Patents by Inventor Kyohei Tonoyama
Kyohei Tonoyama has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 11680307Abstract: A magnetic core includes a metal magnetic powder, which has a large size powder, an intermediate size powder, and a small size powder. A particle size of the large size powder is 10 ?m or more and 60 ?m or less. A particle size of the intermediate size powder is 2.0 ?m or more and less than 10 ?m. A particle size of the small size powder is 0.1 ?m or more and less than 2.0 ?m. The large size powder, the intermediate size powder, and the small size powder have an insulation coating. When A1 represents an average insulation coating thickness of the large size powder, A2 represents an average insulation coating thickness of the intermediate size powder, A3 represents an average insulation coating thickness of the small size powder, A3 is 30 nm or more and 100 nm or less, A3/A1?1.3, and A3/A2?1.0.Type: GrantFiled: October 15, 2021Date of Patent: June 20, 2023Assignee: TDK CORPORATIONInventors: Kyohei Tonoyama, Ken Satoh, Kentaro Saito, Miyuki Asai, Hitoshi Ohkubo
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Patent number: 11657949Abstract: A magnetic core and a coil component with excellent permeability, core loss, DC superimposition property, and withstand voltage. A magnetic core has a metal magnetic powder containing resin including a metal magnetic powder. The metal magnetic powder includes a large size powder, an intermediate size powder, and a small size powder. A particle size of the large size powder is 10 ?m or more and 60 ?m or less. A particle size of the intermediate size powder is 2.0 ?m or more and less than 10 ?m. A particle size of the small size powder is 0.1 ?m or more and less than 2.0 ?m. The large size powder includes a nano crystal. A ratio of the large size powder existing with respect to the metal magnetic powder is 39% or more and 91% or less in terms of an area ratio in a cross section of the magnetic core.Type: GrantFiled: October 25, 2019Date of Patent: May 23, 2023Assignee: TDK CORPORATIONInventors: Kyohei Tonoyama, Ken Satoh, Kentaro Saito, Miyuki Asai, Hitoshi Ohkubo
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Publication number: 20230119388Abstract: In the coil component, the external terminal and the metal magnetic powder-containing resin constituting the element body are not in direct contact with each other, and thus high ESD resistance is obtained. That is, even when a high transient voltage is applied between the pair of external terminals, insulation breakdown is less likely to occur, and an improvement in breakdown voltage with respect to the transient voltage can be realized.Type: ApplicationFiled: October 12, 2022Publication date: April 20, 2023Applicant: TDK CORPORATIONInventors: Shota OTSUKA, Takashi KUDO, Kyohei TONOYAMA, Taiji MATSUI, Ken SATOH, Miyuki ASAI
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Publication number: 20230123939Abstract: In a coil component includes an insulating layer interposed between an external terminal and an element body and formed in an entire region excluding a connection region in a formation region in which the external terminal is formed, even when a high transient voltage is applied between the pair of external terminals, insulation breakdown does not occur or hardly occurs because of the insulating layer.Type: ApplicationFiled: October 12, 2022Publication date: April 20, 2023Applicant: TDK CORPORATIONInventors: Shota OTSUKA, Takashi KUDO, Kyohei TONOYAMA, Taiji MATSUI
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Publication number: 20220375675Abstract: A coil-embedded magnetic core capable of achieving improvements both in insulation and initial magnetic permeability, and coil devices thereof. The coil-embedded magnetic core embedding a coil made of a conductor, including magnetic powder and a resin, in which the coil-embedded magnetic core further includes a modifier.Type: ApplicationFiled: May 10, 2022Publication date: November 24, 2022Applicant: TDK CORPORATIONInventors: Kentaro SAITO, Shota OTSUKA, Kyohei TONOYAMA, Tomonaga NISHIKAWA, Mitsuo NATORI, Yuuichi KAWAGUCHI, Junichi SHIMAMURA
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Publication number: 20220108836Abstract: In a multilayer coil component, a part filled with a resin and a void part not filled with the resin exist between a plurality of metal magnetic particles in an element body, one main surface of the element body is a mounting surface with respect to an external electronic component, and the edge of an external electrode is positioned on the mounting surface. In the element body, a high void region where the porosity caused by the void part is higher than the porosity of the other part in the element body extends from the edge of the external electrode on the mounting surface toward an end surface of the element body.Type: ApplicationFiled: September 30, 2021Publication date: April 7, 2022Applicant: TDK CORPORATIONInventors: Yusuke NAGAI, Takashi SUZUKI, Kazuhiro EBINA, Kunihiko KAWASAKI, Shinichi KONDO, Keito YASUDA, Ryuichi WADA, Makoto MORITA, Takashi KUDO, Kyohei TONOYAMA
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Publication number: 20220037068Abstract: A magnetic core includes a metal magnetic powder, which has a large size powder, an intermediate size powder, and a small size powder. A particle size of the large size powder is 10 ?m or more and 60 ?m or less. A particle size of the intermediate size powder is 2.0 ?m or more and less than 10 ?m. A particle size of the small size powder is 0.1 ?m or more and less than 2.0 ?m. The large size powder, the intermediate size powder, and the small size powder have an insulation coating. When A1 represents an average insulation coating thickness of the large size powder, A2 represents an average insulation coating thickness of the intermediate size powder, A3 represents an average insulation coating thickness of the small size powder, A3 is 30 nm or more and 100 nm or less, A3/A1?1.3, and A3/A2?1.0.Type: ApplicationFiled: October 15, 2021Publication date: February 3, 2022Applicant: TDK CORPORATIONInventors: Kyohei TONOYAMA, Ken SATOH, Kentaro SAITO, Miyuki ASAI, Hitoshi OHKUBO
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Patent number: 11183320Abstract: A magnetic core includes a metal magnetic powder, which has a large size powder, an intermediate size powder, and a small size powder. A particle size of the large size powder is 10 ?m or more and 60 ?m or less. A particle size of the intermediate size powder is 2.0 ?m or more and less than 10 ?m. A particle size of the small size powder is 0.1 ?m or more and less than 2.0 ?m. The large size powder, the intermediate size powder, and the small size powder have an insulation coating. When A1 represents an average insulation coating thickness of the large size powder, A2 represents an average insulation coating thickness of the intermediate size powder, A3 represents an average insulation coating thickness of the small size powder, A3 is 30 nm or more and 100 nm or less, A3/A1?1.3, and A3/A2?1.0.Type: GrantFiled: October 25, 2019Date of Patent: November 23, 2021Assignee: TDK CORPORATIONInventors: Kyohei Tonoyama, Ken Satoh, Kentaro Saito, Miyuki Asai, Hitoshi Ohkubo
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Publication number: 20210358683Abstract: An electronic component according to the present invention includes: a leadout electrode portion provided on an outer surface of an element main body; and a resin electrode layer formed at a part of the outer surface of the element main body and connected to the leadout electrode portion. The leadout electrode portion contains copper as a main component, and the resin electrode layer includes a conductor powder containing silver, and a resin. Further, a diffusion layer containing copper oxide and silver is formed at an interface between the leadout electrode portion and the resin electrode layer.Type: ApplicationFiled: May 14, 2021Publication date: November 18, 2021Applicant: TDK CORPORATIONInventors: Kyosuke INUI, Makoto MORITA, Takashi KUDO, Toshiyuki ANBO, Kyohei TONOYAMA, Fuyuki MIURA, Masanori SUGAI, Eietsu ABE, Toru TONOGAI, Yuichi OYANAGI
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Publication number: 20210319944Abstract: To provide a coil device capable of preventing a short circuit between turns of the coil part. A coil device 2 includes a core part 4 including a magnetic powder 41 and a resin 42, and a coil part 6 embedded in the core part 4 and having a wound wire 6a with an insulation coating layer 61.Type: ApplicationFiled: April 14, 2021Publication date: October 14, 2021Applicant: TDK CORPORATIONInventors: Satoshi SUGIMOTO, Kyohei TONOYAMA, Miyuki ASAI, Takamasa IWASAKI
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Patent number: 11049641Abstract: A coil device comprising a coil, and a magnetic metal powder containing resin covering said coil. Said magnetic metal powder comprises at least two types of magnetic metal powders with different D50. The magnetic metal powder having larger D50 is defined as a large diameter powder, and the magnetic metal powder having smaller D50 is defined as a small diameter powder among the two types of said magnetic metal powder. Said large diameter powder is made of iron or iron based alloy. Said small diameter powder is made of Ni—Fe alloy. Said small diameter powder has D50 of 0.5 to 1.5 ?m. Said large diameter powder and said small diameter powder respectively comprises an insulation coating layer.Type: GrantFiled: November 29, 2016Date of Patent: June 29, 2021Assignee: TDK CORPORATIONInventors: Hitoshi Ohkubo, Kyohei Tonoyama, Shigeki Sato
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Patent number: 10847298Abstract: A coil device includes a conductor and a terminal electrode. The conductor is embedded in a core body and wound in a coil shape. The terminal electrode is formed on an end surface of the core body and connected with a lead end of the conductor. The coil device further includes a dummy conductor embedded in the core body separately from the conductor. An end part of the dummy conductor exposed from the end surface of the core body separately from the lead end is connected with the terminal electrode.Type: GrantFiled: February 1, 2018Date of Patent: November 24, 2020Assignee: TDK CORPORATIONInventors: Takashi Kudo, Makoto Morita, Fuyuki Miura, Naoki Satou, Kyohei Tonoyama, Yasunori Chiba, Masanori Sugai, Junichi Aoyado
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Publication number: 20200135380Abstract: A magnetic core and a coil component with excellent permeability, core loss, DC superimposition property, and withstand voltage. A magnetic core has a metal magnetic powder containing resin including a metal magnetic powder. The metal magnetic powder includes a large size powder, an intermediate size powder, and a small size powder. A particle size of the large size powder is 10 ?m or more and 60 ?m or less. A particle size of the intermediate size powder is 2.0 ?m or more and less than 10 ?m. A particle size of the small size powder is 0.1 ?m or more and less than 2.0 ?m. The large size powder includes a nano crystal. A ratio of the large size powder existing with respect to the metal magnetic powder is 39% or more and 91% or less in terms of an area ratio in a cross section of the magnetic core.Type: ApplicationFiled: October 25, 2019Publication date: April 30, 2020Applicant: TDK CORPORATIONInventors: Kyohei TONOYAMA, Ken SATOH, Kentaro SAITO, Miyuki ASAI, Hitoshi OHKUBO
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Publication number: 20200135371Abstract: A magnetic core includes a metal magnetic powder, which has a large size powder, an intermediate size powder, and a small size powder. A particle size of the large size powder is 10 ?m or more and 60 ?m or less. A particle size of the intermediate size powder is 2.0 ?m or more and less than 10 ?m. A particle size of the small size powder is 0.1 ?m or more and less than 2.0 ?m. The large size powder, the intermediate size powder, and the small size powder have an insulation coating. When A1 represents an average insulation coating thickness of the large size powder, A2 represents an average insulation coating thickness of the intermediate size powder, A3 represents an average insulation coating thickness of the small size powder, A3 is 30 nm or more and 100 nm or less, A3/A1?1.3, and A3/A2?1.0.Type: ApplicationFiled: October 25, 2019Publication date: April 30, 2020Applicant: TDK CORPORATIONInventors: Kyohei TONOYAMA, Ken SATOH, Kentaro SAITO, Miyuki ASAI, Hitoshi OHKUBO
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Patent number: 10147540Abstract: In a planar coil element and a method for producing the same, a metal magnetic powder-containing resin containing an oblate or needle-like first metal magnetic powder contains a second metal magnetic powder having an average particle size (1 ?m) smaller than that (32 ?m) of the first metal magnetic powder, which significantly reduces the viscosity of the metal magnetic powder-containing resin. Therefore, the metal magnetic powder-containing resin is easy to handle when applied to enclose a coil unit, which makes it easy to produce the planar coil element.Type: GrantFiled: March 21, 2013Date of Patent: December 4, 2018Assignee: TDK CORPORATIONInventors: Kyohei Tonoyama, Makoto Morita, Tomokazu Ito, Hitoshi Ohkubo, Manabu Ohta, Yoshihiro Maeda, Yuuya Kaname, Hideharu Moro
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Publication number: 20180226184Abstract: A coil device includes a conductor and a terminal electrode. The conductor is embedded in a core body and wound in a coil shape. The terminal electrode is formed on an end surface of the core body and connected with a lead end of the conductor. The coil device further includes a dummy conductor embedded in the core body separately from the conductor. An end part of the dummy conductor exposed from the end surface of the core body separately from the lead end is connected with the terminal electrode.Type: ApplicationFiled: February 1, 2018Publication date: August 9, 2018Applicant: TDK CORPORATIONInventors: Takashi KUDO, Makoto MORITA, Fuyuki MIURA, Naoki SATOU, Kyohei TONOYAMA, Yasunori CHIBA, Masanori SUGAI, Junichi AOYADO
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Publication number: 20170154720Abstract: A coil device comprising a coil, and a magnetic metal powder containing resin covering said coil. Said magnetic metal powder comprises at least two types of magnetic metal powders with different D50. The magnetic metal powder having larger D50 is defined as a large diameter powder, and the magnetic metal powder having smaller D50 is defined as a small diameter powder among the two types of said magnetic metal powder. Said large diameter powder is made of iron or iron based alloy. Said small diameter powder is made of Ni—Fe alloy. Said small diameter powder has D50 of 0.5 to 1.5 ?m. Said large diameter powder and said small diameter powder respectively comprises an insulation coating layer.Type: ApplicationFiled: November 29, 2016Publication date: June 1, 2017Inventors: Hitoshi OHKUBO, Kyohei TONOYAMA, Shigeki SATO
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Patent number: 9406420Abstract: A coil component 1 is provided with coil conductors 10a and 10b and a magnetic metal powder containing resin 22 (22a and 22b) covering the coil conductors 10a and 10b. The magnetic metal powder containing resin 22 includes first metal powder having a first average grain diameter, second metal powder having a second average grain diameter that is smaller than the first average grain diameter, and third metal powder having a third average grain diameter that is smaller than the second average grain diameter. The first average grain diameter is 15 ?m or more and 100 ?m or less. The third average grain diameter is 2 ?m or less. The first metal powder mainly contains Permalloy and the second and third metal powders mainly contain carbonyl iron.Type: GrantFiled: September 4, 2013Date of Patent: August 2, 2016Assignee: TDK CORPORATIONInventors: Hitoshi Ohkubo, Kyohei Tonoyama, Makoto Morita, Tomokazu Ito, Hideto Itoh, Yoshihiro Maeda, Manabu Ohta, Yuuya Kaname, Takahiro Kawahara
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Patent number: 9236171Abstract: A coil component includes: an insulating resin layer provided between a first planar spiral conductor formed on a back surface of a first substrate and a second planer spiral conductor formed on a back surface of a second substrate; an upper core covering a third second planer spiral conductor formed on a front surface of the first substrate on which the insulating resin layer is formed; and a lower core covering a fourth planer spiral conductor formed on a front surface of the second substrate on which the insulating resin layer is formed. One of the upper and lower cores is formed of a metal-magnetic-powder-containing resin. The coil component includes connecting portions disposed respectively at center and outside portions of each of the first and second substrates so as to physically connect the upper and lower cores.Type: GrantFiled: October 14, 2011Date of Patent: January 12, 2016Assignee: TDK CorporationInventors: Tomokazu Ito, Hitoshi Ohkubo, Yoshihiro Maeda, Makoto Morita, Toshiyuki Anbo, Kyohei Tonoyama, Manabu Ohta
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Patent number: 8975997Abstract: In a planar coil element, the quantitative ratio of inclined particles to total particles of a first metal magnetic powder contained in a metal magnetic powder-containing resin provided in a through hole of a coil unit is higher than the quantitative ratio of inclined particles to total particles of the first metal magnetic powder contained in the metal magnetic powder-containing resin provided in other than the through hole, and many of particles of the first metal magnetic powder in the magnetic core are inclined particles whose major axes are inclined with respect to the thickness direction and the planar direction of a substrate. Therefore, the planar coil element has improved strength as compared to a planar coil element shown in FIG. 9A and has improved magnetic permeability as compared to a planar coil element shown in FIG. 9B.Type: GrantFiled: March 19, 2013Date of Patent: March 10, 2015Assignee: TDK CorporationInventors: Kyohei Tonoyama, Makoto Morita, Tomokazu Ito, Hitoshi Ohkubo, Manabu Ohta, Yoshihiro Maeda, Yuuya Kaname, Hideharu Moro