A method for producing MnZn-ferrite comprising Fe, Mn and Zn as main components, and at least Co, Si and Ca as sub-components, the main components in the MnZn-ferrite comprising 53-56% by mol (as Fe.sub.2O.sub.3) of Fe, and 3-9% by mol (as ZnO) of Zn, the balance being Mn as MnO, comprising the step of sintering a green body to obtain MnZn-ferrite; the sintering comprising a temperature-elevating step, a high-temperature-keeping step, and a cooling step; the high-temperature-keeping step being conducted at a keeping temperature of higher than 1050° C. and lower than 1150° C. in an atmosphere having an oxygen concentration of 0.4-2% by volume; the oxygen concentration being in a range of 0.001-0.2% by volume during cooling from 900° C. to 400° C. in the cooling step; and the cooling speed between (Tc+70)° C. and 100° C. being 50° C./hour or more, wherein Tc represents a Curie temperature (° C.) calculated from % by mass of Fe.sub.2O.sub.3 and ZnO.

Provided is a core component having a powder compact and a resin-molded portion joined to each other. In a core component including a powder compact obtained by compression molding a raw material powder containing a soft magnetic powder and a resin-molded portion formed on the surface of the powder compact, and constituting a part of a magnetic core disposed inside and outside a coil included in a reactor, an intermediate layer formed of a silane coupling agent is provided between the powder compact and the resin-molded portion. The powder compact and the resin-molded portion can be bound to each other via the intermediate layer formed of the silane coupling agent. The silane coupling agent not only binds chemically to the surface of the powder compact but also binds chemically to the resin-molded portion, and therefore, the joining the powder compact and the resin-molded portion via the intermediate layer.

A power inductor includes a winding and a metal magnetic powder core. The metal magnetic powder core is configured to support the winding, and the winding uses a metal conductive sheet. During assembly, the metal magnetic powder core is integrated with the winding through pressing, the metal magnetic powder core wraps the winding, and the metal magnetic powder core is insulated from the winding. The winding has a first pin and a second pin, and the first pin and the second pin are exposed on different surfaces of the metal magnetic powder core. Pins are separately disposed on two different surfaces of the power inductor. In addition, the winding is formed by integrally pressing the metal conductive sheet and the metal magnetic powder core.

Permanent magnets and methods of making the same are disclosed herein. The permanent magnets include a 3D-printed, i.e., additively manufactured, framework and an infiltrate such that there is a discrete magnetic phase and a discrete non-magnetic phase or two discrete magnetic phases. The infiltrate may provide superior strength, elasticity or magnetic properties.

Provided is a method for manufacturing a high-density integrally-molded induct comprising the following steps: (1) winding an enameled wire coil to be spiral; (2) mechanically pressing first ferromagnetic powder into a magnetic core; (3) mounting the magnetic core into a. hollow cavity of the enameled wire coil; (4) mounting the enameled wire coil provided with the magnetic core into an injection mold; (5) uniformly mixing and stirring resin glue, a coupling agent and an accelerant, to obtain high-temperature resin glue; (6) uniformly stirring second ferromagnetic powder and the high-temperature resin glue, to obtain a magnetic composite material; (7) injecting the magnetic composite material into a mold cavity of the injection mold for molding, and solidifying the magnetic composite material to obtain an outer magnet; and (8) cooling and de-molding the outer magnet, to obtain a molded inductor. The inductor obtained using the above method is small in size, high in density, high in relative permeability, better in heat dissipation, and lone in service life. The inductor is simply manufactured using an integral molding method, thus reducing the production cost.

A coil component includes a core including a winding core portion, a first flange portion, and a second flange portion, and a plate member that is mounted on the first flange portion and the second flange portion. A distance in a height direction between the plate member and the first flange portion, or a distance in the height direction between the plate member and the second flange portion, or both vary in a length direction, or in a width direction, or both.

Disclosed herein is a coil component that includes a magnetic element body, a coil conductor embedded in the magnetic element body and having an end portion exposed from the magnetic element body, and a terminal electrode connected to the end portion of the coil conductor. The terminal electrode includes a conductive resin contacting the end portion of the coil conductor and containing conductive particles and a resin material, and a metal film covering the conductive resin. The end portion of the coil conductor has an exposed surface exposed from the magnetic element body and contacting the conductive resin and a non-exposed surface covered with the magnetic element body. The exposed surface is larger in surface roughness than the non-exposed surface.

A method for fabricating magnetic cores, wherein the magnetic cores have at least two materials with different magnetic properties. The materials are selected from a ferrite material, an oxide ceramic material and a superparamagnetic material and are formed alternately in individual regions along the magnetic core.

A coil component includes: a first substrate body and a second substrate body, both formed in a manner containing a magnetic material; an adhesive containing an organic material and a filler, for bonding the first substrate body and the second substrate body; a coil formed by a conductor having an insulating film; and electrodes connected electrically to the coil; wherein the surface roughness of the face of the first substrate body bonded to the second substrate body via the adhesive is higher than the average grain size of the filler.

Disclosed is a novel high-density magnetic composite material for an inductor. The material is composed of 6-12% of high-temperature resin glue and 88-94% of magnetic powder body in percentage by weight. An integrated inductor magnetic core is simply prepared by means of the magnetic composite material of the disclosure without a large press, thus saving the device investment. The mold loss in a pressing process is reduced, and the production cost is reduced. The operation is simple, a magnet of a complex shape can be produced, and an oversized magnet can be produced. A closed magnetic circuit is formed, and the EMI effect is good. The magnetic composite material of the disclosure enables the density of a solidified magnet to be high under the action of special high-temperature resin glue, it can be guaranteed that the density is 5.5-6.2 g/cm3, the sensitive quality value for preparing an inductor is high, and the initial permeability can be 14μ or above. The magnetic composite material of the disclosure can bear a higher temperature, and can work at the temperature of 180° C. The magnetic composite material of the disclosure is high in utilization rate, low in scrap rate and low in dust rate, and meets the requirement for environmental protection.