A method of fabricating an inductor device includes preparing a conductive coil, connecting two terminals to one of two ends of the conductive coil, molding a pillar from a plurality of first composite material powders by a pressing process where each first composite material powder is composed of a first magnetic material powder coated with a first thermosetting resin, placing the pillar in a surrounding space formed by the conductive coil, molding a cladding body from a plurality of second composite powders where the second composite material powders is composed of a second magnetic material powder coated with a second thermosetting resin, heating the cladding body, the conductive coil and the pillar cladded by the cladding body such that the plurality of first magnetic material powders are bonded by the cured first thermosetting resin and the plurality of second magnetic material powders are bonded by the cured second thermosetting resin.

A core component is made of a sintered body of an inorganic powder, in which the core component includes a columnar winding portion and a flange portion integrally formed with the columnar winding portion at both axial ends of the columnar winding portion, in which when observed in a cross section perpendicular to an axial direction, a surface layer portion of the columnar winding portion and a surface layer portion of the flange portion have a void occupancy area smaller than a void occupancy area of an inside of the columnar winding portion and of an inside of the flange portion, respectively.

A coil component includes a body having a molded portion and a cover portion disposed on one surface of the molded portion, and including magnetic metal powder; a winding coil disposed between one surface of the molded portion and the cover portion and embedded in the body, and including a coating layer surrounding a surface of each of a plurality of turns; and a first protective film disposed between the one surface of the molded portion and the cover portion and between at least a portion of the surface of the winding coil and the cover portion.

A manganese-zinc ferrite with a high magnetic permeability at negative temperature and low loss at high temperature consists of Fe.sub.2O.sub.3, MnO and ZnO, and additives consisting of CaCO.sub.3, ZrO.sub.2, Co.sub.2O.sub.3 and SnO.sub.2 are also added. A method for preparing the manganese-zinc ferrite is further provided. According to the method, by reasonably adjusting a ratio of Mn to Zn to Fe and appropriately increasing the content of Co in the additives, a manganese-zinc ferrite material with both a high magnetic permeability and low loss at about −20° C. and low loss at 120-140° C. is obtained. The manganese-zinc ferrite material has two loss valleys at about −20° C. and about 100° C. in a temperature range of −30° C. to 140° C., which expands the application range of the manganese-zinc ferrite material.

A core component is made of a sintered body of an inorganic powder, in which the core component includes a columnar winding portion around which a conductive wire is wound, the columnar winding portion having a first axial end and a second axial end and a flange portion integrally formed with the winding portion at both axial ends of the winding portion, in which the columnar winding portion includes, in a cross section orthogonal to an axial center, a first region having a curved outer peripheral surface having a first radius of curvature and a second region having a curved surface having a second radius of curvature, the second radius of curvature is smaller than the first radius of curvature and the first region and the second region are connected with each other via a first projection.

A forming method of a composite magnetic sheet. The forming method comprises a preparing step, a forming step and a heat-treating step. In the preparing step, magnetic slurry is prepared by mixing at least a soft magnetic powder having a flat shape, a first resin having a solid component and a second resin having a solid component, weight loss of the solid component of the first resin being 4.0% or less at 220° C., weight loss of the solid component of the second resin being 5.0% or more at 220° C. In the forming step, the magnetic slurry is formed into an intermediate body having a sheet-like shape. In the heat-treating step, the intermediate body is heat-treated at a heat-treatment temperature between 220° C. and 400° C. (both inclusive).

A method for producing an inductive charging device may include inserting a ferrite and a coil, wound from a braid, into a mould; and encasing the ferrite and the braid at least partially with a plastic in a low pressure casting method, a pressing transfer moulding method, or an injection moulding method.

A system for forming a bulk material having insulated boundaries from a metal material and a source of an insulating material is provided. The system includes a heating device, a deposition device, a coating device, and a support configured to support the bulk material. The heating device heats the metal material to form particles having a softened or molten state and the coating device coats the metal material with the insulating material from the source and the deposition device deposits particles of the metal material in the softened or molten state on the support to form the bulk material having insulated boundaries.

A coil component includes a winding core that includes a winding core portion, a first flange portion, and a second flange portion. The coil component further includes a plate core that has a main surface facing the winding core portion, the first flange portion, and the second flange portion, that extends between the first flange portion and the second flange portion, and that is secured to the winding core by using adhesive. Each of the first flange portion and the second flange portion has an upper surface that faces the main surface of the plate core. Recessed portions are formed on the corresponding upper surfaces. Protrusions may be formed in corresponding regions in which the recessed portions are formed.

An magnetic component structure with thermal conductive filler is provided in the present invention, including an upper magnetic core, a lower magnetic core combining with the upper magnetic core to form a casing with a front opening and a rear opening, and a coil mounted in the casing, where two terminals of the coil extend outwardly from the front opening, and a thermal conductive filler filling between the casing and the coil in the casing.