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Coil component

Imported: 23 Feb '17 | Published: 22 Oct '02

Masahito Tada, Keiichiro Suzuki, Sadao Nakanishi

USPTO - Utility Patents

Abstract

A coil part which is obtained by sealing at least part of the periphery of a coil with a conductor wound on a bobbin with a high heat-conductive and magnetism-impermeable resin composition, and can efficiently guide out a magnetic flux generated to the outside and efficiently radiate heat generated to the outside.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS.

1(

a) and

1(

b) are a front elevation and a side elevation illustrating an exemplary bobbin, respectively.

FIG. 2 is a side elevation illustrating a coil with a conductor wound on the bobbin.

FIG. 3 is a bird's-eye view illustrating an exemplary coil part obtained by sealing the coil with a conductor wound on the bobbin with a resin composition.

Claims

1. A coil part obtained by sealing at least part of the periphery of a coil with a conductor wound on a bobbin with a high heat-conductive and magnetism-impermeable resin composition (A) comprising 10 to 80 wt. % of a synthetic resin (a), 90 to 20 wt. % of a high heat-conductive and magnetism-impermeable inorganic filler (b), and 0 to 30 wt. % of another magnetism-impermeable inorganic filler (c).

2. The coil part according to claim 1, wherein the thermal conductivity of the magnetism-impermeable resin composition (A) is 0.7 W/mK or higher.

3. The coil part according to claim 1, wherein the volume resistivity of the magnetism-impermeable resin composition (A) is 1.0×10

9 cm or higher.

4. The coil part according to claim 1, wherein the high heat-conductive and magnetism-impermeable resin composition (A) has a thermal conductivity of 0.7 W/mK or higher and a volume resistivity of 1.0×10

9 cm or higher.

5. The coil part according to claim 1, wherein the synthetic resin (a) is at least one synthetic resin selected from the group consisting of thermoplastic resins, thermosetting resins and thermoplastic elastomers.

6. The coil part according to claim 5, wherein the thermoplastic resin is a polyolefin, polyamide or poly(arylene sulfide).

7. The coil part according to claim 6, wherein the poly(arylene sulfide) is poly(phenylene sulfide).

8. The coil part according to claim 1, wherein the high heat-conductive and magnetism-impermeable inorganic filler (b) is at least one selected from the group consisting of alumina, silicon oxide, iron oxide, calcium oxide, magnesium oxide, zinc, tin, aluminum, brass, gold, silver, copper, platinum, beryllium, bronze, beryllium copper, stainless steel, nickel, graphite, calcite, fluorite and boron nitride.

9. The coil part according to claim 8, wherein the high heat-conductive and magnetism-impermeable inorganic filler (b) is at least one selected from the group consisting of alumina, silicon oxide, iron oxide, calcium oxide and magnesium oxide.

10. The coil part according to claim 9, wherein the metal oxide is alumina.

11. The coil part according to claim 10, wherein the alumina is -alumina.

12. The coil part according to claim 1, wherein said another magnetism-impermeable inorganic filler (c) is a fibrous filler.

13. The coil part according to claim 12, wherein the fibrous filler is glass fiber.

14. The coil part according to claim 1, wherein the high magnetism-impermeable resin composition (A) is a resin composition containing poly(phenylene sulfide) as the synthetic resin (a), -alumina as the high heat-conductive and magnetism-impermeable inorganic filler (b) and glass fiber as said another magnetism-impermeable inorganic filler (c).

15. The coil part according to claim 14, wherein the magnetism-impermeable resin composition (A) has a thermal conductivity of 0.7 W/mK or higher and a volume resistivity of 1.0×10

9 cm or higher.

16. The coil part according to claim 1, wherein the bobbin is formed from a synthetic resin composition (B).

17. The coil part according to claim 16, wherein the synthetic resin composition (B) is a magnetism-permeable resin composition (B

1).

18. The coil part according to claim 17, wherein the magnetism-permeable resin composition (B

1) has an A.C. initial permeability of 2 or higher.

19. The coil part according to claim 17, wherein the magnetism-permeable resin composition (B

1) has a volume resistivity of 1.0×10

9 cm or higher.

20. The coil part according to claim 17, wherein the magnetism-permeable resin composition (B

1) is a resin composition containing 10 to 80 wt. % of a synthetic resin (d), 20 to 90 wt. % of a powdered magnetic material (e) and 0 to 30 wt. % of a magnetism-impermeable inorganic filler (f).

21. The coil part according to claim 20, wherein the synthetic resin (d) is at least one synthetic resin selected from the group consisting of thermoplastic resins, thermosetting resins and thermoplastic elastomers.

22. The coil part according to claim 21, wherein the thermoplastic resin is a polyolefin, polyamide or poly(arylene sulfide).

23. The coil part according to claim 22, wherein the poly(arylene sulfide) is poly(phenylene sulfide).

24. The coil part according to claim 20, wherein the powdered magnetic material (e) is at least one selected from the group consisting of metal oxide type powdered magnetic materials and metal alloy type powdered magnetic materials.

25. The coil part according to claim 20, wherein the powdered magnetic material (e) is at least one metal oxide type powdered magnetic material selected from the group consisting of Mg—Zn ferrite and Ni—Zn ferrite.

26. The coil part according to claim 16, wherein the synthetic resin composition (B) is a magnetism-impermeable resin composition (B

2).

27. The coil part according to claim 26, wherein the magnetism-impermeable resin composition (B

2) has a volume resistivity of 1.0×10

9 cm or higher.

28. The coil part according to claim 26, wherein the magnetism-impermeable resin composition (B

2) is a resin composition containing 10 to 80 wt. % of a synthetic resin (d) and 20 to 90 wt. % of a magnetism-impermeable inorganic filler (f).

29. The coil part according to claim 28, wherein the synthetic resin (d) is at least one synthetic resin selected from the group consisting of thermoplastic resins, thermosetting resins and thermoplastic elastomers.

30. The coil part according to claim 29, wherein the thermoplastic resin is a polyolefin, polyamide or poly(arylene sulfide).

31. The coil part according to claim 30, wherein the poly(arylene sulfide) is poly(phenylene sulfide).

32. The coil part according to claim 28, wherein the magnetism-impermeable inorganic filler (f) is at least one selected from the group consisting of powdered metal oxides and fibrous fillers.

33. The coil part according to claim 26, wherein the magnetism-impermeable resin composition (B

2) is a resin composition containing 10 to 80 wt. % of a synthetic resin (d), 20 to 90 wt. % of a high heat-conductive and magnetism-impermeable inorganic filler (fl) and 0 to 30 wt. % of another magnetism-impermeable inorganic filler (f

2).

34. The coil part according to claim 33, wherein the magnetism-impermeable resin composition (B

2) is a resin composition containing poly(phenylene sulfide) as the synthetic resin (d), -alumina as the high heat-conductive and magnetism-impermeable inorganic filler (fl) and glass fiber as said another magnetism-impermeable inorganic filler (f

2).

35. The coil part according to claim 1, wherein the coil part obtained by sealing with the magnetism-impermeable resin composition (A) has a radiating structure portion on the surface of the sealed portion.

36. The coil part according to claim 35, wherein the radiating structure portion is composed of fins formed integrally with the sealed portion formed by the magnetism-impermeable resin composition (A).

37. A coil part obtained by sealing at least part of the periphery of a coil with a conductor wound on a bobbin with a high heat-conductive and magnetism-impermeable resin composition (A), wherein the bobbin is formed from a magnetism-permeable synthetic resin composition (B

1) having an A.C. initial permeability of 2 or higher.

38. The coil part according to claim 37, wherein the high heat-conductive and magnetism-impermeable resin composition (A) has a thermal conductivity of 0.7 W/mK or higher and a volume resistivity of 1.0×10

9 cm or higher.

39. A coil part obtained by sealing at least part of the periphery of a coil with a conductor wound on a bobbin with a high heat-conductive and magnetism-impermeable resin composition (A), wherein the bobbin is formed from a magnetism-permeable synthetic resin composition (B

1) which comprises 10 to 80 wt. % of a synthetic resin (d), 20 to 90 wt. % of a powdered magnetic material (e), and 0 to 30 wt. % of a magnetism-impermeable inorganic filler (f).

40. The coil part according to claim 39, wherein the high heat-conductive and magnetism-impermeable resin composition (A) has a thermal conductivity of 0.7 W/mK or higher and a volume resistivity of 1.0×10

9 cm or higher.