Method of manufacturing a magnetic element
AssigneeMatsushita Electric Industrial Co., Ltd.
InventorsOsamu Inoue, Junichi Kato, Nobuya Matsutani, Hiroshi Fujii, Takeshi Takahashi
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Abstract
The present invention provides a composite magnetic body containing metallic magnetic powder and thermosetting resin and having a packing ratio of the metallic magnetic powder of 65 vol % to 90 vol % and an electrical resistivity of at least 104 Ω·cm. When a coil is embedded in this composite magnetic body, a miniature magnetic element can be obtained that has a high inductance value and is excellent in DC bias characteristics.
Claims19
A method of manufacturing a magnetic element comprising a composite magnetic body containing metallic magnetic powder and thermosetting resin and having a packing ratio of the metallic magnetic powder of 65 vol % to 90 vol % and an electrical resistivity of at least 104 Ω·cm, and a coil embedded in the composite magnetic body, the method comprising:
- dividing uncured thermosetting resin into first and second portions;
- mixing metallic magnetic powder and the first portion of the thermosetting resin present in an uncured state to provide a first mixture;
- pre-heating the first mixture;
- mixing the pre-heated first mixture and the second portion of the thermosetting resin to provide a second mixture;
- obtaining a molded body by pressure-molding the second mixture to embed the coil;
- and
- curing the second mixture of the thermosetting resin by heating the molded body.
Dependencies are inferred from the claim text.