Patent ID: 7219416

Claim:
A method of manufacturing a magnetic element comprising a composite magnetic body containing metallic magnetic powder and thermosetting resin and having a packing ratio of the metallic magnetic powder of 65 vol % to 90 vol % and an electrical resistivity of at least 10 4 Ω·cm, and a coil embedded in the composite magnetic body, the method comprising: dividing uncured thermosetting resin into first and second portions; mixing metallic magnetic powder and the first portion of the thermosetting resin present in an uncured state to provide a first mixture; pre-heating the first mixture; mixing the pre-heated first mixture and the second portion of the thermosetting resin to provide a second mixture; obtaining a molded body by pressure-molding the second mixture to embed the coil; and curing the second mixture of the thermosetting resin by heating the molded body.