inductors tuotorial
TRANSCRIPT
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Guidebook for TDK Inductors & Noise Suppression Components
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DC-DC converter
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Inductor's World
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Inductor's World
Welcome to the wor ld of inductors!
You may wonder what exactly electroniccomponents are. Actually they are indispensableitems because electronic devices commonlyused in cell phones, PC's, TV sets, gamemachines, and so on are made up of electroniccomponents. Among them, inductors are a
group of hard workers, performing a varietyof tasksand were getting busier and busierwith the advent of the ubiquitous society inwhich people can easily access a mass ofinformation at any time and any place.Now let me introduce the members of ourinductor world and describe the excellent jobsthey are doing!
Nice to meet you! Im an inductor,one of electronic components.
Let's gointo the worldof inductors.
We pull outonly the desired
signals!
Noise suppressingcomponents
High-frequency inductors
We serveto stabilize
voltage!
Signal inductors
Power inductors
We arecontrolling
signals!
We arecontrolling
high-frequencysignals!
We serveto eliminate
noise!
Noise suppressioncomponents
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An inductor is actually just another name for a coil. Inductors are known as suchbecause, to use a technical term, they have inductive properties. That is, it can beobserved that when an electric current flows through a coil, it produces a magneticfield; or when a magnetic field passes through a coil, it produces an electric current.
What really is an inductor?
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Inductor's World
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Inductor's World
A coil is a long wire that iswound around and around,many many turns.An electric current flowingthrough the coil can producemagnetic field lines just like amagnet.
Inductance
How caninductance (L)be increased?
By increasing thenumber of turns (n)
By using amagnetic core ()
By increasingcoil diameter (S)
Power of the inner coreto concentrate
magnetic field lines(magnetic permeability)
Number ofturns squared
Area ofthe ring
1/Lengthof coil
Coefficientcalculated byDr. Nagaoka,
a physicist
More magnetic field lines are produced when a core is placed inside acoil. This is because the core has the power to concentrate themagnetic field lines. The capability of producing magnetic field lines isreferred to as inductance (L). TDKs specialty is to develop corematerials having larger magnetic permeability(), that is, materialsthat can concentrate more magnetic field lines.
Core Coil without core Inductor (coil)
Various important electronic devices have been produced
using this property, including motors and generators.
Lkn2SLkn2S
1
A coil can transform itselfinto a magnet.
Electric current producesa magnetic field.
When a magnet is moved back and forththrough a coil, an electric current flowsthrough the coil.This is because the coil makes an electriccurrent so that it can produce anopposing magnetic field to counteract themagnetic field produced by the magnet.
A coil can generateelectricity.
Magnetic field producesan electric current.
An inductor is made more powerfulwhen a core is placed inside.
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Coils can store electrical energy in a form of magnetic energy using theproperty that an electric current flowing through a coil produces amagnetic field, which in turn produces an electric current. In other
words, coils offer a means of storing energy on the basis of inductivity(reactive magnetic flux).
Voltage regulating converters are stabilized when used in combinationwith inductors that can store magnetic energy,capacitors that can store electric energy, and a switch.
Choke meansto clog up
the flow of an alternatingelectric current.
Basic principle of choke-coils
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Inductor's World
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Inductor's World
Electric
signals
PassZero frequency, that is,direct current isallowed to pass.
BrakingThe voltage of the passingsignals decreases withincreasing frequencies.
Signal stoppedThe voltage approaches zeroat further higher frequencies,finally stopping the signals.
Low-pass filter High-pass filter
Inductors can be used in combination with capacitors, whichcomplement the function of inductors, to form LC filters that canseparate the required signals from unwanted ones.
Function of coils depends on signal frequencies.This is because the higher the frequency,the less easily the signal flows.
High-frequencysignals areremoved whenthey passthrough thecapacitor.
Low-frequencysignals pass throughthe filter (low-pass)and are sent to theoutput.
Low-frequencysignals areremoved whenthey passthrough theinductor.
High-frequencysignals pass throughthe capacitor (highpass) and are sent tothe output.
OutputInput OutputInput
Noise
An electric current flows in the circuit,and energy is stored in the inductor(charging).
The energy stored in the capacitor is consumed(discharging), and the capacitor, in turn,stores energy and releases it.
Directcurrent
Diode
Semiconductor switching(current is turned ON andOFF at a high speed)
As soon as the current is turned off,the inductor produces magneticfluxes and releases the stored energy.
DC-DC converter (voltage step-down type)
Inductor(choke-coil)
Switching controls causethe output voltage to change
(basic principle ofDC-DC converters).
Capacitor
Coils can control signalsNoise is eliminated,or only the desired signals are allowed to pass.
Coils can store energy Voltage is stabilized.
Inductors can be roughly divided into two types according to their function.One is to control signals, and the other is to store electrical energy.Function of inductors
Reactive magnetic fluxes aregenerated in the coil to counteractthe changes in electric current.
Energy is stored in the coil becauseof the reactive magnetic fluxagainst the alternating current.
Low-pass filtersare also used to
remove high-frequencynoise.
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Signal inductors,wire-wound type
Signal inductors are the basic TDK inductors.They have small transmission loss (lowresistance), featuring a large current-handlingcapacity and high accuracy (narrow tolerance),thus providing a rich lineup that can satisfy the
specifications of our customers.
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Inductor's World
Power inductors,wire-wound type
Signal inductors,multilayer type
It was TDK who developed the worlds first inductors without winding.TDK has also developed high-frequency glass ceramic inductors and thelow-transmission loss Gigaspiral Multilayer Structure.
Noise suppression components,thin-film type
TDK has commercialized thin-film common mode filters to meet thedemand for smaller and thinner electronic devices, forming thin-film
of high flux density ferrite material and high-resolution pattern thinfilm coils on the basis ofstate-of-the-art nanotechnology.
MLK(Gigaspiral Multilayer Structure)
Divided,L-shaped ferrite core
Wire-wound coil
Externalelectrode
Drumcore
MLG
V-shaped ferrite corescorrespond to clothing!
TDK have developed special power inductors based on a newlydesigned unique structure, where a drum core is sandwiched by two
V-shaped cores, thus successfully achieving a large current capacityand reduction in calorific loss.
Ferrite core
Internalelectrode
Internalelectrode
Externalelectrode
Externalelectrode
Wire-wound coil
Exterior resin
Because there is a wide range of applications for and types of electronic devices,various types of inductors are required.TDK inductors are manufactured in many different shapes and sizes, including wire-wound or multilayer inductors, depending on where and how they are to be used.
Various types of inductors
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Inductor's World
Signalinductors(for controllingsignals)
Powerinductors(for stabilizingvoltage)
Noisesuppressioncomponents
GLF NLCV
SLF
ACM MEA
VLCF SLF
ACT ZJYS
MLF NLV TPL
SLF RLFVLF
ACM MMZTCM MEA
VLCF
MLG MLKMLG MLKMLG
GLF
MLK
GLF NL
Installation of
electric components
NLV MLF
Connection to
the Internet Automobaile LANs
High-speed
processing
One-segment
broadcasting
Increased
functionality
Mobile devices(mobile phones or music players)
Inductors are used forvarious equipmentand applications!
Applications andtypes of inductors
Family of inductors for various applications
AutomobilesPersonal computersand gamemachines
Television sets
Larger and thinnerDigitalization
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Trends in mobile phones and marketrequirements for inductorsIncreased number of ICs installed resulting from increase in functions
Increased demand for power inductorsHigh-density circuit board resulting from the increased number of components
Further reduction in size and weightHigh-resolution screen, speech quality assurance
Various noise suppression measures
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Inductor's World
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Inductor's World
Mobile phones are becoming more and more convenient multimedia
terminals as they feature a variety of functions, including cameras, color
liquid crystal displays, GPS navigation, digital money, one segment
broadcasting, and built-in compact HDDs. Inductors are also expected to
contribute to the further enhancement of multifunction mobile phones,
improved battery lives, and improved speech quality.
More and moreTDK inductors are being installed.
Cell phones
The smallest power coilin the industry
High-frequency noiseis absorbed andemitted as heat.
Noise suppressioncomponent in which four
LC filters are integratedinto a single package
Common mode filterdeveloped using thin-
film technology
LC's built-inT-shaped or-shaped
filter
Power supply circuits /DC-DC converters
Power inductors
VLF
Camera circuit section
Chip bead
MMZ
Flexible printedcircuit board (FPC)
LC filter array
MEA
Serial cable
Common mode array
TCM
Logic circuit
LC filter
MEM
EMC countermeasures at the LCD interface
As multifunction mobile phones are becoming popular, energysaving and noise suppression appear to be a problem. Our powerinductors VLF series are now widely used, because theinductors can reduce heating loss and handle a high level ofelectric current, thus contributing to energy saving.
The keys that support multifunction devices areenergy saving and noise suppression.
Serial transmission is the key to improving the design freedom ofmobile phones as the LCD display is often opened, closed, orreversed while in operation. To meet this requirement, we havedeveloped the TCM series of thin-film common mode noisesuppression filters.
To receive one segment broadcasting, we need to payattention not only to the communication frequency band (800MHz 2 GHz), but also the broadcasting frequency band (470 770 MHz). TDK has developed industrys first noise suppressioncomponents in its MEA series for one segment broadcasting.
The thinnest power coildeveloped using TDK'soriginal platingmethod
High-frequencycircuit
High-frequency
inductors
MLG
MLK
Transmission loss isreduced, and high-frequency signals arearranged.
An FPC with 40 or moreparallel signal wires isused as an interface tosend signals to the LCD.
Serial transmission has offered away to enable high-speed, high-capacity data transmission, and areduction in the number ofsignal wires. As a result, thehinge segment could be
narrowed, which, in turn,enabled free omni-directionalmovement. However, at thesame time, common mode noisesuppression measures areneeded.
However, paralleltransmission cannotmatch high-resolutionLCDs and increasedcontent.
Mainstream technique for noise suppressionmeasures in parallel transmission systems isto use LC filters (low-pass filters) combinedwith inductors and capacitors.
In serial transmission systems, common modefilters are indispensable devices to remove thecommon mode noise caused by the phase lagbetween differential signals.
Parallel transmission High-speed serial transmission
Faster transfer speed
Increase in designfreedom
Common modeNoise suppressionmeasures
Noisesuppression
measures
Noisesuppressionmeasures
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Trends in game machines andmarket needs for inductorsDemand for reduction in size and weight
Transition to smaller SMD componentsIncreased number of DC-DC converters resulting from increase in functions
Increased demand for power inductorsBuilt-in fast digital interface
Noise suppression measures using common mode filtersUse of wireless LAN
Increased number of high-frequency components such as high-frequency inductors
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Inductor's World
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Inductor's World
Graphics processing power for recent game machines with high-
definition 3D image processing is so high that it is almost comparable to
that of supercomputers. TDK inductors and noise suppression
components are used in new-generation game machines equipped with
blue-ray discs, HDDs, and wireless LAN capability.
CPU / Graphic processing unit /Image output circuit
Noise suppressioncomponents
Controller
Clamp filter
ZCAT
USB/IEEE interface
TCM
Impedance matching
Do not regard game machines as mere toys. Actually, a game machine is anintegrated mass of state-of-the-art electronic device technologies. Graphicsprocessing power is superior to that of PCs, and comparable to that of somesupercomputers. Some game machines will not only be equipped with HDDs, but
can also use next-
generation DVDs and blue-ray discs.As game machines progress,more and more informationprocessing capacity isrequired, and manyinductors are required fornoise suppression and signalcontrol. Next, we will learnabout impedance, which isindispensable for signalprocessing.
A game machine is an integrated body ofstate-of-the-art technology.
DVD circuit section /HDD circuit section
Power inductor
Signal inductor
GLFMLFMLGMLK
Power supply circuit /DC-DC converter
NLCV
Power inductoroptimized in terms ofmagnetic path design
and dimensions
Transmission loss is reduced,and high-frequency signals
are controlled.
Noise is reduced by onlypassing appropriate
signals through the cable.
Common mode filterfor high-speed datatransmission lines
High-frequency noiseis absorbed andemitted as heat.
ACM
MMZ
Impedance is the resistance to alternatingcurrent flow in an electrical circuit.Impedance can be roughly consideredfrom two directions, that is, 1) impedancetoward the signal source direction, and 2)
impedance toward the load direction.Impedance matching is required betweenthe two impedances. Unless the matchingbetween them is properly performed, thecircuit reflects back some of the signals,causing transmission loss, or distortssignals, preventing normal transmission ofdata. This is why we need signal inductorsto do their job. TDK has a rich lineup ofinductors, including the MLF seriesandthe high-frequency MLG seriesinductors, which satisfy our customersneeds for signal inductors.
SLFVLCF
Loadimpedance
Signal sourceimpedance
Signal coilsare used to perform
impedance matching.
Common mode filterdeveloped using thin-film technology
Decoupling coil for ICpower supply lines
More and moreTDK inductors are being installed.
Game machines
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Trends in television sets andmarket needs for inductorsReduction in panel size and thickness, emphasis on design
Transition from components with lead wire to SMDHigh-density circuit board
Less space for inductors (reduction in occupied area)Lower electric power consumption for energy saving
Lower direct-current resistance of power inductorsNetworking with digital equipment
Noise suppression of high-speed digital interface circuits
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Inductor's World
In place of CRT-based television sets, mainstream televisions are now
those with large-screen flat displays or plasma displays. After the
beginning of terrestrial digital broadcasting, not only screen size, but
also image quality and various optional functions are drawing
consumers attention.
Digital block / Digital tuner
Signal inductorNoise suppressioncomponents
MMZ
Differential transmission system andcommon mode noise
In Japan, analog broadcasting will finish at the end of July 2011, and digitalbroadcasting will follow. The well known white, red, and yellow cable connectorswill disappear, and all the transmission systems for television sets will be unified
with a High-Definition Multimedia Interface (HDMI). In other words, you can easilyconnect your television set to otherequipment through a single cable.HDMI uses a differential transmissionsystem to send high quality signals ata high speed without compressingthem. However, one problem iscommon mode noise. TDK tookadvantage of filter designtechniques and various advancedtechnologies that have beenaccumulated in the company, andhave successfully developed theACM-H and TCM-H seriescommon mode filters that have a farwider transmission band thanconventional filters.
Audio-visual equipment can beeasily connected to television sets usingthe next-generation interface, HDMI.
Noise can be divided into two types: normal mode and
common mode noise. Common mode noise is caused by thedifferential transmission system in which a pair of identicalsignals but of opposite polarities are sent.
NLCV
Power supply circuit /DC-DC converter
Power inductor
SLFVLCF
DVI/HDMIinterface
Common mode filter
ACMTCMCommon mode filtersare used to absorb andstabilize common modecomponents.
Occurrence of common mode noise
Phase lag
Difference in signal amplitude
Shaped waveform
Difference between rise timeand fall time
Output to HDMI terminal
Input to HDMI terminal
VHF/UHF input
VHF/UHF output
To antennaVHF/UHF input
Audio output
No white, red, and yellow cables are necessary.
Audio input
Power inductoroptimized in termsof magnetic pathdesign anddimensions
Decoupling coilfor IC powersupply lines
High-frequencynoise is absorbedand emitted as heat.
Common mode filterfor high-speed datatransmission lines
Common modefilter developedby using thin-filmtechnology
Transmission lossis reduced, and
signals arecontrolled.
Power cord
Clamp filter
ZCATNoise is reducedby only passingappropriatesignals throughthe cable.
More and moreTDK inductors are being installed.
Television sets
MLFGLF
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Trends in automobiles andmarket needs for inductorsPursuit of safety High-reliability, impact resistance, water resistanceECU installation in engine rooms 40~125C, high-reliabilityNoise suppression measures applied to in-vehicle LAN Common mode filters for automobiles
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Inductor's World
It is said that an automobile is made up of more than 20,000 components,
and the percentage of electronic components to the total number of
components is constantly increasing. Further, electronic components are
not allowed to malfunction because they are used in the vehicles to
which our lives are committed. What is needed is a highly reliable
product that can be used even in a harsh environment.
The Controller Area Network (CAN)BUS is one of the standards for in-vehicle LANs, which was designed toreduce the weight of automobiles. ACAN-BUS is less subject to noise
because it uses the differentialtransmission system, but commonmode noise still becomes a problem.The performance of TDKs ACTseries common mode filterhas beenenhanced, and they are now availablein a temperature range from 40 to150 C. The common mode filters aredesigned for good performance inharsh environments such as in engineroom. In addition, TDK has alsodeveloped theACM-V seriescommon mode filters for automobileECU power supply lines.
Common mode filters are indispensable forvehicles equipped with electrical components.
Moisture-resistant
small size power inductor
Heatproof SLFavailable up to 125
C
Moisture-resistantpower inductor
Heatproof RLFavailable up to 150
C
Transponder coil
TPLseries
High-speedCAN
Low-speedCAN
LIN
Safety use
MultimediaPower train / Body
Engine Control Unit (ECU), etc.
Heatproof ACTavailable up to 150
C
Common modefilter for in-vehicleLAN (CAN-BUS /FlexRay)
ACMGuaranteed inthe temperaturerange from -40 to 125
C.Used for noisesuppression in ECU powersupply lines.
Common mode filterfor in-vehicle LAN(CAN-BUS)
Common mode filter for MOST
Heatproof ACMavailable up to 105
C
Common mode filter formultimedia in-vehicle LAN (MOST)
Heatproof clamp filterfor automobile use
ZCAT
High-reliability large-
current three-terminal filter
ACHEMC filter for glass antennas
ZCD
High-frequency inductor
MLGMLK
Transponder(transponder coil, air-pressure sensor, etc.)
Transmitting andreceiving antenna
Car navigation, ETC, etc.
Tire pressure monitoring systems(TPMS), immobilizer
(motor vehicle antitheft systems),keyless entry systems, etc.Antenna coil for
receiving radio waves
Power inductor optimizedin terms of magnetic path
design and dimensionsPower inductoroptimized in termsof magnetic pathdesign anddimensions
Transmission loss is reduced,and high-frequency signals
are controlled.
Noise is reduced byonly passing appropriatesignals through the cable.
More and moreTDK inductors are being installed.
Automobiles
ZJYSTire-Pressure Monitoring System(TPMS)
needs transponder coilInstallation of the tire pressure surveillance system in North-Americanautomobiles was made obligatory in 2003. This surveillance system is awireless communication-based safe-driving system, and uses a pressure sensorto detect information on individual tires,which is wirelessly sent to the mainsystem in the drivers compartment. TDKsTPL series transponder coils are used asantenna coils to receive the signals fromthe sensors. In order to develop small,high-sensitivity, and reliable transpondercoils, advanced core technology and wire-winding techniques are required.
CAN is divided into three typesdepending on communication speed:
High-speed CAN (250k~500kbps)Low-speed CAN (around 125kbps)LIN (20kbps)
In the above picture, common mode filtersare used at the points marked with open circles.
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Magnetic core for inductors is where TDK started.
Long years of accumulated raw material technology
Advanced wire-winding technique,accurate to an order of microns
Layering technique that enabled realization ofinductors without wire-wound coils
It is virtually impossible to wind wires around very small coil cores, which are lessthan 1 mm long. TDK has developed machines that can wind wires not onlyaccurately, but also at a high speed around many tiny cores. For example, the high-precision automatic wire-winding machine (lower-left picture) is capable ofsimultaneously winding wires around a large number of coil cores. In addition, thegap between wires for common mode filters (lower-right picture) is controlled to an
order of microns. Two wires are
wound at the same time and at thesame space interval to produceeffective noise suppressioncomponents.
The first key point to raw material technology is composition. The basiccharacteristic of raw materials is decided by what materials are mixed at what rateand at what timing. The next point is firing. Not only temperature and firing time,but also the environment in the firing furnace (oxygen condensation) must be
accurately controlled. In addition, very small
cores must be very carefully formed to preventthem from becoming cracked or chipped.
As we have explained, coils are made by winding wires aroundcores, but TDK has upset this conventional wisdom. Ferrite materialis first processed to a paste, which is then formed as a thin sheet offilm. Next, a conductive pattern is printed on the film. Then, some
films with conductive patterns are stacked in layers, and finally thelaminated body is fired. Using this innovative method, TDKrealized the worlds first chip inductor in 1980. TDK inductors weremanufactured on the basis of TDKs original techniques from itsaccumulated know-how such as paste mixing, pattern printing,laminating, and firing.
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Inductor's World
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Inductor's World
The worlds first commercialized ferrite cores
Layered structure ofchip inductorsCrystal structure of ferrite
The magnetic material referred to as ferrite is widely used foralmost all inductor cores. TDK was founded to industrialize themanufacture of ferrite. Since then, TDK has launched productsthat serve to support our lives, including not only inductors, butcapacitors, magnetic heads, andrecording media, on the basis ofthe material technologycultivated through ferrite
manufacturing, as wellas process technologiesthat can takeadvantage of thosematerials.
Microscopic
molding
Ferrite core that isnarrower than the lead ina mechanical pencil
Originating
from TDK!
Advancedwire-winding
technique
This is where
TDK started.
Why are TDK inductors so competitive? The answer is because TDK has beenconsistently tackling various issues from raw material technology to processtechnology, and even the development of devices.TDKs advantages
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Inductor's World
Inductors are manufactured through various processes.Furthermore, expert know-how is required for each of thoseprocesses. Here, lets see how typical wire-wound products andmultilayer products are manufactured.
Wire-winding
Frame processing
Molding
A wire is wound around the core,and the terminals of the wire areconnected to the core.
The wire-wound core issandwiched by the frame.
Resin is poured over thecoil sandwiched by theframe.
The resin-covered coil is separated,and the frame is bent to formelectrodes
Core manufacturingAfter the processes of creatingthe fine particles, molding, andfiring, electrodes are formed onthe manufactured core (magneticcore).
Terminal treatment
Ferrite powder and resinare mixed to form ferritepaste.
Paste forming
The ferrite paste is flattenedinto a sheet form, andelectrodes are printed on it.
Sheet formingand printing
The stacked sheets are cut witha blade into the prescribed size,and perfectly fired in a furnace.
Both ends of the fired coil aredipped in electrode paste, andthen baked. Next, the entirebody of the coil is dipped inplating solution.
Electrode-printed ferrite sheetsare stacked in layers andpressed.
Multilayer process
Cutting and firing
Electrode coating and plating
Wire-winding type Multilayer type
Manufacturing process of in ductors
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TDK Inductors World
Date of Issue: September 5 2006 Publisher: Corporate Communications Department TDK Corporation
History of TDK Inductors and Noise Suppression Components
* Thi b h i i t d l d
1937 Worlds first ferrite coil cores launched
1962 TDKs first coils (peaking coils for TVs) launched
1962 TDKs first noise suppression device, Synchro V Socket, launched
1964 Linearity coils for color TVs launched1965 Line filters for color TVs launched
1972 Feed-through noise filter FN for communication instruments
and measuring equipment launched
1973 Dust-cored SF coils for noise filters launched
1977 Voltage step-up coil WT to drive sound-making devices in wristwatches launched
1978 Automatic manufacturing lines for small fixed coils (SP type) introduced
1980 The worlds first multilayer chip coil MLF launched
1982 Leadless coil NL launched
1983 Multilayer LC filter MXF launched
1985 Three-terminal signal noise filter ZJS launched
1988 Power chip coil SLF launched
1988 Multilayer integrated device MHD launched
1989 Clamp-type noise filter ZCAT launched
1990 Awarded the Okochi Memorial Technology Prize for developing technologies
and commercial production of multilayer integrated circuits
1991 Received the Science and Technology Merit Award under the Director-General of Science
and Technology Agencys Award for developing multilayer integrated circuits
1993 Thin-film chip coil NLU launched
1995 Multilayer LC filter array MEA (-type) launched
1996 High-frequency multilayer coil MLG launched
1998 High-frequency multilayer coil MLK launched
1999 Multilayer power bead MPZ launched
2000 Small common mode filter ACM2012 launched
2002 Wire-wound magnetic shield coil GLF1608 launched
2003 Multilayer chip bead MMZ0603 launched
2003 Thin-film common mode filter TCM launched2003 Transponder coil TPL for automobiles launched
2003 Power coil RLF7045/RLF10165 for automobiles launched
2003 Power coil VLF launched
2004 Multilayer chip bead MMZ0402 commercialized
2005 Power coil TFC commercialized (thinnest in the industry
and manufactured using our own plating method)
2006 High-frequency multilayer coil MLG0402 commercialized
(smallest multilayer ceramic coil in the industry)