising:
a magnetic core having at least one magnetic gap, each of which has a gap length of about 50 to 10,000 μm in a magnetic path; a magnet for magnetic bias arranged in the neighborhood of the magnetic gap in order to supply magnetic bias from both sides of the magnetic gap; and a coil having at least one turn applied to the magnetic core, wherein: the magnet for magnetic bias is a bonded magnet comprising a resin and a magnet powder dispersed in the resin and having a resistivity of 1 Ω·cm or more; the magnet powder comprising a rare-earth magnet powder having an intrinsic coercive force of 5 KOe or more, a Curie point of 300° C. or more, a maximum particle diameter of 150 μm or less, and an average particle diameter of 2 to 50 μm and coated with inorganic glass; and the rare-earth magnet powder is selected from the group consisting of a Sm—Co magnet powder, Nd—Fe—B magnet powder, and Sm—Fe—N magnet powder.
- 2. The inductor component according to claim 1, wherein the permanent magnet for magnetic bias is molded by die molding.
- 3. The inductor component according to claim 2, wherein the permanent magnet for magnetic bias has a molding compressibility of 20% or more.
- 4. The inductor component according to claim 1, wherein the surface of the permanent magnet for magnetic bias is coated with a heat-resistant resin or heat-resistant coating having a heat resistance temperature of 120° C. or more.
- 5. The inductor component according to claim 1, wherein the inorganic glass has a softening point of 220° C. to 550° C.
- 6. The inductor component according to claim 1, wherein the content of the inorganic glass is 10% by weight or less.
- 7. The inductor component according to claim 1, wherein the content of the resin is 20% or more, the resin being at least one selected from the group consisting of polypropylene resins, 6-nylon resins, 12-nylon resins, polyimide resins, polyethylene resins, and epoxy resins.
- 8. An inductor component to be subjected to a solder reflow treatment, comprising:
a magnetic core having at least one magnetic gap each of which has a gap length of about 50 to 10,000 μm in a magnetic path; a magnet for magnetic bias arranged in the neighborhood of the magnetic gap in order to supply magnetic bias from both sides of the magnetic gap; and a coil having at least one turn applied to the magnetic core, wherein: the magnet for magnetic bias is a bonded magnet comprising a resin and a magnet powder dispersed in the resin and having a resistivity of 1 Ω·cm or more; and the magnet powder comprises a Sm—Co rare-earth magnet powder having an intrinsic coercive force of 10 KOe or more, a Curie point of 500° C. or more, a maximum particle diameter of 150 μm or less, and an average particle diameter of 2.5 to 50 μm and coated with inorganic glass.
- 9. The inductor component according to claim 8, wherein the permanent magnet for magnetic bias is molded by die molding.
- 10. The inductor component according to claim 9, wherein the permanent magnet for magnetic bias has a molding compressibility of 20% or more.
- 11. The inductor component according to claim 8, wherein the surface of the permanent magnet for magnetic bias is coated with a heat-resistant resin or heat-resistant coating having a heat resistance temperature of 270° C. or more.
- 12. The inductor component according to claim 8, wherein the SmCo rare-earth magnet powder is an alloy powder represented by Sm(CobalFe0.15 to 0.25Cu0.05 to 0.06Zr0.02 to 0.03)7.0 to 8.5.
- 13. The inductor component according to claim 8, wherein the inorganic glass has a softening point of 220° C. to 500° C.
- 14. The inductor component according to claim 8, wherein the content of the inorganic glass is 10% by weight or less.
- 15. The inductor component according to claim 8, wherein the content of the resin is 30% by volume or more, and the resin being at least one selected from the group consisting of polyimide resins, poly(amide-imide) resins, epoxy resins, poly(phenylene sulfide) resins, silicone resins, polyester resins, aromatic polyamide resins, and liquid crystal polymers.
- 16. An inductor component comprising:
a magnetic core comprising at least one magnetic gap having a gap length of about 500 μm or less in a magnetic path; a magnet for magnetic bias arranged in the neighborhood of the magnetic gap in order to supply magnetic bias from both sides of the magnetic gap; and a coil having at least one turn applied to the magnetic core, wherein: the magnet for magnetic bias is a bonded magnet comprising a resin and a magnet powder dispersed in the resin and having a resistivity of 0.1 Ω·cm or more and a thickness of 500 μm or less; the magnet powder comprises a rare-earth magnet powder having an intrinsic coercive force of 5 KOe or more, a Curie point of 300° C. or more, a maximum particle diameter of 150 μm or less, and an average particle diameter of 2.0 to 50 μm; and the rare-earth magnet powder is selected from the group consisting of a Sm—Co magnet powder, Nd—Fe—B magnet powder, and Sm—Fe—N magnet powder, and is coated with inorganic glass.
- 17. The inductor component according to claim 16, wherein the permanent magnet for magnetic bias is molded from a mixture of the resin and magnet powder by a film making method, such as a doctor blade method and printing method.
- 18. The inductor component according to claim 16, wherein the permanent magnet for magnetic bias has a molding compressibility of 20% or more.
- 19. The inductor component according to claim 16, wherein the surface of the permanent magnet for magnetic bias is coated with a heat-resistant resin or heat-resistant coating having a heat resistance temperature of 120° C. or more.
- 20. The inductor component according to claim 16, wherein the inorganic glass has a softening point of 220° C. to 500° C.
- 21. The inductor component according to claim 16, wherein the content of the inorganic glass is 10% by weight or less in the permanent magnet.
- 22. The inductor component according to claim 16, wherein the content of the resin is 20% or more, and the resin is at least one selected from the group consisting of polypropylene resins, 6-nylon resins, 12-nylon resins, polyimide resins, polyethylene resins, and epoxy resins.
- 23. An inductor component to be subjected to a solder reflow treatment, comprising:
a magnetic core having at least one magnetic gap each of which has a gap length of about 500 μm or less in a magnetic path; a magnet for magnetic bias arranged in the neighborhood of the magnetic gap in order to supply magnetic bias from both sides of the magnetic gap; and a coil having at least one turn applied to the magnetic core, wherein: the magnet for magnetic bias is a bonded magnet comprising a resin and a magnet powder dispersed in the resin and having a resistivity of 0.1 Ω·cm or more and a thickness of 500 μm or less; and the magnet powder comprises a Sm—Co rare-earth magnet powder having an intrinsic coercive force of 10 KOe or more, a Curie point of 500° C. or more, a maximum particle diameter of 150 μm or less, and an average particle diameter of 2.5 to 50 μm and coated with inorganic glass.
- 24. The inductor component according to claim 23, wherein the permanent magnet for magnetic bias is molded from a mixture of the resin and magnet powder by a film making method, such as a doctor blade method and printing method.
- 25. The inductor component according to claim 23, wherein the permanent magnet for magnetic bias has a molding compressibility of 20% or more.
- 26. The inductor component according to claim 23, wherein the inorganic glass has a softening point of 220° C. to 500° C.
- 27. The inductor component according to claim 23, wherein the content of the inorganic glass is 10% by weight or less in the permanent magnet.
- 28. The inductor component according to claim 23, wherein the surface of the permanent magnet for magnetic bias is coated with a heat-resistant resin or heat-resistant coating having a heat resistance temperature of 270° C or more.
- 29. The inductor component according to claim 23, wherein the SmCo rare-earth magnet powder is an alloy powder represented by Sm(CobalFe0.15 to 0.25Cu0.05 to 0.06Zr0.02 to 0.03)7.0 to 8.5.
- 30. The inductor component according to claim 23, wherein the content of the resin is 30% by volume or more, the resin being at least one selected from the group consisting of polyimide resins, poly(amide-imide) resins, epoxy resins, poly(phenylene sulfide) resins, silicone resins, polyester resins, aromatic polyamide resins, and liquid crystal polymers.
Priority Claims (3)
Number |
Date |
Country |
Kind |
364074/2000 |
Nov 2000 |
JP |
|
364132/2000 |
Nov 2000 |
JP |
|
117665/2001 |
Apr 2001 |
JP |
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application is a divisional application of U.S. application Ser. No. 09/997,066 filed Nov. 29, 2001.
Divisions (1)
|
Number |
Date |
Country |
Parent |
09997066 |
Nov 2001 |
US |
Child |
10844014 |
May 2004 |
US |