Inductor cooling systems and methods are disclosed. A vehicle inductor cooling system may include an inductor assembly secured to a vehicle transmission case and including a core and a conductive coil wrapped around the core. A thermal interface material (TIM) may be spaced apart from the core and may contact a bottom portion of the conductive coil and a surface of the transmission case. The TIM may be configured to transfer heat from the conductive coil to the transmission case. The TIM may be a compressed solid thermal interface material. The TIM may be in contact with at least 85% of a projected surface area of the bottom portion of the conductive coil. The TIM may passively cool the conductive coil(s) of the inductor assembly by transferring heat from the coils to a vehicle transmission case, which may act as a heat sink.

The invention is directed to a surface mountable reactor including: a coil 60; a first magnetic core 5 including an axial portion 5a around which the coil 60 is disposed and flange portions 5b and 5c at both ends thereof; a second magnetic core 10 disposed outside the coil 60 to connect the flange portions of the first magnetic core 5; and a resin mount 30 disposed outside the coil 60, wherein the second magnetic core 10 includes a plurality of components 10a and 10b separable toward outside the coil 60, the circumference of the coil 60 is surrounded by the second magnetic core 10 and the resin mount 30, and the coil 60 has end portions 65 disposed outside the resin mount 30, and to a method for fabrication thereof.

A coil component includes two or more coils configuring a common mode choke coil and functions as an inductor against a normal mode AC current. A coil component includes a pot-type core formed in a box-like shape, a flat plate core, coils, and a partition core formed of a magnetic substance. The coils are accommodated inside the pot-type core and form a common mode choke coil by making the central axes thereof substantially match each other. Further, each of end portions of the coils function as outer electrodes. The partition core is provided between the coils.

Magnetic component assemblies including moldable magnetic materials formed into magnetic bodies, at least one conductive coil, and termination features are disclosed that are advantageously utilized in providing surface mount magnetic components such as inductors and transformers.

A manufacturing method of a coil component comprising the steps of: preparing a coil assembly body in which a coil is attached on a magnetic core and a mold body which is formed with a cavity portion in the inside thereof and which includes at least one opening portion, putting a viscous admixture including magnetic powders and thermosetting resin and the coil assembly body in the cavity portion, pushing the put-in viscous admixture in the mold body, and thermally-curing the pushed-in viscous admixture and forming a magnetic exterior body which covers the coil assembly body.

A coil assembly includes a coil unit in which a coil obtained by winding a winding wire is disposed around a magnetic core, a coil case that accommodates the coil unit, and a potting material with which an inside of the coil case is filled, and the coil case has an elastic fixing portion that is attachable to a resin member to which the coil case is to be fixed. The above-described configuration makes it possible to provide a coil assembly that is unlikely to crack and generate abnormal noises.

Provided is a rectangular wire edgewise-bending processing device for performing an edgewise-bending process for a rectangular wire to form a coil, the rectangular wire edgewise-bending processing device including a fixing unit for fixing the rectangular wire, a pressing tool for pressing a surface formed by a long side of a rectangular cross section of the rectangular wire, and a bending tool for bending the rectangular wire into a predetermined coil shape, wherein the edgewise-bending process is performed while the surface formed by the long side of the rectangular cross section of the rectangular wire is pressed.

In an embodiment, an air-core coil 50 includes a winding part 54 formed by winding a coated conductive wire 52, wherein a pair of leader parts 56 and 58 is interposed between a second core 20 and a first core 40 which contain metal magnetic grains. A first gap 72 is provided between a principle face 50A of one end portion of the winding part 54 in the direction of a winding core axis of the winding part 54 and the first core member 40. A second gap 70 is provided between a principle face 50B of the other end portion and the second core member 20. The coil component is a small and high-performance coil component with a high dielectric withstanding voltage.

A manufacturing method of a coil component comprising the steps of: preparing a coil assembly body in which a coil is attached on a magnetic core and a mold body which is formed with a cavity portion in the inside thereof and which includes at least one opening portion, putting a viscous admixture including magnetic powders and thermosetting resin and the coil assembly body in the cavity portion, pushing the put-in viscous admixture in the mold body, and thermally-curing the pushed-in viscous admixture and forming a magnetic exterior body which covers the coil assembly body

An inductor has a main magnet core, a coil mounted around the main magnet core, and a residual magnet encapsulating the main magnet core and partially encapsulating the coil. The main magnet core is made of a main magnet core powder containing amorphous iron base material and nickel base material powders. The residual magnet is made of a residual magnet powder containing a main magnet powder and a soft magnet powder including an iron-silicon-chromium alloy powder and a carbonyl iron powder. Thus, through a low-loss feature of the amorphous iron base material and nickel base material powders, a loss of the main magnet core is reduced. Furthermore, a magnetic permeability of the residual magnet matches a magnetic permeability of the main magnet core. A magnetic leakage is further avoided, and the alternating current resistance is reduced. A quality factor and a conversion efficiency are enhanced.