US 11,996,233 B2
Method of manufacturing coil component
Takayuki Arai, Tokyo (JP); and Tomoo Kashiwa, Tokyo (JP)
Assigned to TAIYO YUDEN CO., LTD., Tokyo (JP)
Filed by TAIYO YUDEN CO., LTD., Tokyo (JP)
Filed on Dec. 31, 2021, as Appl. No. 17/566,989.
Claims priority of application No. 2021-020895 (JP), filed on Feb. 12, 2021.
Prior Publication US 2022/0262563 A1, Aug. 18, 2022
Int. Cl. H01F 41/04 (2006.01); B22F 1/16 (2022.01); H01F 1/26 (2006.01); H01F 17/04 (2006.01); H01F 27/28 (2006.01); H01F 27/29 (2006.01); H01F 41/02 (2006.01)
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
OG exemplary drawing
 
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.