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 power control module and a method to create the power control module is provided. The power control module includes a plurality of transformers, wherein each transformer of the plurality of transformers includes a stack of ferrite cores comprising a plurality of ferrite cores and a continuous winding. The continuous winding has a plurality of turns through each ferrite core of the plurality of ferrite cores. The plurality of ferrite cores are oriented such that the plurality of ferrite cores are stacked together with legs of the plurality of ferrite cores oriented in opposite directions, and wherein the continuous winding comprises a folded section that extends between the plurality of ferrite cores of the stack of ferrite.

A dry type cast coil transformer (28) includes a hollow body (29), a dome structure (26) extending from the body, and undulation structure (30), defining at least a portion of an outer surface of the dome structure, constructed and arranged to increase an electrical track path in the dome structure.

A coil component includes a molded portion having one surface and another surface opposing each other, and a wound coil disposed on the one surface of the molded portion and including an innermost turn, at least one intermediate turn, and an outermost turn disposed outwardly of a central portion of the one surface of the molded portion. A cover portion is disposed to face the one surface of the molded portion and to cover the wound coil, and first and second external electrodes are connected to the wound coil and arranged to be spaced apart from each other on the other surface of the molded portion. A thickness of one region of the cover portion disposed on the innermost turn is thicker than a thickness of another region of the cover portion disposed on the outermost turn.

A structure includes a first encapsulating layer, and a first coil in the first encapsulating layer. A top surface of the first encapsulating layer is coplanar with a top surface of the first coil, and a bottom surface of the first encapsulating layer is coplanar with a bottom surface of the first coil. A second encapsulating layer is over the first encapsulating layer. A conductive via is in the second encapsulating layer, and the first conductive via is electrically coupled to the first coil. A third encapsulating layer is over the second encapsulating layer. A second coil is in the third encapsulating layer. A top surface of the third encapsulating layer is coplanar with a top surface of the second coil, and a bottom surface of the third encapsulating layer is coplanar with a bottom surface of the second coil.

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.

An insulating layer, which is composed of a material having a higher insulating property than a core, partially covers a surface of the core. A plating layer, which functions as an electrode, is stacked on a surface of the insulating layer. The surface area of the insulating layer is larger than the surface area of the plating layer and the plating layer is stacked inside a region covered by the insulating layer.

The present invention provides a multilayer transformer PCB structure for an electric car and manufacturing method for the same, which includes first and second connecting copper tabs horizontally formed in plural on both surfaces of a base substrate, thereby forming inner layer circuits coupled to battery cells, and third and fourth connecting copper tabs stacked on a top surface of the first connecting copper tab and a top surface of the second connecting copper tab by patterning process a copper material several times as a predetermined thickness, thereby forming outer layer circuits coupled to the battery cells. According to the present invention configured thus, the transformer PCB for an electric car has a structure in which a conductive material having a predetermined thickness is stacked in a multilayer form, and thus an increased quantity of charges to be treated is highly distributed, thereby maximizing current efficiency.

A coil module includes a conductor layer, at least one element, and a sealing resin. The conductor layer is formed along a predetermined plane and includes a wiring portion and a helical-shaped coil portion. The at least one element is mounted on the wiring portion. The sealing resin covers the conductor layer and the at least one element. The sealing resin is integrally formed of a single type of resin material and has a predetermined thickness in a first direction perpendicular to the plane.

A coil includes a wound body and a resin covering. The wound body is configured by winding a conductor. The wound body is pressure-molded. The resin covering covers a surface of the wound body.