A method for making a thin-film inductor includes the steps of: a) forming an array of coil units from an electrically conductive substrate, b) introducing a magnetic material into mold cavities of a mold unit, c) disposing each of the coil units on the magnetic material in a respective one of the mold cavities, d) introducing additional magnetic material into the mold cavities to completely cover the coil units, e) molding the magnetic material and the coil units in the mold unit to form semi-products, and f) forming, on each of the semi-products, two terminal electrodes and electrically connecting the terminal electrodes to the coil unit so as to obtain the thin-film inductors.

A wire-wound core includes a wound core portion and a first flange and a second flange provided on a first end portion and a second end portion, respectively. The first flange has a bottom surface facing a mounting substrate during mounting, a top surface facing away from the bottom surface, an inner end surface coupling the bottom surface with the top surface and facing the wound core portion, an outer end surface facing away from the inner end surface, and a first side surface and a second side surface that face away from each other and each couple the bottom surface with the top surface and the inner end surface with the outer end surface. In a region of the outer end surface close to the bottom surface, a first inclined surface inclined toward the inner end surface as the first inclined surface approaches the bottom surface is provided.

A wire-wound core includes a wound core portion and a first flange and a second flange provided on a first end portion and a second end portion, respectively. The first flange has a bottom surface facing a mounting substrate during mounting, a top surface facing away from the bottom surface, an inner end surface coupling the bottom surface with the top surface and facing the wound core portion, an outer end surface facing away from the inner end surface, and a first side surface and a second side surface that face away from each other and each couple the bottom surface with the top surface and the inner end surface with the outer end surface. In a region of the outer end surface close to the bottom surface, a first inclined surface inclined toward the inner end surface as the first inclined surface approaches the bottom surface is provided.

A coil structure comprises a coil and a conductive terminal part, wherein the coil is formed by a conductive wire comprising a metal wire and at least one insulating layer encapsulating the metal wire, wherein a first terminal part of the metal wire is exposed from the at least one insulating layer, wherein a first portion of the conductive terminal part encapsulates the first terminal part of the metal wire and a second portion of the conductive terminal part extends from said first portion as an electrode for electrically connecting to an external circuit.

A coil structure comprises a coil and a conductive terminal part, wherein the coil is formed by a conductive wire comprising a metal wire and at least one insulating layer encapsulating the metal wire, wherein a first terminal part of the metal wire is exposed from the at least one insulating layer, wherein a first portion of the conductive terminal part encapsulates the first terminal part of the metal wire and a second portion of the conductive terminal part extends from said first portion as an electrode for electrically connecting to an external circuit.

A manufacturing method of a coil component for forming a coil-assembly body in which a coil is mounted on a magnetic-body core, comprising the steps of: inputting the coil-assembly body and an admixture containing a magnetic powder and a resin into a container; applying pressure onto the admixture which is inputted into the container; depressurizing an air pressure of an environment, in which the admixture is placed, to become a negative-pressure lower than the atmospheric pressure at least during the pressurizing process in the step of applying pressure; applying vibration onto the admixture and filling the admixture in the container at least during the depressurizing process in the step of depressurizing; and curing the resin contained in the admixture for the integrated object of the admixture and the coil-assembly body which passed through the step of depressurizing and the step of applying vibration.

A manufacturing method of a coil component for forming a coil-assembly body in which a coil is mounted on a magnetic-body core, comprising the steps of: inputting the coil-assembly body and an admixture containing a magnetic powder and a resin into a container; applying pressure onto the admixture which is inputted into the container; depressurizing an air pressure of an environment, in which the admixture is placed, to become a negative-pressure lower than the atmospheric pressure at least during the pressurizing process in the step of applying pressure; applying vibration onto the admixture and filling the admixture in the container at least during the depressurizing process in the step of depressurizing; and curing the resin contained in the admixture for the integrated object of the admixture and the coil-assembly body which passed through the step of depressurizing and the step of applying vibration.

A transformer and an assembly method thereof are provided. The transformer includes a hollow bobbin, two magnetic cores, a primary winding, a plurality of first secondary windings and a plurality of second secondary windings. The two magnetic cores are inserted into the hollow bobbin. The primary winding is wound around the hollow bobbin. The first secondary windings and the second secondary windings surround the primary winding. The first secondary windings and the second secondary windings are alternately arranged around the primary winding.

A transformer and an assembly method thereof are provided. The transformer includes a hollow bobbin, two magnetic cores, a primary winding, a plurality of first secondary windings and a plurality of second secondary windings. The two magnetic cores are inserted into the hollow bobbin. The primary winding is wound around the hollow bobbin. The first secondary windings and the second secondary windings surround the primary winding. The first secondary windings and the second secondary windings are alternately arranged around the primary winding.

A formed body incorporating a coil by using: a coil formed by winding a conductive wire, and a formed body incorporating the coil, the formed body being formed with a sealing material containing a resin and a magnetic material. The coil is formed by winding the conductive wire so that lead-out ends are positioned at an outer periphery of a wound portion. The formed body is formed so that surfaces of the coil are partially exposed on four side surfaces of the formed body which are parallel to a winding axis of the coil, and the area of a portion of the formed body outside the outer periphery of the wound portion is almost equal to or smaller than the area of a portion of the formed body inside an inner periphery of the wound portion of the coil.