Abstract: An inductor which has a superior shape retaining property of a coil conductor, is superior in mass-productivity, and can be applied to an automated manufacturing line, and a manufacturing method therefor are provided. The surface of a metal wire provided with an insulating film thereon is coated with a thermal melting resin. The thickness of the thermal melting resin is, for example, approximately 1 &mgr;m. As the thermal melting resin, a thermoplastic resin or a thermosetting resin, such as a polyimide resin or an epoxy resin, containing 85 wt % of a powdered ferrite is used. This coated metal wire is densely wound to form a solenoid-type coil conductor. Next, the thermal melting resin is softened by a heat treatment at, for example, 180° C. and is then solidified by spontaneous cooling. Accordingly, the portions of the coil conductor adjacent to each other are bonded together by the thermal melting resin.

Abstract: A method for efficiently and economically manufacturing an inductor using a resin based magnetic material, and a highly reliable inductor that is manufactured by the method, produces a unique inductor including a molded magnetic material member. An inner conductor is disposed in the molded magnetic material member and is exposed at a surface of the molded magnetic material member.

Abstract: A method of producing a bead inductor includes the steps of forming an outer portion outside of a conductor coil, and forming a molded body with the conductor coil embedded therein. The outer portion is formed outside of the conductor coil by disposing the conductor coil in a cavity defined by first and second mold portions, with first and second gates formed in the first mold portion, inserting first and second spacer pin portions, which define a spacer pin which passes through the conductor coil and extends to and closes the second gate, and supplying material containing magnetic powder into the mold cavity from the first gate. The molded body is formed by closing the first gate after the formation of the outer portion, and supplying from the second gate material containing magnetic powder into a space formed by removing the spacer pin portions.

Abstract: A bead inductor has excellent productivity and increased reliability in the connection between an internal conductor and external terminals. A method for manufacturing such a bead inductor includes the steps of forming an internal conductor and the external terminals as an integral, unitary member such that the external terminals are disposed at both ends of the internal conductor and electrically connected thereto; positioning the integral, unitary member in a metallic mold; and molding a resin material or a rubber material including a powdered magnetic substance in the metallic mold so as to embed the internal conductor therein.

Abstract: A method for efficiently and economically manufacturing an inductor using a resin based magnetic material, and a highly reliable inductor that is manufactured by the method, produces a unique inductor including a molded magnetic material member. An inner conductor is disposed in the molded magnetic material member and is exposed at a surface of the molded magnetic material member.

Abstract: A method of manufacturing a bead inductor prevents deformation of a metal coil or dislocation of the axis position of the metal coil caused by injection pressure at the time of injecting a molten resin material from a gate. A coil is fitted onto a coil supporting pin provided on a first lower mold used for injection molding in a cavity of the mold such that the inner periphery of the coil is in close contact with the coil supporting pin. A molten, resin material is injected into the cavity. Then, the coil supporting pin and the first lower mold are removed from the molded product, and a second lower mold without a coil supporting pin is provided for replacing the first lower mold. A molten resin material is injected into the space which had been occupied by the coil supporting pin. After removing the hardened resin molded product from the mold for injection molding, the end parts of the coil are cut so as to be exposed.

Abstract: A inductor is constructed such that at least about two-thirds of a final winding of wire at each end of an internal conductor-coil embedded in a molded magnetic body project from end surfaces of the molded magnetic body by at least about one-fifth of the diameter of the wire. External electrodes are connected with respective portions of the internal conductor-coil, which are exposed at the respective end surfaces of the molded magnetic body.

Abstract: An inductor includes a coiled metal wire, an insulating molded member in which the coiled metal wire is embedded, and metal caps fitted on both ends of the insulating molded member. The metal caps are welded to both ends of the coiled metal wire. Between the metal caps and the end surfaces of the insulating molded member, spaces are defined respectively. The insulating molded member is made of, for example, resin or rubber.

Abstract: A method of manufacturing a bead inductor includes the steps of forming a molded body of a resin material or a rubber material including a powdery magnetic substance with a conductor coil defined by a wound, coated metallic wire; cutting both ends of the molded body so as to expose the ends of the conductor coil; and attaching external terminals to the exposed ends of the conductor coil so that the external terminals are electrically connected to the conductor coil. The connection reliability between the conductor coil and the external terminals is greatly increased in the bead inductor manufactured by the method because convex portions protruding from the end surfaces of the molded body are provided on both ends of the conductor coil, which are exposed by cutting the molded body, so that the external terminals are attached and electrically connected to the convex portions.

Abstract: A method for manufacturing a bead inductor includes the steps of forming a molded body of a resin material or a rubber material including a powdered magnetic substance, including a conductor coil defined by a wound, coated metallic wire embedded in the molded body; cutting both end portions of the molded body so as to expose end portions of the conductor coil; and attaching external terminals to the exposed end portions of the conductor coil so that the conductor coil is electrically connected to the external terminals. In order to increase the reliability of connection between the conductor coil and external terminals, both end portions of the conductor coil are immersed into a solder bath, prior to the molded body forming step, so as to include in the solder bath cutting regions of both end portions of the molded body therein such that soldered portions are formed by removing insulation coating on both end portions of the conductor coil.

Abstract: A conductor pattern for forming coils and lead-out electrodes which are led out from the coils are formed on a magnetic substance sheet. Furthermore, said magnetic substance sheet is provided with through-holes for connecting the conductor patterns. The magnetic substance sheets disposed respectively just over and just under the conductor pattern that becomes the lead-out electrodes are coated with non-magnetic material paste. A laminated chip common mode choke coil is produced by laminating these magnetic substance sheets and baking them integrally and thereafter forming external electrodes. The non-magnetic material diffuses into the magnetic substance sheet by baking the lamination of the magnetic substance sheets, and the permeability of that portion becomes low. Therefore, the magnetic reluctance around the lead-out electrode becomes high, thus reducing leakage flux around that portion. Thereby, coupling between two coils formed in the choke coil becomes good.