CPC H01F 41/04 (2013.01) [B22F 1/16 (2022.01); H01F 1/26 (2013.01); H01F 17/04 (2013.01); H01F 27/2852 (2013.01); H01F 27/292 (2013.01); H01F 41/0246 (2013.01); B22F 2998/10 (2013.01); B22F 2999/00 (2013.01)] | 20 Claims |
1. A method of manufacturing a coil component, comprising steps of:
molding a magnetic material with a base material into an intermediate body including the base material and a substrate body, the base material including a first part and a second part, the first part being surrounded by the substrate body, the second part of the base material being exposed from the substrate body on either side thereof, a main component of the base material being a metal having a lower ionization tendency than iron, the substrate body containing a plurality of metal magnetic particles, a main component of the metal magnetic particles being iron;
after the molding of the intermediate body, bending the second part of the base material on either side into a conductor portion such that the conductor portion includes (i) a buried part surrounded by the substrate body, (ii) an exposed part situated outside the substrate body on either side and (iii) a connecting part connecting the buried part and each exposed part;
after the bending, heating the intermediate body at a first temperature, so that an oxide film containing an oxide of the metal having a lower ionization tendency than iron is formed to cover a surface of the conductor portion; and
after the heating at the first temperature, heating the intermediate body at a second temperature higher than the first temperature (i) to form an oxide coating film containing iron oxide on a surface of each of the metal magnetic particles so that the substrate body is formed into a magnetic base body, (ii) to form the oxide film into an insulating oxide layer containing iron oxide and the metal, and (iii) to anneal the conductor portion.
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