An integrally formed inductor and a manufacturing method thereof, wherein the method comprises: sintering a soft magnetic material to prepare a magnetic core plate with a plurality of grooves; respectively putting hollow coils into the plurality of grooves; putting a magnetic core plate provided with coils into a forming die, adding a soft magnetic material in a fluid state, and integrally forming the soft magnetic material in the fluid state on the magnetic core plate through pressing; coating semi-finished inductors with an insulating material to form an insulating coating layer, and exposing only two terminals of the coils; areas where the coil terminals are exposed on a surface of the insulating coating layer being metallized to form electrodes of the integrally formed inductor. Therefore, the disclosure provides an integrally formed inductor which is subminiature in size, ultra-thin and high in reliability and a manufacturing method thereof.

Disclosed are a soft magnetic iron-based powder, a preparation method therefor, and a soft magnetic component, which are applicable to various industrial fields such as a core of a motor. According to an embodiment of the disclosed soft magnetic iron-based powder, the powder comprises, in wt %, more than 2% of Si, more than 0.02% of Al, more than 0.05% of Mn, more than 0% and less than 0.1% of O, and the balance being Fe and unavoidable impurities, and satisfies [Si]/[Al]>2, wherein the difference in [Si]+[Al]+[Mn] between D.sub.10 and D.sub.90 may be less than 10 wt %. [Si], [Al], and [Mn] represent wt % of respective elements.

A method for producing a bonded magnet, comprising: (i) low-shear compounding of a thermoplastic polymer and magnetic particles to form an initial homogeneous mixture thereof; (ii) feeding the initial homogeneous mixture into a plasticator comprising a low-shear single screw rotating unidirectionally toward a die orifice and housed within a heated barrel to result in heating of the initial homogeneous mixture until the thermoplastic polymer melts and forms a further homogeneous mixture, wherein said further homogeneous mixture is transported within threads of the single screw towards the die orifice and exits the die orifice as a solid pellet; (iii) conveying the solid pellet into a mold and compression molding the pellet in the mold, to form the bonded magnet, wherein the bonded magnet possesses a magnetic particle loading of at least 80 vol % and exhibits one or more magnetic properties varying by less than 5% throughout the bonded magnet.

An isolated power converter package includes a leadframe including a first and second die pad, first and second supports connected to first leads, second leads. A first semiconductor die is on the first die pad and a second semiconductor die is on the second die pad. The molded transformer includes a top and bottom side magnetic sheet each having a magnetic mold material including magnetic particles in a second dielectric material on respective sides of a laminate substrate including a dielectric material and a first coil and a second coil that each include a coil contact. Edges of the laminate substrate are on the supports. Bond wires are between the first die bond pads and the second leads, between the second die bond pads and the second leads, between the first die bond pads and coil contacts, and between the second die bond pads and the coil contacts.

A pair of iron-based E-shaped cores is arranged so that middle leg core parts of respective E-shaped cores are disposed opposite each other, and coils are respectively attached to the middle leg core parts in a winding state. A cross-sectional area of the middle leg core part orthogonal to an extending direction thereof and a cross-sectional area of an outer leg core part orthogonal to an extending direction thereof have a specified relationship.

An inductor includes a body including a magnetic body having a coil embedded therein and containing magnetic powder. The coil has a winding portion in which a conductive wire is wound around and has a pair of lead portions taken out from the winding portion. The inductor also includes a pair of outer electrodes formed on the body. In the inductor, each of the lead portions is exposed from at least one side surface of the magnetic body and is coupled to a corresponding outer electrode. In addition, with respect to a position at which each of the lead portions is exposed from the at least one side surface of the magnetic body, a magnetic powder content in a region closer to one of the principal surfaces is higher than a magnetic powder content in a region closer to the other one of the principal surfaces.

A magnetic body of the coil component contains, as soft magnetic alloy grains, first grains whose alloy components are substantially Fe, Si, and Cr, and second grains which contain, as alloy components, Fe, Si, and an element other than Si or Cr that oxidizes more easily than Fe; the average grain size of the second grains is smaller than the average grain size of the first grains; the first grains have, on their surface, an amorphous oxide film containing Si and Cr; the second grains have, on their surface, a crystalline oxide layer containing the element other than Si or Cr that oxidizes more easily than Fe; and the crystalline oxide forms adhesion parts, each contacting a multiple number of the first grains via the amorphous oxide film thereof and coupling or bridging the multiple number of the first grains. The coil component can offer improved mechanical strength.

An inductor includes a body including a coil and a magnetic portion, and having two facing principal surfaces and side surfaces adjacent to the two principal surfaces. The coil includes a winding portion formed from a conductor and a pair of extended portions extended from the winding portion. The magnetic portion includes magnetic powder and contains the coil. The winding portion includes a first meandering portion and a second meandering portion each including straight portions continuously formed so as to extend substantially circularly from an outer side to an inner side of the body when the winding portion is seen through the principal surfaces of the body from the principal surfaces. The first and second meandering portions are continuously formed on the inner side of the body. The straight portions constituting the first meandering portion and the straight portions constituting the second meandering portion are disposed apart from each other.

A soft magnetic powder including a core containing a soft magnetic metal material and an insulating film covering the surface of the core. The insulating film contains an insulating metal oxide and an iron component, and the iron component is embedded in the insulating film.

A coil component includes a columnar winding core and flanges at ends of the winding core in positive and negative X directions and which protrude outward in a Z direction orthogonal to the X direction. A first wire is wound around the winding core. A metal terminal attached to the flange includes a reception portion extending away from the winding core in a length direction. A direction in which a dimension of the reception portion is the smallest in directions orthogonal to the length direction is a thickness direction, and a width direction is orthogonal to the length and thickness directions. The reception portion and the first wire are connected by a melted portion whose maximum dimension in the width direction is larger than a maximum dimension of the reception portion in the width direction and is at a portion away from the reception portion in the thickness direction.