A bonding structure of a sheet core and a pair of flange parts wherein the pair of flange parts is formed on both ends of a shaft part to constitute a drum core together with the shaft part; the sheet core is bonded, in a manner connecting the pair of flange parts across the shaft part, to the top faces of the flange parts facing away from the bottom faces of the flange parts to be mounted on a circuit board; and a coil-shaped conductor is constituted by sheathed conductive wires wound around the shaft part; wherein the bonding surfaces of each of the flange parts and the sheet core have multiple contact areas where the flange part makes direct contact with the sheet core, as well as adhesive areas between the contact areas where an adhesive is disposed.

A method of manufacturing a composite component according to various aspects of the present disclosure includes disposing a fiber preform in a mold. The fiber preform includes a first portion having a first edge and a second portion having a second edge. The first edge and the second edge cooperate to at least partially define a gap. One of the first portion or the second portion includes a first ferromagnetic material and the other of the first portion or the second portion includes a first magnetic or magnetizable component. The method further includes closing the gap by generating a magnetic field from the first magnetic or magnetizable component. The method further includes injecting a polymer precursor into the mold. The method further includes forming the composite component by solidifying the polymer precursor to form a polymer. The composite component includes the fiber preform and the polymer.

A surface mount inductor includes a coil including a wound portion and a feeder end portion drawn out from the wound portion, a compact that contains a magnetic powder and that encapsulates the coil, and an external terminal disposed on the compact and connected to the coil. The compact has surfaces including two pressed surfaces, opposing each other in a direction of an axis of the wound portion and formed by being pressed in the direction of the axis, and a non-pressed surface, adjacent to the two surfaces and not pressed. The coil is disposed so that the axis of the wound portion is parallel to a mount surface of the compact. The mount surface is included in the non-pressed surface, the feeder end portion is exposed from the mount surface, and the external terminal is formed on only the non-pressed surface and connected to the feeder end portion.

A punch processing method for a laminated iron core includes sequentially feeding the steel sheets to a mold; and performing a plurality of processes in the mold, the plurality of processes includes fixing the steel sheets being stacked to each other at a first fixing part that is positioned outside a closed curved line corresponding to an outermost periphery of the laminated iron core and a second fixing part that is positioned in a portion that finally serves as the laminated iron core; and performing punch processing on the outermost periphery of the laminated iron core while the steel sheets are stacked.

An inductor includes a body that includes a coil and that contains a magnetic portion in which the coil is embedded, and a pair of outer electrodes that is disposed on a mounting surface of the body. The coil includes a winding portion formed by winding a conductive wire that has a coating layer and that has a pair of wide surfaces, and a pair of extended portions that extends from the winding portion. The pair of extended portions includes a twisted portion that is connected to the winding portion. The twisted portion is twisted about a virtual center line of an end portion of the winding portion, and a twisted part bends toward the mounting surface about an axis substantially perpendicular to the wide surfaces at the end portion. End portions of the pair of extended portions near the mounting surface are connected to the pair of outer electrodes.

An embodiment provides a coil component including a base body, and a coil conductor provided in the base body. At least partial region of the base body contains (i) a plurality of first metal magnetic particles having a first aspect ratio greater than one and having a first average particle size and (ii) a plurality of second metal magnetic particles having a second aspect ratio greater than the first aspect ratio, having a second average particle size less than the first average particle size. The first and second metal magnetic particles are oriented in a reference direction in the base body.

In order to provide an air core coil fitting apparatus that can automatically fit an air core coil onto a core, an air core coil fitting apparatus includes a holding member, a coil fitting rod, a rod driving member, a pushing member, and a sending member. The holding member holds a core main body that is formed in a ring shape, has a gap extending through the core main body from an inner circumferential face to an outer circumferential face thereof, and allows an air core coil wound in advance to be fitted onto the core main body from one end thereof. On the coil fitting rod, the air core coil that is to be fitted onto the core main body held by the holding member is fitted. The rod driving member brings a front end of the coil fitting rod close to or into contact with the one end of the core main body held by the holding member. The pushing member pushes the air core coil fitted on the coil fitting rod, toward the one end of the core main body. The sending member is disposed at a circumferential edge of the core main body held by the holding member, and pulls the air core coil pushed by the pushing member and fitted onto the core main body, toward another end of the core main body.

A preparation method for a metal soft magnetic composite material inductor includes: smelting Fe, Si and Cr and then employing a water atomization or gas atomization means to fabricate an alloy powder; after sifting by particle size, mixing powders of different particle size levels and performing coating insulation, and performing post-granulation to obtain a metal soft composite material granulation powder; adopting the granulation powder to press a material cake, and transferring and molding same; adopting a hollow coil in a liquid-phase coating mold cavity, curing and demolding to obtain a semi-finished product, then continuously heating and curing the semi-finished product, and preparing an end electrode to obtain a finished inductor.

An inductor device and a method of fabricating the same. The inductor device according to the invention includes a conductive coil, a pillar and a cladding body. The pillar is molded from a plurality of first composite material powders by a pressing process. Each first composite material powder is composed of a first magnetic material powder coated with a first thermosetting resin. The cladding body is molded from a plurality of second composite powders. Each second composite material powders is composed of a second magnetic material powder coated with a second thermosetting resin. The first weight ratio of the first thermosetting resin to the first composite material powders is less than the second weight ratio of the second thermosetting resin to the second composite material powders. The cladding body and the conductive coil and the pillar cladded by the cladding body are heated to a curing temperature.

A dust core that can significantly reduce the iron loss is provided. The dust core of the present invention includes soft magnetic particles comprising pure iron or an iron alloy and a grain boundary layer existing between adjacent soft magnetic particles. The grain boundary layer has a compound layer comprising M.sub.xFe.sub.2-xSiO.sub.4 (0≤x≤1, M: one or more types of metal elements that serve as divalent cations). Such a dust core is obtained by annealing a compact. The compact is obtained by compression-molding a powder for magnetic cores. In the powder for magnetic cores, coating layers that coat the surfaces of soft magnetic particles are each composed of a composite phase in which spinel-type ferrite represented by M.sub.yFe.sub.3-yO.sub.4 (0≤y≤1, M: one or more types of metal elements that serve as divalent cations) is dispersed on a surface of a silicone resin or inside the silicone resin. The dust core after annealing exhibits a high specific resistance due to the grain boundary layer having the compound layer and can reduce both the eddy-current loss and the hysteresis loss.