JP6425073B2 - Inductor - Google Patents

Description

  The present invention relates to an inductor comprising a coil and a magnetic core.

  As components provided for various products such as automobiles, electrical devices, industrial machines, etc., there is a magnetic component called an inductor including a coil having a winding portion obtained by spirally winding a winding and a magnetic core in which the coil is disposed. .

  Patent Document 1 discloses a choke coil as an example of an inductor. The choke coil includes a coil having a single winding portion, a bobbin having a winding drum (core body) around which the winding is wound, a columnar inner core and a winding portion housed in the winding drum. And a magnetic core having a rectangular frame-like outer core that encloses the outer periphery and forms a closed magnetic path with the inner core.

  Patent documents 2 and 3 disclose a reactor as an example of an inductor. The reactor of Patent Document 2 includes a coil having a single winding portion, and a magnetic core having an inner core portion housed in the winding portion and a connecting core portion covering the coil and the inner core portion. The reactor of Patent Document 3 includes a coil having two winding portions arranged side by side, a magnetic core having a plurality of core pieces and a gap material respectively disposed inside and outside each winding portion, a set of a coil and a magnetic core And an outer resin portion covering an outer periphery of the object.

Unexamined-Japanese-Patent No. 2013-051402 JP, 2011-129593, A JP, 2011-054613, A

  In addition to excellent manufacturability, an inductor excellent in installation workability is also desired.

  In the choke coil of Patent Document 1, it is necessary to assemble a bobbin for holding the coil, an inner core, and an outer core, the number of assembled parts is large, and improvement in productivity is desired. In addition, as shown in FIG. 8 of Patent Document 1, when using an independent fixture for fixing to the installation object, the process of arranging the fixture is required, the number of processes is large, and improvement of the installation workability is also desired. .

  The reactor of Patent Document 2 requires a step of housing the inner core portion in the winding portion and a step of subsequently forming the connection core portion, and the number of steps is large, and improvement in productivity is desired.

  In the reactor of Patent Document 3, since the number of winding parts, the number of core pieces, and the number of gap members are large, the number of assembling parts is further increased, and improvement of the productivity is desired.

  Therefore, it is an object of the present invention to provide an inductor which is excellent in manufacturability as well as requiring no assembly of a coil and a magnetic core and also excellent in installation workability.

  An inductor according to one aspect of the present invention includes a coil including a winding portion formed by winding a winding in a spiral, a winding lead-out portion continuing to the winding portion, and the coil is disposed inside and outside the winding portion. And a magnetic core that forms a closed magnetic circuit. The magnetic core is made of a composite material containing a soft magnetic powder and a resin, and the embedded portion in which the wound portion is embedded and the flange portion including a cylindrical member forming a through hole of the installation fastening member are integrated. It is a molded compact.

  According to the above-described inductor, it is not necessary to assemble the coil and the magnetic core, which is excellent in manufacturability, and also excellent in installation workability.

FIG. 2 is a schematic perspective view of the inductor of the first embodiment. 5 is a front view of the inductor of Embodiment 1. FIG. FIG. 7 is a schematic perspective view of an inductor of a second embodiment.

Description of the embodiment of the present invention
First, the contents of the embodiment of the present invention will be listed and described.
(1) An inductor according to one aspect of the present invention includes a coil including a winding portion formed by spirally winding a winding, a winding lead-out portion continuing to the winding portion, and a coil of the winding portion And a magnetic core disposed inside and outside to form a closed magnetic circuit. The magnetic core is made of a composite material containing soft magnetic powder and a resin, and the embedded portion in which the wound portion is embedded and the flange portion including the cylindrical member forming the through hole of the installation fastening member are integrated. It is a molded compact.

  The above-mentioned inductor is excellent in manufacturability and also excellent in installation workability because of the following reasons.

(Manufacturability)
In the above inductor, since the coil and the magnetic core are integrated, there is no need to assemble the coil and the magnetic core in the manufacturing process. Therefore, when the coil and the magnetic core are parts independent of each other, the above-described inductor has a smaller number of assembled parts and is excellent in manufacturability as compared with the case of including a bobbin.

  Further, the above-mentioned inductor can be manufactured, for example, by housing a coil and a tubular member in a mold and injection molding or the like a molten mixture containing soft magnetic powder and raw material resin. Since the molten mixture is excellent in fluidity, even if it has a complex three-dimensional shape including a buried portion and a flange portion, it further covers the inside and outside of the winding portion of the coil and covers the outer periphery of the cylindrical member. Even if it has a shape, it can be molded accurately and easily. Also from this point, the above-described inductor is excellent in manufacturability.

(Installation work efficiency)
The above-mentioned inductor is mounted on the installation object by tightening an installation fastening member such as a bolt or a screw in the through hole of the flange portion after mounting on the installation object. Therefore, the above-mentioned inductor has few processes compared with the case where the above-mentioned attachment is used, and is excellent in installation operativity.

  (2) As an example of the above-mentioned inductor, a form where the above-mentioned winding lead-out part is not covered with the above-mentioned composite material but is exposed is mentioned.

  It can be said that the magnetic core of the above-described form substantially covers only the winding portion of the coil. Therefore, said form can reduce the raw material usage-amount of a magnetic core.

  (3) As an example of the inductor, the embedded portion and the flange portion are provided with an installation surface on which the installation object is mounted, and the installation surface of the flange portion is the installation object by the installation fastening member In the attached state, the axial direction of the winding portion may be formed so as to be orthogonal to the mounting surface of the installation target.

The above-mentioned form has the following effects in addition to being excellent in the above-mentioned manufacturability and installation workability.
・ The installation surface is large and stable because one surface of the buried part is part of the installation surface.
・ Since the buried part is part of the installation surface, stable installation is possible even if the flange part is made smaller. If the flange portion is made smaller, the size can be reduced, and the amount of raw material used can be reduced as described above.
-Since the installation surface is large, when the soft magnetic powder contains a powder made of a material having excellent thermal conductivity, the heat of the coil is favorably transmitted to the installation object and the heat dissipation is excellent.

  (4) As an example of the above-mentioned inductor, the field by the side of the above-mentioned winding part in the above-mentioned winding lead-out part includes a form including a portion parallel to the axis of the above-mentioned winding part.

  In addition to being excellent in the above-mentioned manufacturability and installation workability, the above-mentioned form may be able to make an installation space small. Here, the installation space of the inductor may be designed based on a virtual rectangular parallelepiped including the inductor. The virtual rectangular parallelepiped includes the connection portion with the winding portion in the winding lead-out portion that can be disposed close to the installation target and the vicinity thereof. Therefore, for example, in the form of (3) described above, when the region on the winding portion side including the connection portion with the winding portion in the winding wire extraction portion is drawn out in the direction orthogonal to the axis of the winding portion, There may be a large number of portions disposed away from the winding portion in the winding lead portion. As a result, a virtual rectangular solid tends to be large. On the other hand, in the configuration of the above (3), if substantially the entire length of the region on the winding portion side is drawn parallel to the axis of the winding portion, the winding lead portion is disposed in the vicinity of the winding portion It is easy to make the virtual cuboid smaller. That is, in this case, the installation space can be reduced and the size is reduced.

  (5) As an example of the above-mentioned inductor, the form in which the above-mentioned winding part is one is mentioned.

  The above-mentioned form is easy to become small compared with the case where it has two winding parts in addition to being excellent in the above-mentioned manufacturability and installation workability, and is small from this point.

Details of the Embodiment of the Present Invention
Hereinafter, specific examples of the inductor according to the embodiment of the present invention will be described with reference to the drawings as appropriate. In the figure, the same name means the same thing.

Embodiment 1
The inductor 1A according to the first embodiment will be described with reference to FIGS. FIG. 2 shows a partial cross-sectional view in which only the flange portion 35 is cut in parallel to the (II)-(II) cutting line shown in FIG. 1, that is, the axis of the through hole 35 h of the flange portion 35.

Overall Configuration The inductor 1A is a magnetic component including a coil 2A having a winding portion 20 formed by winding a winding 2w, and a magnetic core 3A disposed inside and outside the winding portion 20 to form a closed magnetic path. . In the inductor 1A, an installation fastening member (not shown) such as a bolt or a screw is fastened and fixed to an installation target 100 (FIG. 2) such as a substrate, a terminal block, or a water cooling table. In this inductor 1A, the magnetic core 3A is a molded body of a composite material (hereinafter sometimes referred to as a soft magnetic composite material) containing a soft magnetic powder and a resin, and the molded body has the wound portion 20 embedded therein. One of the features of this molded body is that the molded body integrally includes a flange portion 35 including a cylindrical member 350 which forms the through hole 35 h through which the above-mentioned installation fastening member is inserted. Each element will be described below.

Coil The coil 2A is constituted by the winding 2w, and includes a winding portion 20 having at least one turn, and winding lead portions 2Al and 2Al not forming a turn. The coil 2A of this example is continuous with one winding portion 20 formed by spirally winding one continuous winding 2w without a connection portion, and the winding portion 20, and each end of the winding 2w And two winding lead-out portions 2Al and 2Al each including a portion. The winding portion 20 is a buried portion entirely covered with the soft magnetic composite material constituting the magnetic core 3A. The winding lead portions 2Al, 2Al in this example are exposed portions exposed without being covered by the soft magnetic composite material.

.. Winding Wires 2 w constituting the coil 2 A can suitably use a coated wire provided with an insulating coating on the outer periphery of a conductor wire. Here, since the winding portion 20 is covered with the soft magnetic composite material, it can be in contact with components such as soft magnetic powder. When the soft magnetic composite material contains a metal, depending on the operating voltage of the inductor 1A (coil 2A), it is desirable to enhance the insulation between the winding portion 20 and the magnetic core 3A. By making the winding 2 w a coated wire, it is preferable because the insulation between the winding portion 20 and the magnetic core 3 A is excellent regardless of the composition of the soft magnetic composite material.

... Conductor wire The conductor wire may be a flat wire or round wire made of a conductive material such as copper, aluminum, or an alloy thereof.

Insulating Coating As a constituent material of the insulating coating, a resin having excellent electrical insulation such as polyamide imide, which is called enamel, may be mentioned. Furthermore, the constituent material of the insulating coating is preferably one having excellent heat resistance. This is because, in the manufacturing process of the inductor 1A, it comes into contact with a high temperature, specifically a molten mixture which is a raw material of the soft magnetic composite material (magnetic core 3A). The molten mixture may have a high temperature of, for example, 250 ° C. or more and 350 ° C. or less, depending on the type of resin. Therefore, in consideration of the heat history in the manufacturing process, the insulating coating can be made excellent in heat resistance.

  It is possible to have a self-bonding layer on the outermost layer of the insulating coating. In this case, while the gaps between the turns are reduced by pressing the winding portion 20 in the axial direction or the like, the self-fusion layers are joined together by heating as appropriate, whereby the gaps between the turns are springbacked. Can be reduced. Specifically, the gap between the turns can be as thick as the thickness of the insulating coating including the self-bonding layer, and the axial length of the winding portion 20 becomes shorter than the natural length. The inductor 1A including the winding portion 20 compressed in this manner has a small length along the axial direction of the winding portion 20 and is compact. The cross-sectional area, material, and the like of the winding 2w can be selected as appropriate. The winding 2w in this example is a coated flat wire.

· · Other coatings Instead of the above insulation coating or in addition to the insulation coating, a heat resistant layer (not shown) in the region (mainly the winding portion 20) of the coil 2A covered by the soft magnetic composite material (magnetic core 3A) ) Can be used as the coil 2A. The constituent material of the heat-resistant layer is a material which is excellent in heat resistance, and is preferably a material which is also excellent in electrical insulation since it is in contact with the coil 2A. Such materials include, for example, glass, non-metallic inorganic materials such as various ceramics, and organic materials such as heat resistant resins called super engineering plastics such as polyimide. The heat-resistant layer can be formed, for example, by applying the above-described constituent material to the winding portion 20 or the like.

  In addition to the above-mentioned insulation coating, the form provided with the heat-resistant insulating layer made of the above-mentioned material excellent in both heat resistance and electric insulating property is excellent in electric insulating property, and therefore the use with high working voltage, for example about several hundred volts. Specifically, it is suitable for applications of about 100V to 500V. In applications where the working voltage is low, for example, about several tens of volts, specifically about 3V to 50V, it is considered that the heat-resistant insulating layer is not provided, and the insulating coating alone has sufficient electrical insulation.

-Winding part The winding part 20 of this example is an edgewise coil which is formed by edgewise winding a coated flat wire, and whose end face shape is cylindrical. The number of winding portions 20, the end face shape, the number of turns, and the like can be selected as appropriate. For example, the end face may be in the form of a rectangular frame, a racetrack, or the like.

... Installation direction The inductor 1A is attached to the installation object 100 so that the axial direction of the winding portion 20 of the coil 2A is orthogonal to the mounting surface 100f of the installation object 100 as shown in FIG. It may be referred to as “vertically-placed form”, or may be attached to the installation object 100 parallel to the mounting surface 100 f (embodiment 2 described later; hereinafter may be referred to as “horizontally-placed form”). The inductor 1A of this example is vertically mounted, and the magnetic core 3A is formed so as to be stably and vertically mounted on the installation target 100 (described later).

· Winding draw-out portion the winding draw-out portion 2Al, 2Al includes a winding portion 20, are utilized in the coil 2A the conductive path between the external device, such as source power supplies. Each one end is a connection place with an external device, and each other end is a connection place with the winding unit 20. The length of the winding lead portion 2Al, the drawing direction, and the like can be appropriately selected. Both of the winding lead portions 2Al and 2Al in this example are drawn substantially parallel to the axis of the winding portion 20 over the entire length. Specifically, the connection points of the winding lead portions 2Al, 2Al with the winding portion 20 are generally very short portions drawn in the radial direction of the winding portion 20 along the winding direction of the winding portion 20. , And substantially orthogonal to the axis of the winding portion 20. Following this connection point, the winding lead portions 2Al and 2Al are provided so as to be flatwise bent at a substantially right angle from the connection point and to be parallel to the axis of the winding portion 20. That is, in the winding lead portions 2Al, 2Al shown in FIG. 1, not only the region on the winding portion 20 side but substantially the entire length is drawn parallel to the axis of the winding portion 20. Inductor 1A includes a portion parallel to the axis of winding portion 20 in the region on winding portion 20 side in winding extraction portions 2Al, 2Al, so winding extraction portion 2Al, 2Al is disposed close to winding portion 20. There are many regions (substantially full length in the example shown in FIG. 1). Therefore, a virtual rectangular solid including the inductor 1A including the region on the winding portion 20 side in the winding lead-out portions 2Al, 2Al can be reduced, and the installation space (projected area to the installation target 100) can be reduced. In the case of directly attaching one end of the winding lead portions 2Al, 2Al to the installation object 100, for example, the one end may be bent so as to be parallel to the mounting surface 100f of the installation object 100. Even in this case, the area on the other end side of the winding lead portions 2Al, 2Al, that is, the vicinity of the connection portion with the winding portion 20 is close to the winding portion 20 and is small. The drawing directions of the winding lead portions 2Al, 2Al may be different from each other.

Magnetic Core As shown in FIG. 1, the magnetic core 3A is made of a soft magnetic composite material and has a columnar embedded portion 30 embedded with the wound portion 20 which is a part of the coil 2A, and the outer peripheral surface of the embedded portion 30. Is a molded body having a complex three-dimensional shape including two flange portions 35, 35 projecting from the above. The magnetic core 3A is a molded body in which the embedded portion 30 and the flange portions 35 and 35 are integrally formed.

The buried portion 30 is a columnar body by continuously covering the inside and the outside of the winding portion 20 and being provided so as to fill the inner circumferential space of the winding portion 20.
The soft magnetic composite material that constitutes a part of the embedded portion 30 is filled in the inner circumferential space of the winding portion 20. Therefore, the magnetic core 3A can sufficiently secure the passage of the magnetic flux generated by the coil 2A.
The soft magnetic composite material constituting the other portion of the embedded portion 30 passes through one end surface of the winding portion 20 to cover the cylindrical outer peripheral surface of the winding portion 20 and is continuously present in the other end surface of the winding portion 20 Do.
Therefore, the magnetic flux generated by the coil 2A passes through the soft magnetic composite material filling the inner circumferential space described above and the soft magnetic composite material covering the end faces and the outer circumferential surface of the wound portion 20 described above in an annular manner.

  The buried portion 30 in this example is a cylindrical body provided along the outer shape of the cylindrical winding portion 20, and has a circular end surface and a circumferential surface. By making the outer shape of the embedded portion 30 a shape along the outer shape of the winding portion 20, that is, a similar shape, it is possible to reduce the amount of raw material used for the soft magnetic composite material and to shorten the manufacturing time.

  The shape and size of the embedded portion 30 can be appropriately selected within a range in which a closed magnetic path can be formed by covering the entire wound portion 20 and having a desired inductance. For example, the buried portion 30 can have a non-similar shape (such as a rectangular shape in this example) and the outer shape of the winding portion 20. If the embedded portion 30 is enlarged, the installation surface can be enlarged, and the stability of the installation state and the heat dissipation can be enhanced. However, if it is too large, the amount of raw material used for the soft magnetic composite material can be increased.

The flange portion 35 is a projecting piece that protrudes outward in the radial direction of the winding portion 20 from the outer peripheral surface of the winding portion 20, and is a portion that includes the cylindrical member 350.

  As long as the flange portion 35 can hold the tubular member 350, its shape and size can be appropriately selected. If it has a similar shape (here, a shape close to a cylindrical shape) along the outer shape of the cylindrical member 350, the amount of raw material used for the soft magnetic composite material forming the flange portion 35 can be reduced. The flange portion 35 in this example is a projecting piece having a flat surface in the tangential direction with respect to the cylindrical embedded portion 30 in addition to the cylindrical portion along the outer shape of the cylindrical cylindrical member 350. That is, when the magnetic core 3A is planarly viewed in the axial direction of the winding portion 20 of the coil 2A, the flange portion is a point symmetrical shape with the center of the winding portion 20 as an axis but not axisymmetric. 35 and 35 are provided. By so doing, the inductor 1A can be easily made smaller in size along with the vertically placed configuration, and the installation space can be made smaller. In addition, the magnetic core 3A can be provided with a flange portion (protruding piece) so as to be in a point-symmetrical shape and a line-symmetrical shape with the diameter of the winding portion 20 as an axis. Even in this case, the installation space may be reduced.

The number of flanges 35 may be one, but if a plurality of flanges 35 are provided, it is easy to stably fix the inductor 1A to the installation object 100. In the case where the plurality of flanges 35 are provided, it is preferable to provide the flanges 35 at a position opposite to the installation surface 30 d (FIG. 2) of the buried portion 30 for more excellent stability. For example, in the case where two flanges 35 are provided, the diametrically opposed position of the circular installation surface 30 d, and in the case where three flanges 35 are provided, the central angle of the circular installation surface 30 d is 120 ° There is an offset position. Moreover, it is preferable that the flange part 35 is provided in the position which is difficult to interfere with winding lead-out part 2Al, 2Al. In this example, the two flanges 35 are disposed at point-symmetrical positions with respect to the central axis of the circular installation surface 30d in the embedded portion 30 and at positions not substantially in contact with the winding lead portions 2Al, 2Al. Each has 35 (FIG. 1).

... tubular member tubular member 350 is a member to make a transmural hole 35h of the installation fastening member for attaching the embedded portion 30 of the inductor 1A in the installation target 100. Here, by making the magnetic core 3A a soft magnetic composite material, it is possible to form a bolt hole in the magnetic core 3A itself. However, since the soft magnetic composite material contains different materials of soft magnetic powder and resin, it may not have sufficient strength to the tightening force of the bolt. Cracks may occur or creep deformation may occur due to long-term use, resulting in a decrease in bolt tightening force. On the other hand, if the member to create a transmural hole 35h and separate member is a soft magnetic composite material is increased the degree of freedom of the material selection. Specifically, a high strength material, in particular, a material made of a material having sufficient strength against the tightening force of a fastening member such as a bolt can be used. So, in the inductor 1A of Embodiment 1, the cylindrical member 350 which consists of materials different from a soft-magnetic composite material is provided.

  Since the cylindrical member 350 is disposed in the vicinity of the coil 2A, its constituent material is preferably a nonmagnetic material. Moreover, as for the said constituent material, what is excellent in intensity | strength as mentioned above is more preferable. Specific constituent materials include organic materials represented by resins, and inorganic materials represented by metals and ceramics. If it is a resin, it is expected that it is excellent in the bondability of the cylindrical member 350 and the soft magnetic composite material. Fiber reinforced resin etc. can also be used. If the end face of the cylindrical member 350 is a pressure receiving surface for the tightening force of a fastening member such as a bolt, it is difficult to be broken at the time of fastening and the decrease in the tightening force over time is also It can be suppressed. Specific nonmagnetic metals include brass and nonmagnetic stainless steel. In this example, the tubular member 350 is a seamless metal tube.

  The cylindrical member 350 may have a size and a shape that can insert a fastening member such as a bolt, and the size and the shape can be appropriately selected. In FIG. 1, the inner circumferential shape and the outer circumferential shape are similar shapes, and both illustrate a cylindrical shape having a circular cross section. In addition, the cylindrical member 350 can be a cylinder whose inner peripheral shape is different from the outer peripheral shape, for example, an irregularly shaped cylinder whose inner peripheral shape is circular in cross section and whose outer peripheral shape is rectangular in cross section. The inner circumferential shape of the cylindrical member 350 may also be rectangular in cross section, in addition to the circular cross section. That is, the cylindrical member 350 can be a non-cylindrical one such as a polygonal cylindrical shape or an elliptical cylindrical shape other than a cylindrical shape. Furthermore, the outer circumferential surface of the cylindrical member 350 can be provided with projections and recesses, and the like. By devising the outer peripheral shape in this manner, the contact area with the soft magnetic composite material can be increased, and the magnetic core 3 is firmly held, and in addition, effects such as dropout prevention can be expected. If the constituent material of the cylindrical member 350 is resin, metal, ceramics, or the like, a seamless cylindrical material can be easily formed, and such a cylindrical material can be used. In addition, the cylindrical member 350 can utilize what rolled the metal plate etc. in the appropriate shape, or was bend | folded and made cylindrical. In this case, the cylindrical member 350 may not necessarily have a circumferentially closed shape as long as the fastening member can be inserted. For example, the cylindrical member 350 may have a C-shaped cross section. This is because even if the cylindrical member 350 is not completely closed, a part of the insertion hole of the fastening member can be formed of the soft magnetic composite material. In the cylindrical member 350 which shape | molded this board | plate material suitably, the thing of various magnitude | sizes and shapes can be manufactured easily, it is excellent in productivity, and reduction of cost can also be anticipated. The size (inner diameter, outer diameter, length) of the cylindrical member 350 may be selected according to the size, fixing strength, and the like of the installation fastening member.

  In order to make one end surface of the cylindrical member 350 be the pressure receiving surface of the fastening member, the end surface of the cylindrical member 350 is flush with the outer surface of the flange portion 35 or the flange portion 35 protrudes beyond the outer surface of the flange portion 35 Be supported. By using the end face of the cylindrical member 350 as a pressure receiving surface, even when a part of the insertion hole of the fastening member such as a bolt is made of the soft magnetic composite material as described above, It is possible to sufficiently suppress the decline. In the present embodiment, the above-described form is flush, and the entire outer peripheral surface of the cylindrical member 350 is covered with the soft magnetic composite material. Further, in the present example, the other end surface of the cylindrical member 350 is in contact with the mounting surface 100f when the inductor 1A is mounted on the installation target 100. In the above-mentioned protruded form, a part of the outer peripheral surface of the cylindrical member 350 is covered with the soft magnetic composite material.

.. Installation surface The inductor 1A of this example has installation surfaces 30d and 35d on which the circular end surface of the embedded portion 30 of the magnetic core 3A and one surface of the flange portions 35 and 35 are mounted on the installation target 100. I assume. The mounting surfaces 30d, 35d are continuous uniform planes, ie, flush planes. These mounting surfaces 30d, 35d, 35d are molded such that the axial direction of the winding portion 20 is orthogonal to the mounting surface 100f, that is, in the vertical position, in a state where the inductor 1A is attached to the mounting object 100. There is. Therefore, when the inductor 1A is mounted on the installation target 100, the mounting surface 30d of the embedded portion 30 and the mounting surfaces 35d and 35d of the two flanges 35 and 35 are supported by the mounting surface 100f, and the inductor 1A is It is vertically and stably placed on the installation object 100.

The inductor 1A can be in a form in which only the flange portions 35, 35 are directly supported by the installation object 100. In this case, the flange portion 35 may be provided at a leg height as follows. When the inductor 1A is placed on the installation object 100, the surface (the lower surface in FIG. 1 and FIG. 2) of the embedded portion 30 facing the mounting surface 100f of the installation object 100 does not contact the mounting surface 100f. , 35 are made to be in leg height such that only the mounting surfaces 35d, 35d are in contact with the mounting surface 100f. In this embodiment, according to the leg height of the flange portion 35, a gap is provided between the surface (lower surface) opposite to the mounting surface 100f of the buried portion 30 and the mounting surface 100f. An insulating material (not shown) that enhances the insulation between the inductor 1A and the installation target 100 can be disposed in the gap, or the gap can be an air insulating space, an air cooling space, or the like.

Construction materials ... soft magnetic composites ... soft magnetic powder .... composition soft magnetic powder is metal, there are both non-metallic, it can be used known ones. The soft magnetic powder can include powders of multiple compositions as well as powders of single composition.

Examples of the soft magnetic metal include iron group metals (so-called pure metals such as pure iron), Fe-based alloys containing Fe as a main component, and amorphous metals.
Examples of iron group metal elements include Fe, Co and Ni.
The Fe-based alloy contains, for example, 1.0 mass% or more and 20.0 mass% or less in total of one or more elements selected from Si, Ni, Al, Co, and Cr as additive elements, and the balance is Fe And those having a composition comprising unavoidable impurities. Specifically, Fe-Si alloys, Fe-Ni alloys, Fe-Al alloys, Fe-Co alloys, Fe-Cr alloys, Fe-Si-Al alloys (sendust), etc. may be mentioned. 1.0 mass% or more and 8.0 mass% or less is mentioned for Si amount of a Fe-Si type alloy.
Since iron group metals and Fe-based alloys have high saturation magnetization and low eddy current loss depending on the composition, when the magnetic core 3A contains these soft magnetic metal powders, an inductor 1A with high saturation magnetization, low loss Inductor 1A.

  Examples of soft magnetic nonmetals include metal oxides such as oxides containing Fe represented by ferrite. Since soft magnetic nonmetals contain a large amount of electrical insulators and high-resistance materials, when the magnetic core 3A contains powders of these soft magnetic nonmetals, low-loss inductors 1A can be obtained.

Content The higher the content of the soft magnetic powder in the soft magnetic composite material, the better the magnetic properties, for example, the higher the saturation magnetization. On the other hand, when the soft magnetic composite material contains a resin sufficiently, the resin is generally a nonmagnetic material, and this resin can be used for the magnetic gap. Therefore, as shown in FIG. 1, the gap material can be omitted and the direct current superposition characteristic is excellent. A specific content is, for example, 30% by volume or more and 80% by volume or less based on 100% by volume of the soft magnetic composite material. In consideration of saturation magnetization and the like, the content is preferably 50% by volume or more, further 60% by volume or more, 65% by volume or more, and 70% by volume or more. In consideration of direct current superposition characteristics, eddy current loss and the like, the content is preferably 75% by volume or less, more preferably 73% by volume or less, and 70% by volume or less. The content of the soft magnetic powder is more preferably 65% by volume or more and 75% by volume or less.

Size The smaller the size of the soft magnetic powder in the soft magnetic composite material, the lower the eddy current loss and the higher the filling rate. Saturation magnetization tends to be high due to high filling. If the size of the soft magnetic powder is large to some extent, it is possible to prevent aggregation and allow sufficient intercalation of resin between powder particles. As a specific size, the average particle diameter is 50 μm or more and 300 μm or less. The average particle diameter is more preferably 50 μm or more and 100 μm or less. In addition, the soft magnetic powder is a fine coarse mixed powder of relatively small powder particles and relatively large powder particles, it is easy to increase the filling rate. When the average particle diameter is in the above range or a fine coarse mixed powder, the molten mixture is excellent in fluidity and easy to be molded, and the productivity of the magnetic core 3A is excellent.

... Resin ... ... Composition The resin in the soft magnetic composite material holds the soft magnetic powder in a dispersed state, and is interposed between powder particles to function as a magnetic gap. The resin is preferably a thermoplastic resin that can be suitably used for injection molding. Specific thermoplastic resins include polyamide (PA) resin, polyphenylene sulfide (PPS) resin, liquid crystal polymer (LCP), polyimide (PI) resin, fluorine resin and the like. Examples of PA resin include nylon 6, nylon 66, nylon 9T, nylon 10T and the like. PA resin such as nylon 9T, PPS resin, LCP, fluorine resin, etc. are called engineering plastics and are excellent in heat resistance. Therefore, when nylon 9T etc. are included, it can be set as the inductor 1A which is excellent in heat resistance.

.... Content The content of the resin in the soft magnetic composite material is 15% by volume or more, 20% by volume or more, 25% by volume, based on 100% by volume of the soft magnetic composite material, in consideration of direct current superposition characteristics and the like. The above is mentioned. In consideration of saturation magnetization and the like, the content of the resin may be 50% by volume or less, 45% by volume or less, 40% by volume or less, and 35% by volume or less.

Inductor Manufacturing Method The inductor 1A of the first embodiment can be manufactured typically using an injection molding method. In detail, the inductor 1A arranges the winding portion 20 of the coil 2A and the cylindrical member 350 in a mold, and injects and fills the mold with a molten mixture containing a soft magnetic powder and a resin, thereby winding the mold. It is obtained by embedding the turn section 20 and forming so as to include the tubular member 350, and then cooling and solidifying. As described above, the heat-resistant layer or the heat-resistant insulating layer can be separately provided in the winding portion 20, or the self-bonding layer can be fused to reduce the gap between the turns.

  The injection molding method, in particular the insert molding method, has a complex three-dimensional structure in which the winding lead portions 2Al and 2Al are exposed while the entire winding portion 20 of the coil 2A is embedded, and a projecting piece including the tubular member 350 is included. The shape can be formed with high accuracy. That is, the inductor 1A has a large degree of freedom in shape and size, and is excellent in molding accuracy and dimensional accuracy.

Effect Because the inductor 2A and the magnetic core 3A are integrally formed, the inductor 1A according to the first embodiment does not need to be assembled at the time of manufacture, and is excellent in manufacturability. In particular, in the inductor 1A, since the winding lead portion 2Al is exposed from the magnetic core 3A (soft magnetic composite material), the amount of raw material used for the magnetic core 3A can be reduced. Furthermore, the inductor 1A is vertically disposed in that the axial direction of the winding portion 20 is orthogonal to the mounting surface 100f of the installation object 100, in that the winding lead portion 2Al is exposed from the magnetic core 3A (soft magnetic composite material) And, since the mounting surfaces 35d, 30d on which both the flange portion 35 and the embedded portion 30 are supported by the mounting surface 100f are provided, and the flange portion 35 can be easily made smaller, the raw material usage of the magnetic core 3A can be reduced. .

And the inductor 1A is because with a flange portion 35, after placing the inductor 1A in the installation target 100, the installation target 100 by tightening the installation fastening members such as bolts transmural hole 35h of the cylindrical member 350 It is easily attached and excellent in installation workability.

In addition, the inductor 1A of Embodiment 1 has the following effects. The following effects are the effects of the embedded portion 30 having the installation surface 30d. , 6. Except for the second embodiment which will be described later.
1. By the resin contained in the magnetic core 3A, the coil 2A can be firmly held, the strength is excellent, and the coil 2A can be protected.
2. Since the magnetic core 3A is not a combination of a plurality of core pieces but an integral molding, and is in close contact with the coil 2A, vibration and noise due to a gap between components of the combination are not easily generated, and the vibration is And noise can be reduced.
3. The area of the winding lead portion 2Al on the side of the winding portion 20 is a portion disposed parallel to the axis of the winding portion 20, so that the projection area of the installation object 100 with respect to the mounting surface 100f is reduced. Since the unit 20 is one, it is compact.
4. It is compact compared to the case where the coil and the magnetic core are assembled. The reason for this is that although a small gap is usually provided between the assembly parts, this gap can be eliminated in the inductor 1A.
5. Since it is vertically disposed and both the flange portion 35 and the embedded portion 30 are supported by the mounting surface 100f of the installation target 100, the stability of the installation state is excellent.
6. When the soft magnetic powder includes powder made of a material having excellent thermal conductivity such as metal, the coil 2A and the magnetic core 3A are in close contact, and both the flange portion 35 and the embedded portion 30 are the mounting surface of the installation object 100 Since it contacts 100f, heat_generation | fever of the coil 2A resulting from electricity_supply is favorably transmitted to installation object 100, such as a water-cooling stand, and it is excellent in heat dissipation.

Second Embodiment
The inductor 1B of the second embodiment will be described with reference to FIG.
The inductor 1B of the second embodiment is a main difference from the inductor 1A of the first embodiment, which is a vertically mounted configuration, in that the horizontally mounted configuration is used. Hereinafter, this difference will be mainly described, and the overlapping configuration and effects will not be described in detail.

  The basic configuration of the inductor 1B is the same as that of the inductor 1A according to the first embodiment, and includes a coil 2B including one winding portion 20 formed by spirally winding a winding 2w and the above-described soft magnetic composite material And a magnetic core 3B. The magnetic core 3 </ b> B is integrally formed with a buried portion 30 in which the winding portion 20 is buried and a flange portion 35 which protrudes from the outer peripheral surface of the buried portion 30 and which includes the nonmagnetic cylindrical member 350.

  The inductor 1B is mounted horizontally on the installation subject 100 such that the axial direction of the winding portion 20 of the coil 2B is parallel to the placement surface 100f (see FIG. 2) of the installation subject 100 (see FIG. 2) . Here, in the case where the embedded portion 30 of the magnetic core 3B is formed into a cylindrical shape along the outer shape of the cylindrical winding portion 20 as shown in FIG. Therefore, the inductor 1B of this example is provided with a stopper portion 37 that prevents the rotation of the winding portion 20 on a part of the flange portion 35 so that the inductor 1B can be stably and laterally placed on the installation target 100. Specifically, the mounting surface of the flange portion 35 is provided in the tangential direction of the cylindrical embedded portion 30, and the triangular area sandwiched by the installation surface and a part of the outer peripheral surface of the cylindrical embedded portion 30 is filled. Thus, the flange portion 35 is formed. The triangular embedded portion is referred to as a stopper portion 37. Further, the flange portion 35 in this example is provided in a step-like shape so that the vicinity of the cylindrical member 350 is low and the side near the coil 2B is high. By doing this, it is possible to reduce the amount of raw material used for forming the flange portion 35. The inductor 1B is provided with two flanges 35, 35 in a point-symmetrical position around the central axis of the embedded portion 30 (the winding portion 20). Therefore, similarly to the inductor 1A of the first embodiment, the installation space of the inductor 1B is also small and compact.

  The winding lead-out portions 2Bl and 2Bl of the inductor 1B shown in FIG. 3 are not only a region on the winding portion 20 side including the connection portion with the winding portion 20 but substantially the entire length of the winding portion 20. Drawn perpendicular to the axis of. Specifically, each of the winding lead-out portions 2Bl and 2Bl is drawn as it is along the winding direction without being substantially bent from the winding portion 20, and the end portions thereof are as shown in FIG. At the top of the building.

  As in the first embodiment, the inductor 1B of the second embodiment does not require the assembly of the coil 2B and the magnetic core 3B, and is excellent in manufacturability. Further, in the same manner as the first embodiment, the inductor 1B has the winding lead portions 2B1 and 2B1 exposed from the magnetic core 3B, and is excellent in manufacturability also from the point of being able to reduce the amount of material used. Further, the inductor 1B does not require flatwise bending in forming the winding lead portions 2B1 and 2B1 and is excellent in manufacturability also from the point of being excellent in the manufacturability of the coil 2B.

And inductor 1B of the second embodiment, similarly to Embodiment 1, since with a flange portion 35, the installation target by by placing the installation target, tighten the installation fastening members such as bolts transmural hole 35h It is easy to install on top of the In particular, although the inductor 1B has a shape in which the embedded portion 30 is easy to rotate, the flange portion 35 includes the stopper portion 37, so that the inductor 1B can be easily placed on the installation object, and thus the installation workability is excellent.

  In addition, although the inductor 1B includes the stopper portion 37 in the flange portion 35, it has a step shape, and in that the stopper portion 37 is partially provided instead of the full length in the axial direction of the embedded portion 30 (wound portion 20), The amount of raw material used for the magnetic core 3B can be easily reduced, and from this point as well, the productivity is excellent. In addition, since the inductor 1B is provided with the flanges 35 and 35 and the stoppers 37 and 37 on both sides of the central axis of the buried portion 30 (the winding portion 20), the rotation of the inductor 1B is prevented. Support.

  In the inductor 1B of the horizontal installation form, a region perpendicular to the axis of the winding portion 20 is included in the region on the winding portion 20 side in the winding extraction portions 2B1 and 2B1, so that the winding extraction portions 2B1 and 2B1 are wound. There are many regions arranged close to 20 (substantially the entire length in this example). Therefore, a virtual rectangular solid including the inductor 1B including the region on the winding portion 20 side in the winding lead portions 2B1 and 2B1 can be reduced, and the installation space (projected area with respect to the installation target) can be reduced. As described above, even in the horizontal installation mode, the installation space can be reduced depending on the drawing state of the winding lead portion 2Bl.

[Modification]
In the first and second embodiments, the case where the winding wire lead-out portion is drawn so as to extend vertically in the drawing has been described. In addition, the winding wire lead-out portion may be drawn out so as to extend laterally in the drawing.

  For example, in the case of the coil 2A shown in FIG. 1, without flatwise bending the connection portion with the winding portion 20 in the winding lead-out portion 2Al, 2Al, the coil 2B shown in FIG. The lead portions 2Al, 2Al can be stretched left and right, that is, in the vertical position, they can be pulled out perpendicularly to the axis. This inductor has a size along the axial direction of the winding portion 20, that is, a distance from the mounting surface 100f of the installation object 100 to a size along the axial direction of the winding portion 20 in the embedded portion 30. , Is small in size due to its low bulk.

  For example, in the case of the coil 2B shown in FIG. 3, if the connection portions of the winding lead portions 2Bl and 2Bl with the winding portion 20 are flatly bent substantially at right angles as shown in FIG. 1, the winding lead portions 2Bl and 2Bl Can be in the form of being stretched to the left and right, that is, in the form of being drawn out parallel to the axis in the horizontal orientation. The inductor has a size along the radial direction of the winding portion 20, that is, a distance from the mounting surface 100f of the installation object 100 to be about the outer diameter of the winding portion 20, and is small in size because of low volume.

  The present invention is not limited to these exemplifications, but is shown by the claims, and is intended to include all modifications within the scope and meaning equivalent to the claims.

  For example, as a coil, there is provided a coil having two winding parts, and arranged in parallel so that the axial direction of each winding part is parallel, a form including coaxially longitudinally arranged ones, and ones laminated concentrically And the like.

  The above inductors can be used as choke coils, reactors, transformers and the like. The choke coil, the reactor, and the like are various types such as an on-vehicle converter (typically a DC-DC converter) mounted on a vehicle such as a hybrid vehicle, a plug-in hybrid vehicle, an electric vehicle, or a fuel cell vehicle It can be used for converters, power converter components, and other electrical circuit components.

DESCRIPTION OF SYMBOLS 1A, 1B Inductor 2A, 2B Coil 2w Winding 20 Winding part 2Al, 2Bl Winding lead-out part 3A, 3B Magnetic core 30 Buried part 35 Flange part 350 Tubular member 35h Through hole 30d, 35d Installation surface 37 Stopper part 100 installation Target 100f mounting surface

Claims (4)

A coil comprising: a cylindrical winding portion formed by spirally winding a winding; and a winding lead-out portion continuous to the winding portion;
And a magnetic core disposed inside and outside the winding portion to form a closed magnetic path,
The magnetic core is
Composed of a composite material containing soft magnetic powder and resin,
It is a molded body in which a buried portion, in which the wound portion is buried, and a plurality of flange portions including a tubular member for forming a through hole of the setting fastening member, are integrally molded,
The axial direction of the winding part by the installation fastening member in a state attached to the Installation object is molded so as to be perpendicular to the mounting surface of the installation target,
In a plan view from the axial direction of the winding portion, the shape is point-symmetrical and not line-symmetrical.
The constituent material of the cylindrical member is a nonmagnetic material,
The buried portion is
It is a cylindrical body along the outer shape of the wound portion,
Each flange part is
A projecting piece having a flat surface along a tangential direction of the buried portion;
The inductor provided in the point symmetrical position centering on the central axis of the said winding part.   The inductor according to claim 1, wherein the winding lead portion is exposed without being covered by the composite material. The embedded portion and the flange portion includes an inductor according to claim 1 or claim 2 obtain Bei the installation surface to be placed on the installation target. Region of the winding portion of the winding draw-out portion includes an inductor as claimed in any one of claims 3, including a portion parallel to the axis of the winding portion.

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