A coil-embedded dust core and a method for manufacturing the coil-embedded
dust core are provided. The coil-embedded dust core comprises a coil
formed from a flat conductor wound in a coil configuration, and a green
body consisting of insulating material-coated ferromagnetic metal
particles. This results in a coil-embedded dust core more compact in size
but with larger inductance. A rectangular wire can be used as the flat
conductor. In addition, parts of the coil may function as terminal
sections. In this case, the terminal sections of the coil may be formed
wider than other part of the coil. The coil-embedded dust core is less
prone to joint failures between a coil and terminal sections and to
insulation failures of the coil and the terminal section with respect to
the magnetic powder. The coil-embedded dust core is more compact while
achieving larger inductance.
