WO2021215135A1

WO2021215135A1 - Magnetic body core and inductor element

Info

Publication number: WO2021215135A1
Application number: PCT/JP2021/009822
Authority: WO
Inventors: 智樹岡野
Original assignee: 株式会社村田製作所
Priority date: 2020-04-23
Filing date: 2021-03-11
Publication date: 2021-10-28

Abstract

A magnetic body core (21) has mutually opposing main surfaces (21c, 21d) and a columnar external shape. Moreover, the magnetic body core (21) has through-holes (21a) that pass in a -Z direction from one main surface (21c) of the mutually opposing main surfaces (21c, 21d) toward the other main surface (21d). Each through-hole (21a) has a tapered part (211a) in which the side surfaces are inclined, the opening (21aa) on the main surface (21c) side being larger than the opening (21ab) on the main surface (21d) side.

Description

Magnetic core and inductor element

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

A plurality of flat ring-shaped compacts are arranged in close proximity to each other so that the axial directions of the flat through holes of the flat ring-shaped compacts are perpendicular to each other with powder interposed between the flat ring-shaped compacts adjacent to each other. Then, a method for producing a magnetic core for firing a flat ring-shaped molded product has been proposed (see, for example, Patent Document 1). Here, the flat ring-shaped molded body is formed by molding a magnetic material powder such as ferrite kneaded with a binder or the like into a flat ring shape having flat through holes.

Japanese Unexamined Patent Publication No. 2000-260645

By the way, this kind of flat ring-shaped molded body is produced by heating the mold and the magnetic material powder in a state where the magnetic material powder is charged inside the mold and sintering the magnetic material powder. Is common. In this case, as the mold, for example, a first mold having a concave portion and a second mold having a convex portion inserted inside the concave portion and fixed to the first mold are used. Then, with the magnetic material powder charged inside the concave portion of the first mold, the second mold is inserted into the first mold with the convex portion inserted inside the concave portion of the first mold. Fix it. Here, when the flat ring-shaped molded product is taken out after sintering the magnetic material powder to generate a flat ring-shaped molded product, the side wall of the convex portion of the second mold is flattened through the flat ring-shaped molded product. By rubbing the inner wall of the hole, the flat through hole may be deformed. Therefore, when a plurality of flat ring-shaped molded bodies are produced by this manufacturing method, there is a risk that the electrical characteristics may vary among the plurality of flat ring-shaped molded bodies.

The present invention has been made in view of the above reasons, and an object of the present invention is to provide a magnetic core and an inductor element in which variations in electrical characteristics are suppressed.

In order to achieve the above object, the magnetic core according to the present invention is
A magnetic core having one main surface and the other main surface facing each other and having a columnar outer shape.
It has a through hole penetrating in the first direction from the one main surface to the other main surface.
The through hole has a tapered portion whose side surface is inclined, and the opening on one main surface side is wider than the opening on the other main surface side.
When viewed in a plan view from the first direction, the entire opening on the other main surface side is included inside the opening on the one main surface side.

Further, the magnetic core according to the present invention is
It has two through holes
The two through holes may be arranged side by side in one direction orthogonal to the first direction.

The inductor element according to the present invention from another point of view is
With the magnetic core
A coil arranged around the magnetic core is provided.
The coil
A first conductor portion having a flat plate-shaped first portion abutting on the other main surface and two second portions erected in the first portion and arranged inside the two through holes, respectively. ,
It has a flat plate-shaped second conductor portion that is connected to the tip of the second portion and is in contact with the one main surface.

Further, the inductor element according to the present invention is
The two second portions may each extend in a direction in which the distance between the tips of the two second portions increases.

Further, the inductor element according to the present invention is
The two second portions may each extend in a direction in which the distance between the tips of the two second portions becomes shorter.

Further, the inductor element according to the present invention is
The two second portions may each extend in a direction parallel to the first direction.

By the way, as a mold used when generating a magnetic core from a powder material which is a base of a magnetic core, a first mold having a concave portion and a convex having at least one convex portion inserted inside the concave portion. It is common to use a second mold in which the base end portion of the portion corresponds to the first opening side and the tip end portion side of the convex portion corresponds to the second opening portion. Here, according to the present invention, the through hole of the magnetic core has a tapered portion whose side surface is inclined, and the opening on one main surface side is wider than the opening on the other main surface side. In this case, the convex portion of the second mold has a shape in which the area of the cross section of the base end portion orthogonal to the above-mentioned one direction is larger than the area of the cross section of the tip portion of the convex portion orthogonal to the above-mentioned one direction. .. Therefore, after fixing the second mold to the first mold so that the convex portion thereof is inserted into the concave portion of the first mold, the concave portion of the first mold and the convex portion of the second mold are formed. When the powder material, which is the base of the magnetic core, is put into the region generated between the two, and the powder material is sintered by heating the first mold, the second mold, and the powder material, the first mold, the second mold, and the powder material are sintered. When the 2 molds are separated from the 1st mold, the side wall of the convex portion can be prevented from rubbing the inner wall of at least one through hole of the magnetic core. Therefore, since the deformation of at least one through hole caused by the side wall of the convex portion rubbing the inner wall of at least one through hole of the magnetic core can be suppressed, the magnetic material caused by the deformation of at least one through hole. It is possible to suppress variations in the electrical characteristics of the core.

It is an exploded perspective view of the inductor element which concerns on embodiment of this invention. It is a perspective view of the coil which concerns on embodiment. It is a perspective view of the coil which concerns on embodiment. It is a side view of the coil which concerns on embodiment. It is a perspective view of the magnetic material core which concerns on embodiment. It is a front view of the magnetic material core which concerns on embodiment. FIG. 5 is a cross-sectional arrow view taken along the line AA of FIG. 4A of the magnetic core according to the embodiment. It is sectional drawing for demonstrating the manufacturing method of the inductor element which concerns on embodiment, and is sectional drawing which shows the state which filled the region generated between the 1st mold and 2nd mold with a magnetic material. It is sectional drawing for demonstrating the manufacturing method of the inductor element which concerns on embodiment, and is sectional drawing which shows the state which the 2nd mold is separated from the 1st mold. It is sectional drawing of a part of the inductor element which concerns on embodiment. It is an exploded perspective view of the inductor element which concerns on a modification. It is a perspective view of the coil which concerns on the modification. It is a perspective view of the coil which concerns on the modification. It is a side view of the coil which concerns on a modification. It is sectional drawing of a part of the inductor element which concerns on embodiment. It is an exploded perspective view of the inductor element which concerns on a modification. It is a perspective view of the coil which concerns on the modification. It is a perspective view of the coil which concerns on the modification. It is a side view of the coil which concerns on a modification. It is a front view of the magnetic core which concerns on a modification. FIG. 5 is a cross-sectional arrow view taken along line BB of FIG. 12A of the magnetic core according to the modified example. It is a front view of the magnetic core which concerns on a modification. FIG. 3 is a cross-sectional arrow view taken along line CC of FIG. 13A of the magnetic core according to the modified example.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The inductor element according to the present embodiment includes a magnetic core and a coil wound around a part of the magnetic core. The magnetic core is formed in a block shape from a magnetic material and is provided with at least one through hole along one direction. The coil has a first conductor portion and a second conductor portion. The first conductor portion includes a long first portion and two second portions extending in the same direction from both ends in the longitudinal direction of the first portion and at least one of which is inserted into the at least one through hole. , Have. The second conductor portion is connected to the other end portion of at least one of the two second portions of the first conductor portion, which is opposite to one end portion continuous with the first portion. Then, at least one through hole of the magnetic core has an area of a cross section orthogonal to the above-mentioned one direction from one first opening to the other second opening in the extending direction of each of the at least one through holes. It has a shape that gradually decreases toward the part. The second opening is located inside the first opening when viewed from the above-mentioned one direction.

As shown in FIG. 1, the inductor element 1 according to the present embodiment includes a coil 10 and a magnetic core 21. The coil 10 has

conductor groups

11 and 12, and is wound around a part of the magnetic core 21. As shown in FIGS. 2A and 2B, the conductor group 11 has four

conductors

111, 112, 113, 114 arranged along the winding axis J1 of the coil 10. The conductor portion 111 is connected to a connecting portion 111d extending along the Y-axis direction and bending in the Z-axis direction, and a rising portion 111a rising in the + Z direction from the end portion of the connecting portion 111d on the −Y direction side. This is a first conductor portion having a main portion 111c extending in the −X direction from an end portion on the + Y direction side of the portion 111d. Here, the rising portion 111a extends in a direction inclined from the side continuous with the connecting portion 111d toward the + X direction with respect to the + Z direction. The conductor portion 112 has a flat plate-shaped first portion 112d having a portion extending in a direction inclined in the + Y direction rather than the + X direction and a portion extending in the ± X direction from each of both ends thereof, and the first portion 112d. This is a first conductor portion having

second portions

112a and 112b rising in the + Z direction from both ends in the Y-axis direction of the above. Here, the second portion 112a extends in a direction inclined from the side continuous with the first portion 112d toward the + X direction with respect to the + Z direction. Further, the second portion 112b extends in a direction inclined from the side continuous with the first portion 112d toward the −X direction with respect to the + Z direction.

The conductor portion 113 is a long plate-shaped first portion 113d having a portion extending in a direction inclined in the + Y direction rather than the + X direction and a portion extending in the ± Y direction from each of both end portions thereof. It is a long first conductor portion having

second portions

113a and 113b rising in the + Z direction from both ends of the main portion 113d in the Y-axis direction. Here, the second portion 113a extends in a direction inclined from the side continuous with the first portion 113d toward the + X direction with respect to the + Z direction. Further, the second portion 113b extends in a direction inclined from the side continuous with the first portion 113d toward the −X direction with respect to the + Z direction. The conductor portion 114 includes a connecting portion 114d extending along the Y-axis direction and bending in the Z-axis direction, a rising portion 114b rising in the + Z direction from the end of the connecting portion 114d on the + Y direction side, and a connecting portion. It is a first conductor portion having a main portion 114c extending in the + X direction from an end portion of 114d on the −Y direction side. Here, the rising portion 114b extends in a direction inclined toward the −X direction with respect to the + Z direction from the side continuous with the main portion 114d.

Here, as shown in FIG. 2C, the second portion 113a of the conductor portion 113 extends in a direction inclined toward the + X direction by an angle D1 with respect to the + Z direction from the side continuous with the first portion 113d. There is. The rising portion 111a of the conductor portion 111 and the second portion 112a of the conductor portion 112 also extend in a direction inclined in the + X direction by an angle D1 with respect to the + Z direction from the side continuous with the connecting

portions

111d and 112d. doing. Further, the rising portion 114b of the conductor portion 114 extends in a direction inclined toward the −X direction by an angle D1 with respect to the + Z direction from the side continuous with the connecting portion 114d. The

second portions

112b and 113b of the

conductor portions

112 and 113 also extend in a direction inclined toward the −X direction by an angle D1 with respect to the + Z direction from the side continuous with the

main portions

112d and 113d. .. Then, in the Y-axis direction, the maximum width L12 between the ends of the two

second portions

112a and 112b of the conductor portion 112 on the + Z direction side is the maximum width L11 of the end portion of the conductor portion 112 on the first portion 112d side. Shorter than. Here, in the Y-axis direction, the winding shaft J1 of the coil 10 and the other end portion opposite to one end side continuous from the first portion 112d of the conductor portion 112 to the first portion 112d of the

second portion

112a and 112b. Corresponds to the direction toward, that is, the direction orthogonal to the + Z direction. Further, in the Y-axis direction, the maximum width L12 between the ends of the two

second portions

113a and 113b of the conductor portion 113 on the + Z direction side is also the maximum width L11 of the end portion of the conductor portion 113 on the first portion 113d side. Shorter than. That is, the two

second portions

112b and 113b are respectively extended in a direction in which the distance between the tip portions is shortened.

As shown in FIG. 1, the conductor portion group 12 has three

flat conductor portions

121, 122, and 123. The conductor portion 121 is a conductor portion 112 located on the tip end portion of the rising portion 111a of the conductor portion 111, that is, the end portion on the + Z direction side and the rising portion 111a on the opposite side of the winding shaft J1 of the coil 10. It is a second conductor portion erected between the end portion of the second portion 112b on the + Z direction side. In the conductor portion 121, the end portion of the rising portion 111b on the + Z direction side and the end portion of the second portion 112c on the + Z direction side are welded on the −Z direction side thereof. The conductor portion 122 includes an end portion of the second portion 112a of the conductor portion 112 of the two

conductor portions

112 and 113 adjacent to each other in the winding axis J1 direction of the coil 10 on the + Z direction side, and a second portion of the conductor portion 112. The 112b is a second conductor portion erected between the second portion 113b of the conductor portion 113 located on the opposite side of the winding shaft J1 and the end portion on the + Z direction side. In the conductor portion 122, the end portion of the second portion 112a on the + Z direction side and the end portion of the second portion 113b on the + Z direction side are welded on the −Z direction side thereof. The conductor portion 123 is a second conductor portion erected between the end portion of the second portion 113a of the conductor portion 113 on the + Z direction side and the end portion of the rising portion 114b of the conductor portion 114 on the + Z direction side. be.

As shown in FIG. 3, the magnetic core 21 has a flat prismatic shape, that is, a rectangular parallelepiped outer shape. The magnetic core 21 has one main surface 21c and the other main surface 21d facing each other in the thickness direction, and two through holes 21a penetrating from one main surface 21c toward the other main surface 21d in the −Z direction. Be prepared. The two through holes 21a are arranged side by side in the X-axis direction orthogonal to the Z-axis direction. The two through holes 21a of the magnetic core 21 have an area of a cross section orthogonal to the Z-axis direction from the opening 21aa, which is one first opening in the extending direction of each of the two through holes 21a. It has a shape that gradually decreases toward the opening 21ab, which is the other second opening. That is, the through hole 21a has a tapered portion 211a whose side surface is inclined, and the opening 21aa on one main surface 21c side is wider than the opening 21ab on the other main surface 21d side. Further, the opening 21ab is located inside the opening 21aa when viewed from the Z-axis direction. That is, as shown in FIGS. 4A and 4B, when viewed in a plan view from the + Z direction, the entire opening 21ab on the other main surface 21d side is included inside the opening 21aa on the one main surface 21c side. .. In other words, when viewed in a plan view from the + Z direction, the entire peripheral edge of the opening 21ab on the other main surface 21d side is located inside the peripheral edge of the opening 21aa on the one main surface 21c side. Further, as shown in FIG. 4A, the center C11 of the opening 21aa of the magnetic core 21 coincides with the center C12 of the opening 21ab when viewed from the Z-axis direction. That is, as shown in FIG. 4B, the stretching direction of the central axis J21 of the two through holes 21a of the magnetic core 21 coincides with the Z-axis direction. The tapered portion 211a of the through hole 21a in the magnetic core 21 is inclined by an angle D21 with respect to the Z-axis direction. Here, the angle D21 can be set to, for example, an angle within the range of 0 degrees or more and 20 degrees or less. The angle D21 is preferably as large as possible from the viewpoint of suppressing contact with the coil 10. Further, the angle D21 is substantially the same as the inclination angle D1 of the

second portions

112a and 112b of the

conductor portions

112 and 113 and the inclination angle D1 of the rising

portions

111a and 114b. Here, the

first portions

112d and 113d of the coil 10 are in contact with the main surface 21d of the magnetic core 21. Further, the

second portions

112a, 112b, 113a and 113b of the coil 10 are erected from both ends of the

first portions

112d and 113d and are arranged inside the two through holes 21a, respectively. Further, the

conductor portions

121, 122, and 123 of the coil 10 are in contact with the main surface 21d of the magnetic core 21.

Next, a method for manufacturing the magnetic core 21 according to the present embodiment will be described. In this method of manufacturing the magnetic core 21, a first mold P1 having a concave portion Pt and a second mold P2 having a convex portion P21 are prepared as shown in FIG. 5A. Here, the inner shape of the recess Pt has substantially the same shape as the outer shape of the magnetic core 21 to be manufactured, and has a flat rectangular parallelepiped shape. The convex portion P21 has substantially the same shape as the region inside the through hole 21a of the magnetic core 21, and has a trapezoidal pyramid shape. That is, the convex portion P21 has a shape in which the area of the cross section orthogonal to the Z-axis direction gradually decreases toward the −Z direction. First, the second mold P2 is fixed to the first mold P1 so that the convex portion P21 is inserted into the concave portion Pt of the first mold P1. Next, the magnetic powder PM, which is the base of the magnetic core, is charged into the region S1 formed between the concave Pt of the first mold P1 and the convex portion P21 of the second mold P2. Subsequently, the first mold P1, the second mold P2, and the magnetic powder PM are heated to sinter the powder material. As a result, the magnetic core 21 is formed in the region S1 surrounded by the first mold P1 and the second mold P2. After that, as shown by the arrow AR1 in FIG. 5B, the second mold P2 is separated from the first mold P1. Here, the side wall of the convex portion P21 is inclined so that the area of the cross section of the convex portion P21 orthogonal to the Z-axis direction gradually decreases toward the −Z direction. As a result, when the second mold P2 is moved in the + Z direction with respect to the first mold P1 and separated from the first mold P1, the side wall of the convex portion P21 is a tapered portion of the through hole 21a of the magnetic core 21. The 211a can be prevented from rubbing.

Next, the assembly direction of the inductor element 1 according to the present embodiment will be described. First, a magnetic core 21, a conductor group 11 forming a part of the coil 10, a conductor plate (not shown) having a support member (not shown) supporting them, and a part of the coil 10 are formed. The conductor unit group 12 to be used is prepared. Next, the rising

portions

111a, 114b of the

conductor portions

111, 114 forming the conductor portion group 11 in the conductor plate and the

second portions

112a, 112b, 113a, 113b of the

conductor portions

112, 113 are bent in the same direction. Subsequently, the rising

portions

111a and 114b of the

conductor portions

111 and 114 and the

second portions

112a, 112b, 113a and 113b of the

conductor portions

112 and 113 are inserted into the through hole 21a through the opening portion 21ab of the magnetic core 21. After that, the

conductor portions

121, 122, 123 constituting the conductor portion group 12 are welded to the rising

portions

111a, 114b of the

conductor portions

111, 114 and the tip portions of the

second portions

112a, 112b, 113a, 113b of the

conductor portions

112, 113. do. Next, the inductor element 1 is manufactured by separating the

conductor portions

111, 112, 113, 114 from the support member.

As described above, according to the magnetic core 21 according to the present embodiment, the area of the cross section orthogonal to the Z-axis direction of the two through holes 21a of the magnetic core 21 is the extension of each of the two through holes 21a. It gradually decreases from one opening 21aa in the current direction toward the other opening 21ab. In this case, the convex portion P21 of the second mold P2 has an area of a cross section orthogonal to the Z-axis direction of the base end portion thereof and an area of a cross section orthogonal to the Z-axis direction of the tip portion of the convex portion P21 on the −Z direction side. The shape is larger than that. Therefore, after fixing the second mold P2 to the first mold P1, magnetism is formed in the region S1 formed between the inside of the concave portion Pt of the first mold P1 and the convex portion P21 of the second mold P2. The magnetic core 21 is formed by heating the first mold P1, the second mold P2, and the magnetic powder PM in a state of being filled with the body powder PM and sintering the magnetic powder PM, and then the second mold. When the mold P2 is separated from the first mold P1, the side wall of the convex portion P21 can prevent the tapered portion 211a of the through hole 21a of the magnetic core 21 from rubbing. Therefore, the deformation of the through hole 21a caused by the side wall of the convex portion P21 of the second mold P2 rubbing the tapered portion 211a of the through hole 21a of the magnetic core 21 can be suppressed. Therefore, when a plurality of magnetic cores 21 are generated, it is possible to suppress variations in the electrical characteristics of the magnetic cores 21 due to deformation of the through holes 21a.

Further, according to the magnetic core 21 according to the present embodiment, the angle D21 formed by the Z-axis direction of the inner wall of the through hole 21a of the magnetic core 21 is the

second portion

112a, 112b, 113a of the

conductor portions

112, 113. , 113b, which is substantially the same as the inclination angle D2 and the rising

portions

111a, 114b, which are the inclination angles D1. As a result, the

conductor portions

111a and 114b and the

second portions

112a, 112b, 113a and 113b of the

conductor portions

112 and 113 are inserted into the through holes 21a of the magnetic core 21 in a state where the rising

portions

111a and 114b of the

conductor portions

111 and 114 are inserted into the through holes 21a of the magnetic material core 21. , 112, 113, 114 move in the X-axis direction and come into contact with the tapered portion 211a of the magnetic core 21, the rising

portions

111a, 114b and the

second portions

112a, 112b, 113a, 113b penetrate the magnetic core 21. It comes into surface contact with the tapered portion 211a of the hole 21a. Therefore, since the force applied to the tapered portion 211a of the magnetic core 21 is dispersed, the occurrence of defects in the magnetic core 21 is suppressed by that amount.

By the way, in the assembling process of the inductor element 1, the rising

portions

111a and 114b of the

conductor portions

111 and 114 and the

second portions

112a, 112b, 113a and 113b of the

conductor portions

112 and 113 are inserted into the through holes 21a of the magnetic core 21. In this state, the

conductor portions

111, 112, 113, 114 can move in the X-axis direction. On the other hand, in the inductor element 1 according to the present embodiment, in the Y-axis direction, the maximum width L12 between the ends of the two

second portions

112a and 112b of the conductor portion 112 on the + Z direction side is the conductor portion. It is shorter than the maximum width L11 of the end portion of the first portion 112 on the 112d side. Further, in the Y-axis direction, the maximum width L12 between the ends of the two

second portions

113a and 113b of the conductor portion 113 on the + Z direction side is also the maximum width L11 of the end portion of the conductor portion 113 on the first portion 113d side. Shorter than. As a result, in the assembly process of the inductor element 1, as shown in FIG. 6 (only the

conductor portions

113 and 114 are shown in FIG. 6), the rising

portions

111a and 114b of the

conductor portions

111 and 114 and the

conductor portions

112 and 113 are shown. In a state where the

second portions

112a, 112b, 113a, 113b of the above are inserted into the through holes 21a of the magnetic core 21, the ends of the rising

portions

111a, 114b and the

second portions

112a, 112b, 113a, 113b are formed. It is closer to the tapered portion 211a of the magnetic core 21 than when it is parallel to the Z-axis direction. Then, the movement of the

conductor portions

111, 112, 113, 114 in the X-axis direction is restricted by that amount. Therefore, there is an advantage that the amount of misalignment of the coil 10 with respect to the magnetic core 21 can be reduced in the assembly process of the inductor element 1.

Although each embodiment of the present invention has been described above, the present invention is not limited to the configuration of the above-described embodiment. For example, as in the inductor element 2 shown in FIG. 7, the rising portions 2111a and the

second portions

2112a and 2113a of the

conductor portions

2111, 2112 and 2113 are + Z from the side continuous with the connecting portions 111d, the

first portions

112d and 113d. It may extend in a direction inclined toward the −X direction with respect to the direction. In FIG. 7, the same reference numerals as those in FIG. 1 are attached to the same configurations as those in the embodiment. Further, the

second portions

2112b, 2113b, and the rising portion 2114b of the

conductor portions

2112, 2113, and 2114 are inclined from the side continuous with the

first portions

112d, 113d and the connecting portion 114d toward the + X direction with respect to the + Z direction. It may extend in the direction.

The inductor element 2 according to this modification includes a coil 2010 and a magnetic core 21. The coil 2010 has

conductor groups

2011 and 12. As shown in FIGS. 8A and 8B, the conductor group 11 has four

conductors

2111, 2112, 2113, and 2114 arranged along the winding axis J1 of the coil 2010. In addition, in FIG. 8A and FIG. 8B, the same reference numerals as those in FIGS. 2A and 2B are attached to the same configurations as those in the embodiment. The conductor portion 2111 has a connecting portion 111d, a rising portion 2111a, and a main portion 111c. The conductor portion 2112 has a first portion 112d and a

second portion

2112a and 2112b. The conductor portion 2113 has a first portion 113d and a

second portion

2113a and 2113b. The conductor portion 2114 has a connecting portion 114d, a rising portion 2114b, and a main portion 114c. As shown in FIG. 8C, the second portion 2113a of the conductor portion 2113 extends in a direction inclined toward the −X direction by an angle D2 with respect to the + Z direction from the side continuous with the first portion 113d. The rising portion 2111a of the conductor portion 2111 and the second portion 2112a of the conductor portion 2112 are also inclined toward the −X direction by an angle D2 with respect to the + Z direction from the side continuous with the connecting portion 111d and the first portion 112d. It extends in the direction. Further, the rising portion 2114b of the conductor portion 2114 extends in a direction inclined from the side continuous with the connecting portion 114d to the + X direction side by an angle D2 with respect to the + Z direction. The

second portions

2112b and 2113b of the

conductor portions

2112 and 2113 also extend in a direction inclined toward the + X direction by an angle D1 with respect to the + Z direction from the side continuous with the

main portions

112d and 113d. Here, the angle D21 formed by the Z-axis direction of the inner wall of the through hole 21a of the magnetic core 21 shown in FIG. It is substantially the same as the inclination angle D2 of 2111a and 2114b. Then, in the Y-axis direction, the maximum width L22 between the ends of the two

second portions

2112a and 2112b of the conductor portion 2112 on the + Z direction side is the maximum width L21 of the end portion of the conductor portion 2112 on the first portion 2112d side. Longer than. Further, in the Y-axis direction, the maximum width L22 between the ends of the two

second portions

2113a and 2113b of the conductor portion 2113 on the + Z direction side is also the maximum width L21 of the end portion of the conductor portion 2113 on the first portion 113d side. Longer than. That is, each of the two

second portions

2113a and 2113b extends in a direction in which the distance between the tip portions increases.

According to this configuration, in the assembling process of the inductor element 2, as shown in FIG. 9 (only the

conductor portions

2113 and 2114 are shown in FIG. 9), the rising

portions

2111a and 2114b and the conductor portion of the

conductor portions

2111 and 2114 are shown. With the

second portion

2112a, 2112b, 2113a, and 2113b of 2112 and 2113 inserted through the through hole 21a of the magnetic core 21, the rising

portions

2111a and 2114b and the ends of the

second portion

2112a, 2112b, 2113a, and 2113b , The taper portion 211a of the magnetic core 21 is closer to the case where they are parallel to the Z-axis direction. Then, the movement of the

conductor portions

2111, 2112, 2113, and 2114 in the X-axis direction is restricted accordingly. Therefore, there is an advantage that the amount of misalignment of the coil 2010 with respect to the magnetic core 21 can be reduced in the assembly process of the inductor element 2.

Further, according to this configuration, the angle D21 formed with the Z-axis direction of the inner wall of the through hole 21a of the magnetic core 21 is the inclination angle D2 of the

second portion

2112a, 2112b, 2113a, 2113b of the

conductor portion

2112, 2113 and standing. It is substantially the same as the inclination angle D2 of the

upper portions

2111a and 2114b. As a result, the conductor portion 2111 is inserted into the through hole 21a of the magnetic core 21 with the rising

portions

2111a and 2114b of the

conductor portion

2111 and 2114 and the

second portion

2112a, 2112b, 2113a and 2113b of the

conductor portion

2112 and 2113 being inserted through the through hole 21a of the magnetic core 21. When 21,12,2113, and 2114 move in the X-axis direction and come into contact with the tapered portion 211a of the magnetic core 21, the rising

portion

2111a, 2114b and the

second portion

2112a, 2112b, 2113a, and 2113b penetrate the magnetic core 21. It comes into surface contact with the tapered portion 211a of the hole 21a. Therefore, since the force applied to the tapered portion 211a of the magnetic core 21 is dispersed, the occurrence of defects in the magnetic core 21 is suppressed by that amount.

In the embodiment, an example in which the rising portion 111a of the conductor portion 111, the

second portions

112a, 112b, 113a, 113b of the

conductor portions

112, 113 and the rising portion 114b of the conductor portion 114 are inclined with respect to the Z-axis direction. Was explained. However, the present invention is not limited to this, for example, as in the inductor element 3 shown in FIG. 10, the rising portion 3111a of the conductor portion 3111, the

second portion

3112a, 3112b, 3113a, 3113b of the

conductor portion

3112, 3113, and the rising portion of the conductor portion 3114. The 3114b may extend along the Z-axis direction.

The inductor element 3 according to this modification includes a coil 3010 and a magnetic core 21. The coil 3010 has

conductor groups

3011 and 12. As shown in FIGS. 11A and 11B, the conductor group 3011 has four

conductors

3111, 3112, 3113, and 3114 arranged along the winding axis J1 of the coil 3010. In addition, in FIG. 11A and FIG. 11B, the same reference numerals as those in FIGS. 2A and 2B are attached to the same configurations as those in the embodiment. The conductor portion 3111 has a connecting portion 111d, a rising portion 3111a, and a main portion 111c. The conductor portion 3112 has a first portion 112d and a

second portion

3112a and 3112b. The conductor portion 3113 has a first portion 113d and a

second portion

3113a and 3113b. The conductor portion 3114 has a connecting portion 114d, a rising portion 3114b, and a main portion 114c. As shown in FIG. 11C, the second portion 3113a of the conductor portion 3113 extends parallel to the Z-axis direction from the side continuous with the first portion 113d. The rising portion 3111a of the conductor portion 3111 and the second portion 3112a of the conductor portion 3112 also extend parallel to the Z-axis direction from the side continuous with the connecting portion 111d and the first portion 112d. Further, the rising portion 3114b of the conductor portion 3114 extends parallel to the connecting portion 114d in the Z-axis direction from the side continuous with the connecting portion 114d. The

second portions

3112b and 3113b of the

conductor portions

3112 and 3113 also extend parallel to the

main portions

112d and 113d in the Z-axis direction. Then, in the Y-axis direction, the maximum width between the ends of the two

second portions

3112a and 3112b of the conductor portion 3112 on the + Z direction side is equal to the maximum width of the end portion of the conductor portion 3112 on the first portion 3112d side. .. Further, in the Y-axis direction, the maximum width between the ends of the two

second portions

3113a and 3113b of the conductor portion 3113 on the + Z direction side is also equal to the maximum width of the end portion of the conductor portion 3113 on the first portion 113d side. .. That is, the two

second portions

112b and 113b each extend in a direction parallel to the Z-axis direction.

According to this configuration, in the assembly process of the inductor element 3, the

second portions

3112a, 3112b, 3113a, and 3113b of the

conductor portions

3112 and 3113 constituting the coil 3010 can be easily inserted into the through holes 21a of the magnetic core 21. The inductor element 3 can be assembled efficiently.

In the embodiment, an example in which the stretching direction of the central axis J21 of the two through holes 21a of the magnetic core 21 coincides with the Z-axis direction has been described. However, the present invention is not limited to this, and as in the magnetic core 4021 shown in FIGS. 12A and 12B, the center C41 of each of the two openings 4021aa is located at the center C42 of each of the two openings 4021ab when viewed from the Z-axis direction. On the other hand, the magnetic core 4021 may be displaced toward the peripheral edge side. In other words, the stretching directions of the central axes J4021 of each of the two through holes 4021a of the magnetic core 4021 may be stretched so as to intersect the Z-axis direction and to be separated from each other toward the + Z direction. Here, of the two through holes 4021a, the tapered portion 4211b on the + X direction side of the through hole 4021a located on the + X direction side is inclined with respect to the Z axis direction, and the tapered portion 4211a on the −X direction side is It is parallel to the Z-axis direction. Further, of the two through holes 4021a, the inner wall 4211b on the + X direction side of the through hole 4021a located on the −X direction side is parallel to the Z axis direction, and the tapered portion 4211a on the + X direction side is relative to the Z axis direction. Is tilted.

Alternatively, for example, as in the magnetic core 5021 shown in FIGS. 13A and 13B, when viewed from the Z-axis direction, the center C51 of each of the two openings 5021aa is the magnetic core with respect to the center C52 of each of the two openings 5021ab. It may be shifted toward the center of 5021. In other words, the stretching directions of the central axes J5021 of the two through holes 5021a of the magnetic core 5021 may be stretched so as to intersect the Z-axis direction and approach each other toward the + Z direction. Here, of the two through holes 5021a, the tapered portion 5211b on the −X direction side of the through hole 5021a located on the + X direction side is inclined with respect to the Z axis direction, and the tapered portion 5211a on the + X direction side is It is parallel to the Z-axis direction. Further, of the two through holes 5021a, the tapered portion 5211a on the −X direction side of the through hole 5021a located on the −X direction side is parallel to the Z axis direction, and the tapered portion 5211b on the + X direction side is in the Z axis direction. It is inclined with respect to. The angle D521 formed by the tapered portion 5211b and the Z-axis direction can be set to an angle within a range of, for example, 0 degrees or more and 20 degrees or less, as in the case of the tapered portion 211a described in the embodiment. From the viewpoint of suppressing contact, it is preferable that the size is as large as possible.

In the embodiment, an example has been described in which the tapered portion 211a of the through hole 21a of the magnetic core 21 is an inclined surface that is linearly inclined in a cross section parallel to the Z-axis direction. However, the present invention is not limited to this, and for example, the inner wall of the through hole of the magnetic core may be a curved surface curved in a cross section parallel to the Z-axis direction.

Although the embodiments and modifications of the present invention have been described above, the present invention is not limited thereto. The present invention includes a combination of embodiments and modifications as appropriate, and modifications thereof as appropriate.

As the magnetic material, an insulator material such as a resin containing ferrite powder can be adopted. As the ferrite powder, Ni—Zn-based ferrite, Mn—Zn-based ferrite, and Ni—Cu—Zn-based ferrite powder can be adopted. Further, as the resin, a thermoplastic resin such as polypropylene, polyamide or polystyrene or a thermosetting resin such as a phenol resin or an epoxy resin can be adopted.

In the embodiment, an example in which the magnetic core 21 has a flat rectangular parallelepiped outer shape has been described, but the shape of the magnetic core 21 is not limited to a rectangular parallelepiped as long as it is columnar, for example, a flat columnar shape. It may be a polygonal column.

The present invention enables various embodiments and modifications without departing from the broad spirit and scope of the present invention. Moreover, the above-described embodiment is for explaining the present invention, and does not limit the scope of the present invention. That is, the scope of the present invention is indicated not by the embodiment but by the claims. And various modifications made within the scope of the claims and within the equivalent meaning of the invention are considered to be within the scope of the invention.

This application is based on Japanese Patent Application No. 2020-076482 filed on April 23, 2020. The specification, claims and the entire drawings of Japanese Patent Application No. 2020-076482 are incorporated herein by reference.

The present invention is suitable as an inductor element including a magnetic core and a coil.

1,2,3: inductor element, 10,2010,3010: coil, 11,12: conductor group, 21,4021,5021: magnetic core, 21a, 4021a, 5021a: through hole, 21aa, 21ab, 4021aa, 4021ab, 5021aa, 5021ab: Opening, 21c, 21d: Main surface, 111,112,113,114,121,122,123,2111,2112,2113,2114,3111,3112,3113,3114: Conductor, 111a , 114b: Rising edge, 111c, 114c: Main part, 111d, 114d: Connecting part, 112a, 112b, 113a, 113b: Second part, 112d, 113d: First part, 211a, 4211a, 4211b, 5211a, 5211b: Tapered part, C11, C12, C41, C42, C51, C52: Center, P1: 1st mold, P2: 2nd mold, P21: Convex part, PM: Magnetic material powder, Pt: Concave, S1: Region, J1: Winding shaft, J21, J4021, J5021: Central shaft

Claims

A magnetic core having one main surface and the other main surface facing each other and having a columnar outer shape.
It has a through hole penetrating in the first direction from the one main surface to the other main surface.
The through hole has a tapered portion whose side surface is inclined, and the opening on one main surface side is wider than the opening on the other main surface side.
When viewed in a plan view from the first direction, the entire opening on the main surface side of the other is included inside the opening on the main surface side of the other.
Magnetic core.
It has two through holes
The two through holes are arranged side by side in one direction orthogonal to the first direction.
The magnetic core according to claim 1.
The magnetic core according to claim 2 and
A coil arranged around the magnetic core is provided.
The coil
A first conductor portion having a flat plate-shaped first portion abutting on the other main surface and two second portions erected in the first portion and arranged inside the two through holes, respectively. ,
It has a flat plate-shaped second conductor portion that is connected to the tip of the second portion and abuts on one of the main surfaces.
Inductor element.
Each of the two second portions extends in a direction in which the distance between the tips of the two second portions increases.
The inductor element according to claim 3.
Each of the two second parts extends in a direction in which the distance between the tips of the two second parts becomes shorter.
The inductor element according to claim 3.
The two second sites each extend in a direction parallel to the first direction.
The inductor element according to claim 3.