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1. 发明授权

US06791445B2 Coil-embedded dust core and method for manufacturing the same 有权
公开(公告)号：US06791445B2
公开(公告)日：2004-09-14
申请号：US10078947
申请日：2002-02-19
申请人： Kazuhiko Shibata , Takashi Nagasaka , Junetsu Tamura , Yasuhiko Kitajima , Hideharu Moro , Tsutomu Chou , Tsuneo Suzuki
发明人： Kazuhiko Shibata , Takashi Nagasaka , Junetsu Tamura , Yasuhiko Kitajima , Hideharu Moro , Tsutomu Chou , Tsuneo Suzuki
IPC分类号： H01F2702
CPC分类号： H01F17/04 , H01F27/027 , H01F41/0246 , H01F41/127 , H01F2017/046 , Y10T29/4902 , Y10T29/49071
摘要： 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.

2. 发明授权

US06940387B2 Coil-embedded dust core and method for manufacturing the same 有权
标题翻译：线圈式防尘芯及其制造方法
公开(公告)号：US06940387B2
公开(公告)日：2005-09-06
申请号：US10816630
申请日：2004-04-02
申请人： Kazuhiko Shibata , Takashi Nagasaka , Junetsu Tamura , Yasuhiko Kitajima , Hideharu Moro , Tsutomu Chou , Tsuneo Suzuki
发明人： Kazuhiko Shibata , Takashi Nagasaka , Junetsu Tamura , Yasuhiko Kitajima , Hideharu Moro , Tsutomu Chou , Tsuneo Suzuki
IPC分类号： H01F17/04 , H01F27/02 , H01F27/29 , H01F41/02 , H01F41/04 , H01F41/12 , H01F5/00
CPC分类号： H01F17/04 , H01F27/027 , H01F41/0246 , H01F41/127 , H01F2017/046 , Y10T29/4902 , Y10T29/49071
摘要： 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.
摘要翻译：提供了一种线圈嵌入式防尘芯和一种用于制造线圈嵌入式防尘芯的方法。线圈嵌入式防尘芯包括由缠绕在线圈构造中的扁平导体形成的线圈和由绝缘材料涂覆的铁磁性金属颗粒组成的生坯体。这导致线圈嵌入式防尘芯体的尺寸更小，但电感更大。可以使用矩形线作为扁平导体。此外，线圈的部分可以用作端子部分。在这种情况下，线圈的端子部分可以形成为比线圈的其它部分更宽。线圈嵌入式防尘芯不容易发生线圈和端子部分之间的接合故障，并且线圈和端子部分相对于磁粉的绝缘故障。线圈嵌入式防尘芯更紧凑，同时实现更大的电感。

3. 发明申请

US20050219027A1 Method for manufacturing coil-embedded dust core and coil-embedded dust core 有权
标题翻译：线圈嵌入式防尘芯和线圈嵌入式防尘芯的制造方法
公开(公告)号：US20050219027A1
公开(公告)日：2005-10-06
申请号：US11140348
申请日：2005-05-26
申请人： Sadaki Satoh , Junetsu Tamura , Hideharu Moro , Tsuneo Suzuki
发明人： Sadaki Satoh , Junetsu Tamura , Hideharu Moro , Tsuneo Suzuki
IPC分类号： B22F7/08 , A61B8/08 , H01F17/04 , H01F41/10 , H01F27/02
CPC分类号： A61B8/145 , A61B8/08 , A61B8/4483 , Y10T29/4902 , Y10T29/49071 , Y10T29/49073
摘要： It is an object to provide a method for manufacturing a coil-embedded dust core with a small variation in inductance value with efficiency and the like. A step (a) of charging soft magnetic metal powder including an insulating material, composing a green body 10, so as to cover a coil 1, and a step (b) of compacting the soft magnetic metal powder covering the coil 1 in an axial direction of the coil 1 are included, and 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. Thereby, a coil-embedded dust core with entirely uniform density can be obtained, and according to the coil-embedded dust core with entirely uniform density, a variation in inductance value is reduced and it becomes possible to obtain a predetermined inductance value with stability.
摘要翻译：本发明的目的是提供一种制造具有效率等的电感值变化小的线圈嵌入式防尘芯的方法。包括构成生坯体10的绝缘材料的软磁性金属粉末以覆盖线圈1的步骤（a）和将轴向覆盖线圈1的软磁性金属粉末压实的步骤（b）包括线圈1的方向，并且在步骤（b）中，将软磁性金属粉末压实，同时将填充到与绕组部分相对应的部分中的软金属粉末的量保持为小于软磁体的量将卷绕部的上表面或下表面作为基准加入到不对应于卷绕部的另一部分的金属粉末。由此，可以获得密度完全均匀的线圈嵌入式防尘芯，根据密度完全均匀的线圈嵌入式防尘芯，电感值的变化减小，可以稳定地获得规定的电感值。

4. 发明授权

US07415757B2 Method for manufacturing inductor having coil embedded dust core 有权
标题翻译：具有线圈嵌入式集尘芯的电感器制造方法
公开(公告)号：US07415757B2
公开(公告)日：2008-08-26
申请号：US11140348
申请日：2005-05-26
申请人： Sadaki Satoh , Junetsu Tamura , Hideharu Moro , Tsuneo Suzuki
发明人： Sadaki Satoh , Junetsu Tamura , Hideharu Moro , Tsuneo Suzuki
IPC分类号： H01F7/06
CPC分类号： A61B8/145 , A61B8/08 , A61B8/4483 , Y10T29/4902 , Y10T29/49071 , Y10T29/49073
摘要： 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 10, so as to cover a coil 1, and (b) compacting the soft magnetic metal powder covering the coil 1 in an axial direction of the coil 1. 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.
摘要翻译：具有效率的电感值变化小的线圈嵌入式防尘芯的制造方法包括对构成生坯体10的包含绝缘材料的软磁性金属粉末进行充电以覆盖线圈1的步骤（a）和（b）在线圈1的轴向压实覆盖线圈1的软磁性金属粉末。在步骤（b）中，软磁金属粉末被压实，而被加入到与绕组部分相对应的部分中的软金属粉末的量保持小于装入另一部分的软磁金属粉末的量不对应于绕组部分，其中绕组部分的上表面或下表面作为参考。

5. 发明申请

US20050030143A9 Method for manufacturing coil-embedded dust core and coil-embedded dust core 审中-公开
标题翻译：线圈嵌入式防尘芯和线圈嵌入式防尘芯的制造方法
公开(公告)号：US20050030143A9
公开(公告)日：2005-02-10
申请号：US10392322
申请日：2003-03-19
申请人： Sadaki Satoh , Junetsu Tamura , Hideharu Moro , Tsuneo Suzuki
发明人： Sadaki Satoh , Junetsu Tamura , Hideharu Moro , Tsuneo Suzuki
IPC分类号： B22F7/08 , A61B8/08 , H01F17/04 , H01F41/10 , H01F5/00
CPC分类号： A61B8/145 , A61B8/08 , A61B8/4483 , Y10T29/4902 , Y10T29/49071 , Y10T29/49073
摘要： It is an object to provide a method for manufacturing a coil-embedded dust core with a small variation in inductance value with efficiency and the like. A step (a) of charging soft magnetic metal powder including an insulating material, composing a green body 10, so as to cover a coil 1, and a step (b) of compacting the soft magnetic metal powder covering the coil 1 in an axial direction of the coil 1 are included, and 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. Thereby, a coil-embedded dust core with entirely uniform density can be obtained, and according to the coil-embedded dust core with entirely uniform density, a variation in inductance value is reduced and it becomes possible to obtain a predetermined inductance value with stability.
摘要翻译：本发明的目的是提供一种制造具有效率等的电感值变化小的线圈嵌入式防尘芯的方法。包括构成生坯体10的绝缘材料的软磁性金属粉末以覆盖线圈1的步骤（a）和将轴向覆盖线圈1的软磁性金属粉末压实的步骤（b）包括线圈1的方向，并且在步骤（b）中，将软磁性金属粉末压实，同时将填充到与绕组部分相对应的部分中的软金属粉末的量保持为小于软磁体的量将卷绕部的上表面或下表面作为基准加入到不对应于卷绕部的另一部分的金属粉末。由此，可以获得密度完全均匀的线圈嵌入式防尘芯，根据密度完全均匀的线圈嵌入式防尘芯，电感值的变化减小，可以稳定地获得规定的电感值。

6. 发明授权

US06759935B2 Coil-embedded dust core production process, and coil-embedded dust core formed by the production process 有权
标题翻译：线圈嵌入式粉尘芯生产工艺，以及生产过程中形成的线圈埋尘芯
公开(公告)号：US06759935B2
公开(公告)日：2004-07-06
申请号：US09754126
申请日：2001-01-05
申请人： Hideharu Moro , Tsuneo Suzuki , Tsutomu Chou , Jyunetsu Tamura , Sadaki Sato
发明人： Hideharu Moro , Tsuneo Suzuki , Tsutomu Chou , Jyunetsu Tamura , Sadaki Sato
IPC分类号： H01F2702
CPC分类号： H01F41/005 , B22F7/08 , H01F41/0246 , H01F2017/046 , Y10T29/4902 , Y10T29/49071 , Y10T29/49073 , Y10T29/5313
摘要： The invention provides a process for producing a coil-embedded dust core by embedding a coil in magnetic powders comprising ferromagnetic metal particles coated with an insulating material. At the first compression molding step one portion of magnetic powders is filled in a molding die and then compression molded to form a lower core. At a coil positioning step the coil is positioned on the upper surface of the lower core in the molding die. At a coil embedding step another portion of magnetic powders is again filled in the molding die in such a way that the coil is embedded in these magnetic powders. At the second compression molding step pressure is applied to the lower core and coil in the direction of lamination thereof.
摘要翻译：本发明提供了一种通过将线圈嵌入包含涂有绝缘材料的铁磁金属颗粒的磁性粉末中来生产线圈嵌入式防尘芯的方法。在第一压缩成型步骤中，将一部分磁性粉末填充在成型模具中，然后压缩模制以形成下芯。在线圈定位步骤中，线圈定位在成型模具中的下芯的上表面上。在线圈嵌入步骤中，将另一部分磁粉再次填充在成型模具中，使得线圈嵌入这些磁粉中。在第二压缩成形步骤中，在下层芯和线圈的层压方向施加压力。

7. 发明申请

US20080237532A1 POWDER MAGNETIC CORE 审中-公开
标题翻译：粉末磁芯
公开(公告)号：US20080237532A1
公开(公告)日：2008-10-02
申请号：US12054119
申请日：2008-03-24
申请人： Hideharu Moro , Sadaki Satoh , Tsuneo Suzuki
发明人： Hideharu Moro , Sadaki Satoh , Tsuneo Suzuki
IPC分类号： H01F1/01
CPC分类号： H01F1/26 , B22F2998/00 , C22C33/0278 , C22C2202/02 , H01F27/255 , H01F41/0246 , B22F1/0062
摘要： The object of the present invention is to provide a powder magnetic core having higher dielectric withstand voltage properties than conventional powder magnetic cores, while keeping magnetic permeability at a similar or higher level than in conventional powder magnetic cores. In order to achieve the above object, the present invention provides a powder magnetic core containing a magnetic material powder and a binder resin, wherein the apparent density D of the powder magnetic core, the abundance E of the magnetic material powder in the surface of the powder magnetic core, the mass ratio Rm of the magnetic material powder relative to the powder magnetic core, and the true density Dm of the magnetic material powder satisfy the condition represented by expression (1) Vc>E−a×(D·Rm/Dm)2/3×100 (1) (in expression (1), the units of D and Dm are g/cm3, the unit of E is %, and Rm is unitless. Vc denotes a predefined threshold value, and a denotes a predefined coefficient).
摘要翻译：本发明的目的是提供一种具有比常规粉末磁芯更高的介电耐受性能的粉末磁芯，同时将磁导率保持在与常规粉末磁芯相似或更高的水平。为了实现上述目的，本发明提供一种含有磁性材料粉末和粘合剂树脂的粉末磁芯，其中粉末磁芯的表观密度D，磁性材料粉末表面的磁性材料粉末的丰度E 粉末磁芯，磁性材料粉末相对于粉末磁芯的质量比Rm和磁性材料粉末的真密度Dm满足由式（1）表示的条件<？in-line-formula description =“In 线公式“end =”lead“？> Vc> E-ax（D.Rm / Dm）2/3 x100（1）<？in-line-formula description =”In-line （式（1）中，D和Dm的单位为g / cm 3，E的单位为％，Rm为无单位，Vc表示预定阈值，a表示预定系数）。

8. 发明授权

US06882261B2 Coil-embedded dust core and method for manufacturing the same, and coil and method for manufacturing the same 有权
标题翻译：线圈式防尘芯及其制造方法，线圈及其制造方法
公开(公告)号：US06882261B2
公开(公告)日：2005-04-19
申请号：US10350825
申请日：2003-01-24
申请人： Hideharu Moro , Tsuneo Suzuki
发明人： Hideharu Moro , Tsuneo Suzuki
IPC分类号： H01F1/22 , H01F17/04 , H01F27/02 , H01F27/255 , H01F27/28 , H01F27/29 , H01F41/02 , H01F41/04 , H01F5/00
CPC分类号： H01F41/0246 , H01F27/022 , H01F27/027 , H01F27/255 , H01F27/2847 , H01F27/29 , H01F41/04 , H01F2017/046
摘要： There are provided a coil-embedded dust core that provides high inductance and a method for manufacturing the same. The coil-embedded dust core includes a coil 1 formed by winding a flat conductor 2 and a green body 10 comprising of ferromagnetic metal powder coated with an insulating material. The coil 1 is composed of a winding section 3 in which the flat conductor 2 having front and back surfaces opposed to each other with a predetermined distance is wound and lead-out end sections 4a and 4b that are extended from the winding section 3. Either one of the front and back surfaces of the lead-out end section 4a and either one of the front and back surfaces of the lead-out end section 4b are formed so as to be on the same plane. By using the coil 1 in which the both end sections (lead-out end sections 4a and 4b) are formed on the same plane, the coil-embedded dust core can be made smaller in size, and high inductance can be provided.
摘要翻译：提供了一种提供高电感的线圈嵌入式防尘芯及其制造方法。线圈嵌入式防尘芯包括通过缠绕扁平导体2和包含由绝缘材料涂覆的强磁性金属粉末的生坯体10形成的线圈1。线圈1由卷绕部3构成，卷绕部3将具有预定距离的彼此相对的前后表面的扁平导体2卷绕，并且从卷绕部3延伸的引出端部4a，4b 。引出端部分4a的前后表面之一和引出端部分4b的前表面和后表面中的任一个形成为在同一平面上。通过使用在同一平面上形成两端部（引出端部4a和4b）的线圈1，可以使线圈嵌入式防尘芯体的尺寸更小，并且可以提供高电感。

9. 发明授权

US06527823B2 Powder for dust cores and dust core 有权
公开(公告)号：US06527823B2
公开(公告)日：2003-03-04
申请号：US09891685
申请日：2001-06-26
申请人： Hideharu Moro
发明人： Hideharu Moro
IPC分类号： C22C104
CPC分类号： H01F41/0246 , H01F3/08 , H01F27/255
摘要： To provide a powder for dust cores capable of improving magnetic properties such as magnetic permeability in a molded compacted powder magnetic core and mechanical properties such as size precision of the molded compacted powder magnetic core and radial crushing strength and, a dust core using the powder. A powder for a dust core contains a ferromagnetic powder, an insulating material containing silicone resin and/or phenol resin, and a lubricant, wherein the lubricant contains aluminum stearate, and a dust core using the powder for a dust core.

10. 发明授权

US06940388B2 Dust core 有权
标题翻译：防尘芯
公开(公告)号：US06940388B2
公开(公告)日：2005-09-06
申请号：US10412174
申请日：2003-04-11
申请人： Hideharu Moro
发明人： Hideharu Moro
IPC分类号： H01F1/26 , H01F3/08 , H01F27/255 , H01F41/02 , H01F27/24
CPC分类号： H01F41/0246 , H01F3/08 , H01F27/255 , Y10T29/49032
摘要： A dust core consists essentially of ferromagnetic powder; and an insulating binder, in which the ferromagnetic powder is dispersed; wherein the insulating binder is a silicone resin comprising a trifunctional alkyl-phenyl silicone resin and optionally containing an inorganic insulator such as an inorganic oxide, carbide or nitride. Preferably the alkyl-phenyl silicone resin is a methyl-phenyl silicone resin and comprises about 20 to 70 mol % of trifunctional groups. The dust core can be produced by pressure-molding a ferromagnetic powder, a lubricant and a trifunctional alkyl-phenyl silicone resin binder and heat treating the molded core at a temperature in the range of about 300 to about 800 ° C. for a time period in the range of about 20 minutes to about 2 hours in a non-oxidizing atmosphere. The dust core has high magnetic permeability representing the direct current superimposition characteristics, has reduced core loss and has increased mechanical strength.
摘要翻译：防尘芯主要由铁磁粉末组成; 和分散有铁磁粉末的绝缘粘合剂; 其中所述绝缘粘合剂是包含三官能烷基 - 苯基有机硅树脂并任选地含有无机氧化物，碳化物或氮化物的无机绝缘体的有机硅树脂。烷基 - 苯基硅氧烷树脂优选为甲基 - 苯基有机硅树脂，并且包含约20至70mol％的三官能团。可以通过对铁磁性粉末，润滑剂和三官能烷基 - 苯基有机硅树脂粘合剂进行加压成型，并在约300〜约800℃的温度范围内对成型的芯部进行热处理一段时间在非氧化气氛中约20分钟至约2小时的范围内。防尘芯具有较高的导磁率，代表直流叠加特性，降低了磁芯损耗，增加了机械强度。

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