Core (e.g., Compressed Powder) Patents (Class 336/233)
  • Publication number: 20130106559
    Abstract: An amorphous alloy-based magnetic core with reduced audible noise and a method of making the amorphous alloy-based magnetic core emanating low audible noise, including: placing the core with multiple layers of high strength tape on the core legs, wherein the tapes have a high tensile strength, high dielectric strength and high service temperature, resulting in reduced level of audible noise. When operated under optimum condition, the reduced level of audible noise is 6-10 dB less when compared with a same-size core that has been coated with resin instead.
    Type: Application
    Filed: October 28, 2011
    Publication date: May 2, 2013
    Applicant: METGLAS, INC.
    Inventors: Mark Robert Columbus, Robert Brown, Kengo Takahashi, Ryusuke Hasegawa
  • Publication number: 20130106560
    Abstract: A ceramic electronic component includes a ceramic body, an inner electrode, an outer electrode, and a connecting portion. The inner electrode is disposed inside the ceramic body. The end portion of the inner electrode extends to a surface of the ceramic body. The outer electrode is disposed on the surface of the ceramic body so as to cover the end portion of the inner electrode. The outer electrode includes a resin and a metal. The connecting portion is disposed so as to extend from an inside of the outer electrode to an inside of the ceramic body. In a portion of the surface of the ceramic body on which the outer electrode is disposed, the length of the connecting portion that extends in a direction in which the inner electrode is extends about 2.4 ?m or more.
    Type: Application
    Filed: November 2, 2011
    Publication date: May 2, 2013
    Applicant: Murata Manufacturing Co., Ltd.
    Inventors: Kota ZENZAI, Hisayoshi OMORI, Takashi KANAYAMA, Kiyoyasu SAKURADA, Naoki SHIMIZU, Seiji KATSUTA, Shinji OTANI
  • Publication number: 20130093561
    Abstract: A magnetic core includes a first core and a second core, which is formed of material having a lower magnetic permeability and a higher saturation magnetic flux density than those of the first core. The second core forms a closed magnetic path together with the first core. The second core has a distal surface held in contact with the first core. The area of the distal surface is larger than the smallest cross-sectional area of the second core in a direction perpendicular to the flow direction of magnetic flux in the closed magnetic path.
    Type: Application
    Filed: October 11, 2012
    Publication date: April 18, 2013
    Applicant: KABUSHIKI KAISHA TOYOTA JIDOSHOKKI
    Inventor: KABUSHIKI KAISHA TOYOTA JIDOSHOKKI
  • Patent number: 8421574
    Abstract: According to a first aspect, a secondary side of contactless power transmission apparatus includes: a holding member which is physically separated from a primary side; a magnetic layer; a shield layer for shielding electromagnetic noise; and a heat insulation layer. The secondary coil is a planar coil and supported by the holding member, and at least the magnetic layer is laminated on one side of the planar coil and unified with the planar coil. According to a second aspect, the secondary side of the apparatus includes a plurality of magnetic layers. Each permeability of the magnetic layers is different from each other, and each of the magnetic layers forms a magnetic path with the primary side.
    Type: Grant
    Filed: June 12, 2008
    Date of Patent: April 16, 2013
    Assignee: Panasonic Corporation
    Inventors: Masayuki Suzuki, Hiroyasu Kitamura, Satoru Inakagata, Atsushi Isaka, Tatsuhiko Keishu
  • Patent number: 8415948
    Abstract: A current sensor includes an annular magnetic core that includes a closed magnetic path including a void in a portion thereof, and a magnetic body for focusing flux of a magnetic field generated around a conductor that carries a measured current, and a magnetic detecting portion for detecting flux of a magnetic field generated in the void of the magnetic core. The magnetic core includes a plurality of pairs of stepped portions on a pair of opposing end surfaces that form the void, the stepped portions descending along a direction separating from the conductor.
    Type: Grant
    Filed: January 12, 2010
    Date of Patent: April 9, 2013
    Assignee: Kabushiki Kaisha Tokai Rika Denki Seisakusho
    Inventors: Hiroshi Ueno, Kouichi Itoigawa
  • Patent number: 8416043
    Abstract: A multi-phase coupled inductor includes a powder core material magnetic core and first, second, third, and fourth terminals. The coupled inductor further includes a first winding at least partially embedded in the core and a second winding at least partially embedded in the core. The first winding is electrically coupled between the first and second terminals, and the second winding electrically is coupled between the third and fourth terminals. The second winding is at least partially physically separated from the first winding within the magnetic core. The multi-phase coupled inductor is, for example, used in a power supply.
    Type: Grant
    Filed: February 9, 2011
    Date of Patent: April 9, 2013
    Assignee: Volterra Semiconductor Corporation
    Inventor: Alexandr Ikriannikov
  • Patent number: 8416044
    Abstract: A reactor is composed of a coil and a core placed in the inside area and outer peripheral area of the coil in a container. The core is composed of magnetic powder, non-magnetic powder, and resin. The non-magnetic powder is composed of main component powder and low elastic modulus powder. The main component powder as a main component of the non-magnetic powder is made of one or more kinds of powder of a heat conductivity which is larger than that of the resin. The low elastic modulus powder is made of one or more kinds of powder of an elastic modulus which is smaller than that of the powder forming the main component powder.
    Type: Grant
    Filed: November 16, 2009
    Date of Patent: April 9, 2013
    Assignees: Denso Corporation, NEC Tokin Corporation
    Inventors: Kenji Saka, Takashi Yanbe
  • Patent number: 8416052
    Abstract: The invention comprises an inductor configured for filtering medium and/or high voltage power. The inductor includes an inductor core formed of a plurality of coated magnetic particles, each of a majority of the coated magnetic particles including: a magnetic particle core and a non-magnetic coating about a corresponding magnetic particle core. The inductor optionally includes: (1) a main inductor spacer separating a first turn of a winding from a terminal turn of the winding and (2) a segmenting spacer separating two consecutive turns of the winding about said core. The inductor is configured to convert power into an output current, such as power of at least one thousand five hundred volts with an input current of at least fifty amperes.
    Type: Grant
    Filed: January 31, 2012
    Date of Patent: April 9, 2013
    Inventor: Grant A. MacLennan
  • Patent number: 8416051
    Abstract: A magnetic material constituted by a grain-compacted body comprising a plurality of metal grains made of a Fe—Si—M soft magnetic alloy (where M is a metal element more easily oxidized than Fe) and an oxide film formed on the surface of the metal grains; wherein there are bonding portions via the oxide film formed on the surfaces of adjacent metal grains and direct bonding portions of metal grains in locations where the oxide film is not present.
    Type: Grant
    Filed: December 7, 2011
    Date of Patent: April 9, 2013
    Assignee: Taiyo Yuden Co., Ltd.
    Inventors: Hitoshi Matsuura, Kenji Otake
  • Publication number: 20130082815
    Abstract: A soft magnetic alloy element of high magnetic permeability that allows for easy quality check is constituted by a grain compact including: multiple metal grains 11 constituted by a Fe—Cr—Si soft magnetic alloy; oxide films formed on the surface of the metal grains; and connection parts via the oxide films formed on the surface of adjacent metal grains; wherein, in color difference measurement on the grain compact 1 based on the L*a*b* color system, a* (D65) is ?3 to 5 and b* (D65) is ?8 to 0, and preferably L* (D65) is 22 to 35, as well as an electronic component having such element.
    Type: Application
    Filed: September 26, 2012
    Publication date: April 4, 2013
    Applicant: TAIYO YUDEN CO., LTD.
    Inventor: TAIYO YUDEN CO., LTD.
  • Publication number: 20130076477
    Abstract: The present invention provides a Fe-group-based soft magnetic powder that is used for the pressed powder magnetic cores for a choke coil, reactor coil, etc., and that has a higher magnetic permeability. At least one selected from Fe, Co, or Ni that is generally used is used as the main component of the Fe-group-based alloy (iron-based alloy) soft magnetic powder. The soft magnetic powder is produced by adding a small amount of Nb (0.05-4 wt %) or V, Ta, Ti, Mo, or W, to the molten metal and by means of an inexpensive method such as the water-atomizing method.
    Type: Application
    Filed: June 7, 2011
    Publication date: March 28, 2013
    Inventor: Yasushi Kino
  • Patent number: 8395472
    Abstract: The present invention provides a means to integrate planar coils on silicon, while providing a high inductance. This high inductance is achieved through a special back- and front sided shielding of a material. In many applications, high-value inductors are a necessity. In particular, this holds for applications in power management. In these applications, the inductors are at least 5 of the order of 1 ?H, and must have an equivalent series resistance of less than 0.1?. For this reason, those inductors are always bulky components, of a typical size of 2×2×1 mm 3, which make a fully integrated solution impossible. On the other hand, integrated inductors, which can monolithically be integrated, do exist. However, these inductors suffer either from low inductance values, or 10 very-high DC resistance values.
    Type: Grant
    Filed: June 30, 2009
    Date of Patent: March 12, 2013
    Assignee: NXP B.V.
    Inventors: Freddy Roozeboom, Derk Reefman, Johan Hendrik Klootwijk, Lukas Frederik Tiemeijer, Jaap Ruigrok
  • Patent number: 8390415
    Abstract: A coil component 10 includes: a magnetic core made of a magnetic alloy; a coil having a spiral part placed around a pillar part of the magnetic core; a magnetic sheath formed on the magnetic core in a manner covering the coil except for the bottom face of the magnetic core; and a first external terminal and second external terminal formed on the magnetic core and magnetic sheath; wherein the magnetic sheath has numerous voids inside.
    Type: Grant
    Filed: February 17, 2012
    Date of Patent: March 5, 2013
    Assignee: Taiyo Yuden Co., Ltd.
    Inventors: Hideki Ogawa, Tsuyoshi Matsumoto
  • Patent number: 8378777
    Abstract: A magnetic component and a method for manufacturing a low profile, magnetic component. The method comprises the steps of providing at least one sheet, coupling at least a portion of at least one winding to the at least one sheet, and laminating the at least one sheet with at least a portion of the at least one winding. The magnetic component comprises at least one sheet and at least a portion of at least one winding coupled to the at least one sheet, wherein the at least one sheet is laminated to at least a portion of the at least one winding. The winding may comprise a clip, a preformed coil, a stamped conductive foil, or an etched trace using chemical or laser etching. The sheet may comprise any material capable of being laminated and/or rolled, including, but not limited to, flexible magnetic powder sheets.
    Type: Grant
    Filed: July 29, 2008
    Date of Patent: February 19, 2013
    Assignee: Cooper Technologies Company
    Inventors: Yipeng Yan, Robert James Bogert
  • Publication number: 20130038420
    Abstract: Provided are a green compact from which a low-loss core can be formed, a method of manufacturing the green compact, and a core for a reactor using the green compact. Parts of outer circumferential surfaces of green compacts 41 and 42 are molded with an inner peripheral surface of a through hole 10hA of a die 10A, and the other parts are molded with an outer circumferential surface of a core rod 13A that is inserted and disposed in the through hole 10hA. A raw-material powder P, which is a coated soft magnetic powder, is fed into compacting spaces 31 and 32 and pressurized by using a lower punch 12 (first punch) and an upper punch 11 (second punch). Then, the green compacts 41 and 42 are removed from the compacting spaces 31 and 32 by moving the die 10A with respect to the green compacts 41 and 42 without moving the core rod 13A with respect to the green compacts 41 and 42.
    Type: Application
    Filed: February 16, 2012
    Publication date: February 14, 2013
    Applicants: SUMITOMO ELECTRIC SINTERED ALLOY, LTD., SUMITOMO ELECTRIC INDUSTRIES, LTD.
    Inventors: Masato Uozumi, Atsushi Sato, Kazushi Kusawake
  • Publication number: 20130033354
    Abstract: Disclosed herein are a ferrite powder having a core-shell structure, the core being made of iron (Fe) or iron-based compounds comprising iron (Fe) and the shell being made of metal oxides, a ferrite material comprising the ferrite powder and the glass, and multilayered chip components including the ferrite layer using the ferrite material, inner electrodes, and outer electrodes. According to the exemplary embodiments of the present invention, it is possible to provide the ferrite material capable of improving the change in the inductance L value in response to applied current by suppressing magnetization at high current. The multilayered chip components including the ferrite material according to the exemplary embodiment of the present invention can also be used in a band of MHz.
    Type: Application
    Filed: August 1, 2012
    Publication date: February 7, 2013
    Inventors: Sung Yong An, Myeong Gi Kim, Ic Seob Kim
  • Patent number: 8358191
    Abstract: An inductor may include an electrical conductor for generating a magnetic field; and at least one inductor core unit which is arranged in the region of the conductor and includes an inductor core composed of a magnetizable material and also at least one air gap, a filling material being introduced at least into part of the air gap for the purpose of mechanical stabilization, wherein the filling material is configured in such a way that it has a coefficient of thermal expansion, the value of which lies in a range of ±70% of the value of the coefficient of thermal expansion of the magnetizable material of which the inductor core is composed.
    Type: Grant
    Filed: November 24, 2008
    Date of Patent: January 22, 2013
    Assignee: Osram Gesellschaft mit beschraenkter Haftung
    Inventors: Friedrich Witzani, Andreas Huber
  • Publication number: 20130015939
    Abstract: The present invention provides a powder magnetic core which has a low iron loss and an excellent constancy of magnetic permeability and is suitably used as a core for a reactor mounted on a vehicle. The powder magnetic core is a compact of a mixed powder containing an iron-based soft magnetic powder having an electrical insulating coating formed on its surface and a powder of a low magnetic permeability material having a heat-resistant temperature of 700° C. or higher than 700° C. and a relative magnetic permeability of not more than 1.0000004. The density of the compact is 6.7 Mg/m3 or more, and the low magnetic permeability material exists in the gap among the soft magnetic powder particles in the green compact.
    Type: Application
    Filed: March 25, 2011
    Publication date: January 17, 2013
    Applicant: HITACHI POWDERED METALS CO. LTD.
    Inventors: Takashi Inagaki, Chio Ishihara
  • Patent number: 8350657
    Abstract: A power management module, provides an inductor including one or more electrical conductors disposed around a ferromagnetic ceramic element including one or more metal oxides having fluctuations in metal-oxide compositional uniformity less than or equal to 1.50 mol % throughout the ceramic element.
    Type: Grant
    Filed: January 4, 2007
    Date of Patent: January 8, 2013
    Inventor: L. Pierre deRochemont
  • Publication number: 20130002391
    Abstract: Disclosed herein are a multilayered power inductor including a magnetic layer having a structure in which a metal magnetic powder is distributed on a glass substrate, a composition for the magnetic layer, and a method for preparing a multilayered power inductor. According to an exemplary embodiment of the present invention, the multilayered power inductor including a magnetic layer obtained by mixing the metal magnetic powder having high Ms with the glass substrate has excellent bias characteristics having small variations in capacity even when high current is applied. In addition, the exemplary embodiment of the present invention can use Cu as an inner electrode, instead of an expensive precious metal Ag.
    Type: Application
    Filed: June 27, 2012
    Publication date: January 3, 2013
    Inventors: Ic Seob KIM, Soo Hwan SON, Sung Yong AN, Jin Woo HAHN, Byeong Cheol MOON
  • Publication number: 20120326831
    Abstract: A coil component comprises: a coil bobbin, which has a coil-winding section in an outer circumferential portion so that a coil is to be wound on the coil-winding section, and which has a through-hole in a central portion thereof; a first core and a second core, which have a plurality of magnetic legs respectively, wherein a certain leg of the plurality of the magnetic legs of the first core and a certain leg of the plurality of the magnetic legs of the second core are inserted into the through-hole of the coil bobbin to face each other with a predetermined gap, and wherein facing surfaces of the certain legs of the magnetic legs are fixed by an adhesive; and a protective cover, which is positioned between the coil bobbin and the certain legs to suppress the adhesive from being attached to the coil bobbin.
    Type: Application
    Filed: June 13, 2012
    Publication date: December 27, 2012
    Applicant: MINEBEA CO., LTD.
    Inventors: Mitsuaki SUZUKI, Masahiro TANAKA
  • Publication number: 20120319812
    Abstract: The main purpose of this invention is to improve high forming pressure of existing Fe—Si—Al insulating magnetic powder which is not suitable for forming, combine heterogeneous insulating magnetic powder, produce hollow cup-like cover and Fe—Si—Al rod core for full magnetic path component assembling, and change the shape structure of rod core and cover design, so there will be advantages including easy to winding, assemble and cooling.
    Type: Application
    Filed: June 20, 2011
    Publication date: December 20, 2012
    Inventor: S. R. SHANG
  • Patent number: 8330568
    Abstract: A multilayer coil component includes internal conductors made of silver (Ag) having metal films provided on surfaces thereof to suppress migration of Ag contained in the internal conductors and/or relieve internal stress between magnetic ceramic layers and internal conductor layers without forming gaps at interfaces between the internal conductors including the metal films and a magnetic ceramic surrounding the internal conductors and the interfaces between the internal conductors and the magnetic ceramic. In a manufacturing method for forming a multilayer coil, an acidic solution containing a metal is allowed to penetrate a magnetic ceramic through side surfaces thereof and side gap sections that are regions between side portions of internal conductors and the side surfaces to reach the interfaces between the internal conductors and a surrounding magnetic ceramic, whereby the metal is deposited on surfaces of the internal conductors.
    Type: Grant
    Filed: October 25, 2010
    Date of Patent: December 11, 2012
    Assignee: Murata Manufacturing Co., Ltd.
    Inventors: Masaharu Konoue, Yukio Maeda, Tatsuya Mizuno, Hiroki Hashimoto, Mitsuru Ueda
  • Patent number: 8327524
    Abstract: Disclosed herein is an inductive component whose soft magnetic core is produced by pouring a casting resin into a mold filled with a soft magnetic alloy powder and by subsequently hardening the casting resin with the alloy powder in order to form a solid soft magnetic core. This technique prevents the surface insulation of the alloy particles from becoming damaged, thereby largely preventing the formation of bulky eddy currents in the resulting soft magnetic cores. This enables a distinct reduction in the electric loss of the inductive component.
    Type: Grant
    Filed: August 31, 2007
    Date of Patent: December 11, 2012
    Assignee: Vacuumscmelze GmbH & Co. KG
    Inventor: Markus Brunner
  • Patent number: 8327523
    Abstract: There is provided a method of making two electrically separated inductors using deposition and wet-etching techniques, which inductors are formed by interwinding one of the inductors within the other inductor on the same planar level. In still another aspect of the invention, there is provided a method of making various levels inductors, each level having at least two electrically separated inductors, using deposition and wet-etching techniques. The inductors on each planar level are formed by interwinding one of the inductors within the other inductor, and then stacking these in a preferred manner. In still another aspect, there is provided a manner of connecting together inductors formed according to the above methods in order to achieve various inductor configurations.
    Type: Grant
    Filed: November 28, 2006
    Date of Patent: December 11, 2012
    Assignee: Semiconductor Components Industries, LLC
    Inventors: Adam J. Whitworth, Wenjiang Zeng
  • Publication number: 20120286920
    Abstract: A composite material can include a grain component and a nanostructured grain boundary component. The nanostructured grain boundary component can be insulating and magnetic, so as to provide greater continuity of magnetization of the composite material. The grain component can have an average grain size of about 0.5-50 micrometers. The grain boundary component can have an average grain size of about 1-100 nanometers. The nanostructured magnetic grain boundary material has a magnetic flux density of at least about 250 mT. The grain component can comprise MnZn ferrite particles. The nanostructured grain boundary component can comprise NiZn ferrite nanoparticles. Core components and systems thereof can be manufactured from the composite material.
    Type: Application
    Filed: May 8, 2012
    Publication date: November 15, 2012
    Inventors: Yajie Chen, Vincent G. Harris
  • Patent number: 8310332
    Abstract: A magnetic component and a method of manufacturing the same. The method comprises the steps of providing at least one shaped-core fabricated from an amorphous powder material, coupling at least a portion of at least one winding to the at least one shaped-core, and pressing the at least one shaped-core with at least a portion of the at least one winding. The magnetic component comprises at least one shaped-core fabricated from an amorphous powder material and at least a portion of at least one winding coupled to the at least one shaped-core, wherein the at least one shaped-core is pressed to at least a portion of the at least one winding. The winding may be preformed, semi-preformed, or non-preformed and may include, but is not limited to, a clip or a coil. The amorphous powder material may be an iron-based or cobalt-based amorphous powder material or a nanoamorphous powder material.
    Type: Grant
    Filed: October 8, 2008
    Date of Patent: November 13, 2012
    Assignee: Cooper Technologies Company
    Inventors: Yipeng Yan, Robert James Bogert
  • Publication number: 20120274437
    Abstract: A magnetic material constituted by a grain-compacted body comprising a plurality of metal grains made of a Fe—Si—M soft magnetic alloy (where M is a metal element more easily oxidized than Fe) and an oxide film formed on the surface of the metal grains; wherein there are bonding portions via the oxide film formed on the surfaces of adjacent metal grains and direct bonding portions of metal grains in locations where the oxide film is not present.
    Type: Application
    Filed: December 7, 2011
    Publication date: November 1, 2012
    Applicant: TAIYO YUDEN CO., LTD.
    Inventors: Hitoshi MATSUURA, Kenji OTAKE
  • Publication number: 20120262266
    Abstract: An alloy is provided which consists of Fe100-a-b-c-d-x-y-zCuaNbbMcTdSixByZz and up to 1 at % impurities, M being one or more of the elements Mo, Ta and Zr, T being one or more of the elements V, Mn, Cr, Co and Ni, Z being one or more of the elements C, P and Ge, 0 at %?a<1.5 at %, 0 at %?b<2 at %, 0 at %?(b+c)<2 at %, 0 at %?d<5 at %, 10 at %<x<18 at %, 5 at %<y<11 at % and 0 at %?z<2 at %. The alloy is configured in tape form and has a nanocrystalline structure in which at least 50 vol % of the grains have an average size of less than 100 nm, a hysteresis loop with a central linear region, a remanence ratio Jr/Js of <0.1 and a coercive field strength Hc to anisotropic field strength Ha ratio of <10%.
    Type: Application
    Filed: April 16, 2012
    Publication date: October 18, 2012
    Applicant: Vacuumschmelze GmbH & Co. KG
    Inventors: Giselher HERZER, Christian Polak, Viktoria Budinsky
  • Patent number: 8284010
    Abstract: An inductor includes a coil electrode section in which a first spiral electrode and a second spiral electrode are wound in substantially the same direction, lie in substantially the same plane, and are connected to each other by a connection electrode. The coil electrode section is sandwiched by the first magnetic layer and the second magnetic layer from both directions substantially perpendicular to the plane. A first protrusion electrode and a second protrusion electrode at ends of the first spiral electrode and the second spiral electrode that are opposite to the connection electrode extend in a direction substantially perpendicular to the plane, have a length at which each of the protrusion electrodes protrudes from the first magnetic layer, and define opposite end electrodes of the inductor. Arranging this low-profile inductor on a mounting circuit board achieves a low-profile DC-DC converter including a two-layer structure.
    Type: Grant
    Filed: August 30, 2010
    Date of Patent: October 9, 2012
    Assignee: Murata Manufacturing Co., Ltd.
    Inventors: Hitoshi Tsuji, Sadao Yamashita, Takao Kakinoki
  • Patent number: 8279037
    Abstract: Magnetic component assemblies and core structures including coil coupling arrangements, that are advantageously utilized in providing surface mount magnetic components such as inductors and transformers.
    Type: Grant
    Filed: July 23, 2009
    Date of Patent: October 2, 2012
    Assignee: Cooper Technologies Company
    Inventors: Yipeng Yan, Robert James Bogert
  • Patent number: 8269595
    Abstract: A coil unit includes a planar coil, a coil-receiving housing having a depression that receives the planar coil, the planar coil being disposed in the coil-receiving housing so that a transmission side of the planar coil faces a bottom of the depression, and a substrate having a mounting surface that is provided with a mounted component and faces a non-transmission side of the planar coil, an inner end lead line and an outer end lead line of the planar coil being connected to the substrate. The substrate is secured as a lid of the coil-receiving housing on an open end side of the depression of the coil-receiving housing.
    Type: Grant
    Filed: July 10, 2008
    Date of Patent: September 18, 2012
    Assignee: Seiko Epson Corporation
    Inventors: Hirofumi Okada, Yoichiro Kondo
  • Publication number: 20120229245
    Abstract: Provided is a soft magnetic powder used for obtaining a dust core having a low hysteresis loss, in particular, in a high temperature range. A soft magnetic powder includes an aggregate of composite magnetic particles, each including a soft magnetic particle containing Fe, Si, and Al, and an insulating coating film disposed on the surface thereof, and satisfies the expressions (1) and (2) below: Expression (1) . . . 27?2.5a+b?29 and Expression (2) . . . 6?b?9, where a represents the Si content (mass %) and b represents the Al content (mass %). The soft magnetic powder is capable of reducing the hysteresis loss, in a high-temperature environment, of a dust core obtained using the soft magnetic powder.
    Type: Application
    Filed: May 17, 2011
    Publication date: September 13, 2012
    Applicant: SUMITOMO ELECTRIC INDUSTRIES, LTD
    Inventors: Asako Watanabe, Toru Maeda
  • Publication number: 20120229244
    Abstract: There are provided a dust core in which, even if the surface of a heat-treated compact is ground, the insulation between soft magnetic particles on the ground surface can be ensured in the grinding step, and a method for producing the dust core. The method includes a preparation step of preparing a heat-treated compact 100 by compacting soft magnetic particles having an insulation coating and heating the resultant compact to a predetermined temperature; and a machining step of removing part of the heat-treated compact 100 using a working tool 2. The machining step is performed while an electric current is supplied with a conductive fluid 7L between the heat-treated compact 100 serving as an anode and a working tool 2 that machines the heat-treated compact 100 or a first counter electrode 5 that faces the working tool 2 with a distance therebetween, the working tool 2 or the first counter electrode 5 serving as a cathode.
    Type: Application
    Filed: May 16, 2011
    Publication date: September 13, 2012
    Applicant: Sumitomo Electric Industries, ltd.
    Inventors: Tomoyuki Ueno, Takao Nishioka
  • Publication number: 20120194309
    Abstract: The present invention provides a material which can be used for low pressure molding, and which has a low core loss while maintaining the characteristic of an amorphous powder that is the high coercive force. It provides a magnetic powder material containing, relative to the weight thereof, amorphous powders of 45 to 80 wt %, crystalline powders of 55 to 20 wt %, and a bonding agent. The magnetic powder material contains, relative to the mass thereof, Si of 4.605 to 6.60 mass %, Cr of 2.64 to 3.80 mass %, C of 0.225 to 0.806 mass %, Mn of 0.018 to 0.432 mass %, B of 0.99 to 2.24 mass %, P of equal to or less than 0.0248 mass %, S of equal to or less than 0.0165 mass %, Co of equal to or less than 0.0165 mass %, and a balance of Fe and inevitable impurities.
    Type: Application
    Filed: September 22, 2011
    Publication date: August 2, 2012
    Applicant: SUMIDA CORPORATION
    Inventor: Akihiko NAKAMURA
  • Patent number: 8212641
    Abstract: An electronic device including a core, at least a wire and a magnetic material is provided. The core includes a pillar, a top board and a bottom board. The pillar is disposed between the top board and the bottom board. An area of the top board is smaller than an area of the bottom board. A winding space is fanned among the top board, the bottom board and the pillar. The wire is winded around the pillar and located in the winding space. The magnetic material fills the winding space to encapsulate the wire. The magnetic material includes a resin and a metallic powder, wherein an average particle diameter of the magnetic powder is smaller than 20 ?m.
    Type: Grant
    Filed: February 22, 2010
    Date of Patent: July 3, 2012
    Assignee: Cyntec Co., Ltd.
    Inventors: Tsung-Chan Wu, Roger Hsieh, Yi-Min Huang, Lan-Chin Hsieh
  • Publication number: 20120139680
    Abstract: The invention comprises an inductor configured for filtering medium and/or high voltage power. The inductor includes an inductor core formed of a plurality of coated magnetic particles, each of a majority of the coated magnetic particles including: a magnetic particle core and a non-magnetic coating about a corresponding magnetic particle core. The inductor optionally includes: (1) a main inductor spacer separating a first turn of a winding from a terminal turn of the winding and (2) a segmenting spacer separating two consecutive turns of the winding about said core. The inductor is configured to convert power into an output current, such as power of at least one thousand five hundred volts with an input current of at least fifty amperes.
    Type: Application
    Filed: January 31, 2012
    Publication date: June 7, 2012
    Applicant: CTM Magnetics, Inc.
    Inventor: Grant A. MacLennan
  • Patent number: 8164410
    Abstract: A low-loss ferrite comprising as main components 46.5-49.5% by mol of Fe2O3, 17-26% by mol of ZnO, 4-12% by mol of CuO, and 0.2% or more and less than 1.2% by mol of CoO, the balance being NiO, and 0.03-1.4% by mass (as SnO2) of Sn based on 100% by mass of the main components, and having an average crystal grain size of 0.7-2.5 ?m, and an electronic device obtained by integrally sintering pluralities of layers of this low-loss ferrite and coil-shaped electrodes formed in the laminate.
    Type: Grant
    Filed: April 16, 2008
    Date of Patent: April 24, 2012
    Assignee: Hitachi Metals, Ltd.
    Inventors: Satoru Tanaka, Takeshi Tachibana
  • Publication number: 20120092112
    Abstract: A circuit element is provided for mounting in an electrical connector. The circuit element includes a one-piece toroidal core made of a sintered, ferrite material. The core has a central bore therein defining an inner surface, an outer surface and oppositely facing top and bottom surfaces, and a plurality of equally spaced apart longitudinal channels formed in one of the top, bottom, inner and outer surfaces. A plurality of wires are twisted together in a uniform, repeating pattern to define a group of twisted wires. The group of twisted wires extends through the central bore and is wrapped around the core to define a plurality of uniformly spaced longitudinal turns with a portion of each turn being positioned in one of the channels.
    Type: Application
    Filed: April 14, 2010
    Publication date: April 19, 2012
    Applicant: Molex Incorporated
    Inventors: Timothy R. McClelland, Johnny Chen
  • Publication number: 20120092111
    Abstract: An Fe-based amorphous alloy of the present invention has a composition formula represented by Fe100-a-b-c-x-y-z-tNiaSnbCrcPxCyBzSit, and in the formula, 0 at %?a?10 at %, 0 at %?b?3 at %, 0 at %?c?6 at %, 6.8 at %?x?10.8 at %, 2.2 at %?y?9.8 at %, 0 at %?z?4.2 at %, and 0 at %?t?3.9 at % hold. Accordingly, an Fe-based amorphous alloy used for a powder core and/or a coil encapsulated powder core having a low glass transition temperature (Tg), a high conversion vitrification temperature (Tg/Tm), and excellent magnetization and corrosion resistance can be manufactured.
    Type: Application
    Filed: December 19, 2011
    Publication date: April 19, 2012
    Applicant: ALPS GREEN DEVICES CO., LTD.
    Inventors: Keiko TSUCHIYA, Hisato KOSHIBA, Kazuya KANEKO, Seiichi ABIKO, Takao MIZUSHIMA
  • Publication number: 20120086534
    Abstract: A choke includes a single-piece core entirely made of a same material, the single-piece core having two boards and a pillar located between the two boards, a winding space being located among the two boards and the pillar, wherein the pillar has a non-circular and non-rectangular cross section along a direction substantially perpendicular to an axial direction of the pillar, the cross section of the pillar has a first axis and a second axis intersecting with each other at a center of the cross section of the pillar and are substantially perpendicular with each other, the first axis is longer than the second axis, and the cross section of the pillar is substantially symmetrical to both of the first axis and the second axis.
    Type: Application
    Filed: December 20, 2011
    Publication date: April 12, 2012
    Inventors: Tsung-Chan Wu, Roger Hsieh, Yi-Min Huang, Lan-Chin Hsieh, Yu-Ching Kuo
  • Publication number: 20120081204
    Abstract: The invention relates to a transformer construction comprising a plurality of transformer cores configured to share magnetic flux paths and, as a result, at least one of the cores comprises a post and an associated sidewall having an effective cross-sectional area which is less than that of the post. Such a construction may be employed in a power conditioning unit, for example, for a photovoltaic module, which is configured to operate the cores out of phase from each other. Also described is a transformer winding comprising a longitudinal spine having a first turn emanating from a first portion of the spine in a first transverse direction and a second turn emanating from a second portion of the spine in a second transverse direction, wherein the second transverse direction is opposite to the first transverse direction.
    Type: Application
    Filed: November 15, 2011
    Publication date: April 5, 2012
    Inventors: Paul Garrity, Arturo Silva
  • Patent number: 8130069
    Abstract: The invention comprises an electrical system including at least an inductor configured to carry a magnetic field of less than about thirty Gauss/Oersted. The inductor comprises an inductor core having a plurality of coated particles, each of a majority of the coated particles comprising: at least three layers, a first set of substantially magnetic alternating layers composed of an alloy, and a second set of substantially non-magnetic alternating layers, where the coated particles are about evenly distributed in the inductor core. Optionally, a thermal transfer agent is used to cool the inductor, where the thermal transfer agent includes at least one of: a thermally conductive potting material and a substantially non-conductive liquid coolant in direct contact with the inductor. Optionally, a cooling coil passes through the potting material and/or the liquid coolant.
    Type: Grant
    Filed: June 1, 2011
    Date of Patent: March 6, 2012
    Inventor: Grant A. MacLennan
  • Publication number: 20120049994
    Abstract: Disclosed herein is an inductor core usable with an interleaved Power Factor Correction (PFC) circuit. The inductor core for a power factor correction circuit, the inductor core may include: a first leg on which a first inductor is wound; a second leg on which a second inductor is wound, wherein the first and second inductors are alternately operable in an interleaved manner; and a third leg provided between the first leg and the second leg, wherein the third leg has a different shape from that of the first leg and the second leg.
    Type: Application
    Filed: February 15, 2011
    Publication date: March 1, 2012
    Applicant: SAMSUNG ELECTRONICS CO., LTD.
    Inventors: Sung Yong JOO, Jin Hyung LEE
  • Publication number: 20120032768
    Abstract: Linear variable differential transformers include a core comprising a non-ferromagnetic material and a ferromagnetic material, and a coil assembly including an axial bore within which the core is disposed and through which the core axially translates.
    Type: Application
    Filed: August 3, 2010
    Publication date: February 9, 2012
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: Richard Fox, Gene Holden, Robert Franconi
  • Publication number: 20120001719
    Abstract: Provided is a dust core and a method for manufacturing a thereof, having an effect that the soft magnetic powder is prevented from sintering and bonding together upon heating, the hysteresis loss can be effectively reduced, and the DC B-H characteristics is excellent. In a first mixing process, a soft magnetic powder composed mainly of iron and an inorganic insulating powder of 0.4 wt %-1.5 wt % are mixed by a mixer. A mixture obtained in the first mixing process is heated in a non-oxidizing atmosphere at 1000° C. or more and below a sintering temperature of the soft magnetic powder. In a binder addition process, a silane coupling agent of 0.1-0.5 wt % is added. A binder, e.g. a silicone resin of 0.5-2.0 wt % is added to the soft magnetic alloy powder to which the inorganic insulating powder is attached by the silane coupling agent, and the soft magnetic alloy powders are bonded to each other so as to be granulated.
    Type: Application
    Filed: April 28, 2010
    Publication date: January 5, 2012
    Inventors: Yasuo Oshima, Susumu Handa, Kota Akaiwa
  • Publication number: 20110317318
    Abstract: Ferroic circuit elements that include a set of conductive structures that are at least partially embedded within a ferroic medium are disclosed. The ferroic medium may be a voltage switched dielectric material that includes ferroic particles in accordance with various embodiments. A ferroic circuit element may be at least partially embedded within a substrate in accordance with embodiments of the current invention as an embedded ferroic circuit element. An embedded ferroic circuit element that is an inductor in accordance with embodiments of the current invention may be denoted as an embedded ferroic inductor. An embedded ferroic circuit element that is a capacitor in accordance with embodiments of the current invention may be denoted as an embedded ferroic capacitor.
    Type: Application
    Filed: May 24, 2011
    Publication date: December 29, 2011
    Inventors: Robert Fleming, Bhret Graydon, Daniel Vasquez, Junjun Wu, Farhad Razavi
  • Patent number: 8082655
    Abstract: A method includes forming a winding structure from a single sheet of electrically conductive material, where the winding structure includes a winding base and multiple winding extensions extending from the winding base as a continuous piece of the electrically conductive material. The multiple winding extensions include a base portion that extends from the winding base along a first face of a fully assembled magnetic core, a wrapping portion that extends from the base portion along a second face of the fully assembled magnetic core, and a connection portion that extends from the wrapping portion along a third face of the fully assembled magnetic core, the connection portion comprising an electrical connection surface. The base portion, the wrapping portion, and the connection portion of each winding extend from the winding base such that the integrated windin structure is shaped for placement over the full assembled magnetic core in a single motion.
    Type: Grant
    Filed: May 9, 2011
    Date of Patent: December 27, 2011
    Assignee: International Business Machines Corporation
    Inventors: Chu T. Chung, Chien H. Lin, Randhir S. Malik, Robert Wei
  • Patent number: 8072304
    Abstract: A noncontact power-transmission coil is provided. The noncontact power-transmission coil includes a planar coil and a magnetic layer. The planar coil is formed by winding a linear conductor in a spiral shape substantially in a single plane. The magnetic layer is formed by applying a liquid-form magnetic solution in which magnetic particles are mixed with a binder solvent, so as to cover one planar portion of the planar coil and a side-face portion of the planar coil.
    Type: Grant
    Filed: January 7, 2008
    Date of Patent: December 6, 2011
    Assignees: Sony Ericsson Mobile Communications Japan, Inc., Seiko Epson Corporation
    Inventors: Hiroshi Kato, Kuniharu Suzuki, Katsuya Suzuki, Manabu Yamazaki, Yoichiro Kondo, Kota Onishi, Kentaro Yoda, Mikimoto Jin, Takahiro Kamijo, Haruhiko Sogabe
  • Publication number: 20110279217
    Abstract: A Mn—Zn ferrite core includes a basic component, sub-components, and unavoidable impurities, wherein, as the sub-components, silicon oxide (in terms of SiO2): 50 to 400 mass ppm and calcium oxide (in terms of CaO): 50 to 4000 mass ppm are added to the basic component consisting of iron oxide (in terms of Fe2O3): 51.0 to 54.5 moil, zinc oxide (in terms of ZnO): 8.0 to 12.0 moil, and manganese oxide (in terms of MnO): balance; amounts of phosphorus, boron, sulfur, and chlorine in the unavoidable impurities are reduced as follows, phosphorus: less than 3 mass ppm, boron: less than 3 mass ppm, sulfur: less than 5 mass ppm, and chlorine: less than 10 mass ppm; and a ratio of a measured specific surface of the Mn—Zn ferrite core to an ideal specific surface of the Mn—Zn ferrite core satisfies: Measured specific surface/ideal specific surface<1500 - - - (1).
    Type: Application
    Filed: January 29, 2010
    Publication date: November 17, 2011
    Applicant: JFE CHEMICAL CORPORATION
    Inventors: Hirofumi Yoshida, Yukiko Nakamura, Satoshi Goto