Stacked magnetic cores that can achieve high density with a small footprint, as well as methods of fabricating and using the same, are provided. A stacked magnetic core can be fabricated by depositing nanomagnetic films with control in composition and nanostructure via a continuous electroplating process. The magnetic films are interspersed with thin adhesive films (that can be insulating) in an automated roll-to-roll process. That is, the magnetic films and adhesive films are disposed in an alternating fashion. The adhesive films can keep the magnetic films completely electrically isolated from each other, while also adhering adjacent magnetic films to each other.

A method for connecting lamination parts to form a lamination stack in which lamination parts are stamped out from an electrical strip that is coated with an activatable adhesive layer on at least one of its flat sides and the stamped-out lamination parts are stacked and glued to form lamination stacks, wherein before the lamination parts are stamped out, the electrical strip is embossed in a first sub-region, which produces multiple protruding spacers on at least one flat side of the electrical strip, which spacers, after a first lamination part is stamped out from this first sub-region, facilitate a detachment of the stacked and glued lamination parts into lamination stacks.

Provided is a grain-oriented electrical steel sheet having better transformer iron loss property than conventional grain-oriented electrical steel sheets. A grain-oriented electrical steel sheet comprises: a steel substrate; a forsterite film on a surface of the steel substrate; and a Cr-depleted layer at a boundary between the steel substrate and the forsterite film, the Cr-depleted layer having a Cr concentration that is 0.70 times to 0.90 times a Cr concentration of the steel substrate.

A coil electronic component includes a magnetic body having an internal coil part embedded therein, in which the internal coil part includes an insulating substrate, a first insulator, a coil conductor, and a second insulator. The first insulator is disposed on at least one of first and second main surfaces of the insulating substrate and has a groove formed therein. The coil conductor is formed inside the groove. The second insulator encloses the insulating substrate, the first insulator, and the coil conductor. The first insulator may be formed to a thickness larger than (and no more than 40 μm thicker than) a thickness of the coil conductor on the insulating substrate. The first insulator may be formed to a width of 3 μm to 50 μm. Further, the second insulator may extend to a thickness 1 μm to 20 μm larger than that of the first insulator on the insulating substrate.

In at least some implementations, a lamination stack includes a plurality of plates coupled together, each plate including at least one leg that collectively define a leg of the stack, with the leg of the stack arranged so that a wire coil may be arranged on the leg of the stack, and wherein the leg of the stack includes a location feature arranged to facilitate location of the stack relative to an adjacent component. In at least some implementations, the location feature may be integrally formed with at least one of the plates, and may be defined by a projection extending from a free end of at least one leg of the stack.

A method for manufacturing an electronic-component includes a step of forming a laminate substrate including a plurality of laminates disposed in a direction intersecting with a lamination direction via a division portion by laminating a plurality of insulator layers, and a step of singulating the plurality of laminates by removing the division portion. The step of forming the laminate substrate includes a step of forming an insulator resist layer containing an insulating material on a base material, the insulating material being a constituent material of each of the insulator layers and a step of forming the insulator layer by curing the insulator resist layer by exposure, except for at least an insulator resist portion corresponding to the division portion. The division portion including the insulator resist portion is removed by development in the step of singulating.

A manufacturing method of a thin-film power inductor includes: Alloy powder is mixed with plasticizer, adhesive, curing agent, dispersing agent and organic solvent to form slurry; the slurry is applied on a PET film, and drying to form a magnetic band; and the magnetic band is cut to form a plurality of magnetic sheets. A hole is opened on a magnetic sheet to form a hole-shaped magnetic sheet. Electrodes are processed on an insulating substrate to form a coil layer. Magnetic sheets, hole-shaped magnetic sheets, and the coil layer are stacked to form a block. The block is pressed, and the block is cut to form an individual product. The individual product is baked to form a main body. Silver paste is applied on the main body to form outer electrodes. A nickel layer and a tin layer are electroplated on outer electrodes to form a thin-film power inductor.

A coil component according to one or more embodiments includes a base body having first to sixth surfaces, and a coil conductor including a winding portion that extends around a coil axis intersecting the first and second surfaces. The winding portion includes first, second, third, and fourth portions facing the third, fourth, fifth, and sixth surfaces, respectively when viewed from a direction of the coil axis. The radii of curvature of the first and second portions are both smaller than the radii of curvature of the third and fourth portions. When viewed from the direction of the coil axis, the distance between the first portion and the third surface and the distance between the second portion and the fourth surface are both larger than the distance between the third portion and the fifth surface and the distance between the fourth portion and the sixth surface.

Optimum magnetic core assembly (100) and manufacturing process thereof comprising a primary magnetic alloy (101) and at least one supplementing magnetic alloy (102), made of a magnetic material (90) pre-coated with an electrically insulating layer (90C); the optimum open magnetic core assembly (100) has a pair of ends of a laminated magnetic core (110), each of the pair of ends of the optimum magnetic core assembly (100) being one of a co-facing (111) and a flat (113), or a co-facing (111) and a contoured (114), or a co-planer (112) and a flat (113), or a co-planer (112) and a contoured (114); a process of producing is one of a wrapping based process ONE (30) or a stamping based process TWO (40) followed by a magnetic performance treatment (50); the optimum magnetic core (100) is a hybrid core wherein the laminations are grouped and or interlaced laminations (70).

The present invention provides an apparatus for producing a laminated steel core, which is capable of punching out steel core sheets having a predetermined shape from a thin steel strip while stably supporting the thin steel strip. The present invention also provides a method for producing a laminated steel core. A support 23a provided in a lower die 21 supports a thin steel strip 22 from its bottom and extends across the width of the thin steel strip and in the feed direction of the thin steel strip.