# US 10,312,005 B2 · Gapped core, coil component using same, and method for manufacturing coil component > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,312,005 B2 - Document ID: US10312005B2 - Status: Granted - Kind: B2 - Application number: 15/557,654 - Filed: 2016-06-02 - Published: 2018-03-15 - Granted: 2019-06-04 - Earliest claimed: 2015-06-03 - Applicants: SHT Corporation Limited - Inventors: Yasuomi Takahashi; Masafumi Inoue; Tsunetsugu Imanishi; Hitoshi Yoshimori - Web page: https://patentgrep.com/patent/US10312005B2 ## CPC - H01F 3/14: Constrictions; Gaps, e.g. air-gaps (in magnetic shunt paths H01F3/12) - H01F 17/062: {Toroidal core with turns of coil around it} - H01F 27/255: made from particles (H01F27/26 takes precedence) - H01F 27/266: {Fastening or mounting the core on casing or support (on coil H01F27/30)} - H01F 27/28: Coils; Windings; Conductive connections - H01F 27/2895: {Windings disposed upon ring cores} - H01F 27/306: {Fastening or mounting coils or windings on core, casing or other support} - H01F 37/00: Fixed inductances not covered by group H01F17/00 - H01F 41/0206: {Manufacturing of magnetic cores by mechanical means (magnetic cores per se H01F27/24)} - H01F 41/0246: {Manufacturing of magnetic circuits by moulding or by pressing powder (magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36)} - H01F 41/08: Winding conductors onto closed formers or cores, e.g. threading conductors through toroidal cores - H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES ## Abstract The present invention provides a gapped core that facilitates adjustment of DC bias characteristics, has little variation in those characteristics, and also allows for excellent manufacturing efficiency. A gapped core (10) according to the present invention has a main body (30) and a segment (40) that are obtained by a molded core (20) including an annular magnetic body made of a magnetic material and a resin covering part that covers the magnetic body being cut at a first cutting part and a second cutting part that transect an outer peripheral surface and an inner peripheral surface and approach each other toward an inner periphery of the molded core, the main body (30) having a main body-side first end face formed by cutting at the first cutting part and a main body-side second end face formed by cutting at the second cutting part, and the segment (40) having a segment side first end face formed by cutting at the first cutting part and a segment-side second end face formed by cutting at the second cutting part, the segment being disposed in a cutout part (31) formed between the main body-side first end face and the main body-side second end face of the main body, and the main body-side first end face and the segment-side first end face and/or the main body-side second end face and the segment-side second end face opposing each other across a gap (11). ## Claims ### Claim 1 A gapped core comprising a main body and a segment that are obtained by a molded core including an annular magnetic body made of a magnetic material and a resin covering part that covers the magnetic body being cut at a first cutting part and a second cutting part that transect an outer peripheral surface and an inner peripheral surface and approach each other in an inner peripheral direction of the molded core, the main body having a main body-side first end face formed by cutting at the first cutting part and a main body-side second end face formed by cutting at the second cutting part, and the segment having a segment-side first end face formed by cutting at the first cutting part and a segment-side second end face formed by cutting at the second cutting part, wherein the segment is disposed in a cutout part formed between the main body-side first end face and the main body-side second end face of the main body, the main body-side first end face and the segment-side first end face oppose each other, and the main body-side second end face and the segment-side second end face oppose each other, with a gap existing between the main body-side first end face and the segment-side first end face, a nonmagnetic spacer is inserted between the main body-side first end face and the segment-side first end face, and the spacer is a first resin plate that is inserted between the main body-side first end face and the segment-side first end face, the first resin plate being integrally formed with an attachment that covers at least at an inner peripheral side, an outer peripheral side or a lateral side of the segment. ### Claim 2 (depends on 1) The gapped core according to claim 1, wherein the main body-side second end face and the segment-side second end face oppose each other, with a gap existing between the main body-side second end face and the segment-side second end face, a nonmagnetic spacer is inserted between the main body-side second end face and the segment-side second end face, and the spacer is a second resin plate that is inserted between the main body-side second end face and the segment-side second end face, the first resin plate and the second resin plate being integrally formed with the attachment. ### Claim 3 (depends on 1) The gapped core according to claim 1, wherein an angle formed by the first cutting part and the second cutting part is less than or equal to 90 degrees. ### Claim 4 (depends on 1) A coil component constituted by the segment being pushed into the cutout part, after inserting a pre-wound air core coil into the main body of the gapped core according to claim 1 through the cutout part. ### Claim 5 A gapped core comprising a main body and a segment that are obtained by a molded core including an annular magnetic body made of a magnetic material and a resin covering part that covers the magnetic body being cut at a first cutting part and a second cutting part that transect an outer peripheral surface and an inner peripheral surface and approach each other in an inner peripheral direction of the molded core, the main body having a main body-side first end face formed by cutting at the first cutting part and a main body-side second end face formed by cutting at the second cutting part, and the segment having a segment-side first end face formed by cutting at the first cutting part and a segment-side second end face formed by cutting at the second cutting part, wherein the segment is disposed in a cutout part formed between the main body-side first end face and the main body-side second end face of the main body, the main body-side first end face and the segment-side first end face and/or the main body-side second end face and the segment-side second end face oppose each other across a gap, the magnetic body is a powder compression molded body made of a magnetic material, and the resin covering part is formed by an insert-molding method or a resin powder coating method, a nonmagnetic spacer is inserted between the main body-side first end face and the segment-side first end face, and the spacer is a first resin plate that is inserted between the main body-side first end face and the segment-side first end face, the first resin plate being integrally formed with an attachment that covers at least at an inner peripheral side, an outer peripheral side or a lateral side of the segment. ### Claim 6 (depends on 5) The gapped core according to claim 5, wherein an angle formed by the first cutting part and the second cutting part is less than or equal to 90 degrees. ### Claim 7 (depends on 5) A coil component constituted by the segment being pushed into the cutout part, after inserting a pre-wound air core coil into the main body of the gapped core according to claim 5 through the cutout part. ### Claim 8 A gapped core comprising a main body and a segment that are obtained by a molded core including an annular magnetic body made of a magnetic material and a resin covering part that covers the magnetic body being cut at a first cutting part and a second cutting part that transect an outer peripheral surface and an inner peripheral surface and approach each other in an inner peripheral direction of the molded core, the main body having a main body-side first end face formed by cutting at the first cutting part and a main body-side second end face formed by cutting at the second cutting part, and the segment having a segment-side first end face formed by cutting at the first cutting part and a segment-side second end face formed by cutting at the second cutting part, wherein the segment is disposed in a cutout part formed between the main body-side first end face and the main body-side second end face of the main body, the main body-side first end face and the segment-side first end face and/or the main body-side second end face and the segment-side second end face oppose each other across a gap, and the resin covering part has a main body-side flange part that projects toward the outer peripheral side and/or the lateral side from an end edge on the main body-side second end face side, and a segment-side flange part that projects toward the outer peripheral side and/or the lateral side from an end face on the segment-side second end face side. ### Claim 9 (depends on 8) The gapped core according to claim 8, wherein an angle formed by the first cutting part and the second cutting part is less than or equal to 90 degrees. ### Claim 10 (depends on 8) A coil component constituted by the segment being pushed into the cutout part, after inserting a pre-wound air core coil into the main body of the gapped core according to claim 8 through the cutout part.