Patent ID: 6859994
Filing Date: 2005-03-01
Classification: H01F,Y10T

Abstract:
1. A method for manufacturing an inductor, comprising the steps of: coating a surface of a metal wire having an insulating film thereon with a thermoplastic resin containing magnetic powder to form a coated metal wire; winding the coated metal wire in a single layer to form a solenoid-type coil conductor which is hollow in the inside of the solenoid-type coil conductor; performing a heat treatment on the coil conductor to soften the thermoplastic resin so that portions of the coil conductor that are adjacent to each other are bonded together by the thermoplastic resin; filling a resin containing magnetic powder by injection-molding inside and outside the solenoid-type coil conductor which is placed within a molding die to from an encapsulating molded body having a predetermined shape so as to encapsulate the coil conductor; removing the encapsulating molded body from the molding die; and providing external terminal electrodes on surfaces of the removed encapsulating molded body so as to be electrically connected with the ends of the coil conductor; wherein the steps of winding the coated metal wire, performing heat treatment and filling a resin are performed in this order.