JP2001196226A - Inductor and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an inductor which can be formed thinly and can be manufactured easily and to provide a manufacturing method thereof. SOLUTION: A metal conductor 13 and a sheet of non-magnetic material 14 are interlaminated between a flat-form magnetic member 11 on which a recess 11a is formed and a flat-form magnetic member 12, thereby composing an inductor which has a non-magnetic layer formed between those two magnetic members 11 and 12 by a thickness of the non-magnetic material sheet 14. As a result, the intensity of magnetic field which produces the magnetic saturation is enhanced by a non-magnetic layer between the two magnetic members 11 and 12 and accordingly, the magnetic saturation can be avoided. Furthermore, the value of inductance can be predetermined arbitrarily by varying an arrangement or a shape of the metal conductor 13 between the two magnetic members 11 and 12 and the manufacture is extremely easy.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to an inductor used for an output smoothing circuit of a CPU core power supply and a method of manufacturing the same.

[0002]

2. Description of the Related Art In recent years, various types of output smoothing inductors of a CPU core power supply have been developed in accordance with the low voltage and large current of the CPU specifications.

The shape of this type of inductor has an area occupied by about 12 mm square at the time of mounting, and the height dimension is determined in consideration of a capacitor to be mounted at the same time.

[0004] The inductance required for this type of inductor is becoming smaller as the switching frequency of the power supply increases. At present, 300KH
z is about 1 to 2 μH. When the switching frequency of the power supply is further increased, the inductance required for the smoothing inductor is further reduced, and is expected to be 1 μH or less.

Since a large current of, for example, about 10 A flows through the output smoothing inductor of the CPU core power supply, it is required that a necessary inductance be obtained even when such a large current flows.

In order to suppress heat generation due to a large current,
It is important to reduce the DC resistance. In order to reduce the DC resistance, the cross-sectional area of the conductor may be increased, but the shape of the inductor must be kept within an allowable dimension, and a high degree of space factor in the winding is required.

For these reasons, the output smoothing inductor of the conventional CPU core power supply is a high-density winding of a copper wire having a circular or rectangular cross section around a core made of ferrite, metal powder, or an amorphous alloy. It is manufactured by surrounding the outer periphery with a magnetic material.

[0008]

However, since the output smoothing inductor of the conventional CPU core power supply described above has a structure in which a wire is wound around the core, the manufacturing process becomes complicated, the cost increases, and the shape is inevitably increased. Therefore, there is a problem that the use of a notebook computer or the like imposes restrictions on thinning of the device.

SUMMARY OF THE INVENTION An object of the present invention is to provide an inductor which is easy to manufacture and can be formed thin and a method for manufacturing the same in view of the above problems.

[0010]

According to the present invention, in order to achieve the above object, a metal conductor having two or more terminals including a band or a string having a predetermined length and including both ends is provided. A first and a second plate-shaped magnetic member having a first main surface facing each other and sandwiching the metal conductor between the two main surfaces; and a non-magnetic layer provided between the two plate-shaped magnetic members. A concave portion for disposing the metal conductor is formed on at least one of the first main surface of the first plate-shaped magnetic member and the first main surface of the second plate-shaped magnetic member. We propose an inductor.

According to the inductor, since the concave portion for disposing the metal conductor is formed in at least one of the first and second plate-shaped magnetic members, the arrangement position of the metal conductor can be unified. This makes it possible to keep the inductor characteristics constant when many inductors of the same standard are manufactured. Further, the magnetic field intensity at which magnetic saturation occurs due to the nonmagnetic layer is increased, and magnetic saturation can be avoided.
Further, the inductance value can be arbitrarily set by changing the arrangement and shape of the metal conductor between the two flat magnetic members.

In the present invention, the thickness of the non-magnetic layer is accurately set by forming at least a part of the non-magnetic layer using a magnetic material sheet having a predetermined thickness set in advance. I can do it. Also, a protrusion provided on the main surface of the flat magnetic member, a difference between the depth of the recess and the thickness of the metal conductor, a protrusion provided on the metal conductor, or a tip of a terminal portion of the metal conductor. The thickness of the nonmagnetic layer can be accurately set by using a projection provided on the metal member.

Further, in the present invention, the metal conductor is formed into a predetermined shape by punching a metal plate, thereby simplifying the manufacturing process.

Further, in the present invention, the manufacturing process is simplified by exposing two or more terminal portions including both ends of the metal conductor to the outside to form wiring terminals.

Further, the metal conductor is formed in a strip or string shape, thereby facilitating manufacture. Furthermore, the metal plate is punched into a predetermined shape to form the metal conductor, thereby facilitating manufacture.

Further, by arranging the metal conductor between the first and second plate-shaped magnetic members so as to form a substantially circular arc, the metal conductor is formed in a ring shape so that the inductance value can be set to a desired value.

Further, by forming the plate-shaped magnetic member from a mixture of a magnetic material and a resin, the production is facilitated and the production process is simplified.

Further, by making the first and second plate-shaped magnetic members have different magnetic characteristics, an inductor having two different types of magnetic characteristics at the same time is obtained. The use of ferrite with high magnetic permeability as the flat magnetic member reduces the loss at high frequencies, and the use of metal compacts or amorphous alloys provides excellent DC superposition characteristics. Can be configured.

In the present invention, in order to achieve the above object, according to the nineteenth aspect, a band-shaped or string-shaped metal conductor having two or more terminal portions including both ends is sandwiched between flat magnetic members. A method of manufacturing an inductor in which a nonmagnetic layer is formed on at least a portion other than a metal conductor between plate-shaped magnetic members, wherein the metal conductor is arranged such that a terminal portion of the metal conductor is located outside a main surface. Forming a recess on the main surface of the plate-shaped magnetic member, arranging a portion of the metal conductor other than the terminal portion in the recess, and bonding the metal conductor to the main surface of the plate-shaped magnetic member; A step of laminating another flat magnetic member with a conductor and a non-magnetic material sheet of a predetermined thickness sandwiched therebetween and bonding them, and a step of forming the wiring terminal by bending the terminal portion of the metal conductor. Manufacturing method for inductors It was to easily manufacturing the inductor.

According to the present invention, in order to achieve the above object, according to a twentieth aspect, a band-shaped or string-shaped metal conductor having two or more terminals including both ends is sandwiched between flat magnetic members. A method of manufacturing an inductor in which a nonmagnetic layer is formed on at least a portion other than a metal conductor between plate-shaped magnetic members, wherein the metal conductor is arranged such that a terminal portion of the metal conductor is located outside a main surface. Forming a recess on the main surface of the flat magnetic member, arranging a portion of the metal conductor other than the terminal portion in the recess and bonding the same, and removing a part of the main surface of the flat magnetic member. To apply the adhesive,
A step of laminating a non-magnetic material sheet of a predetermined thickness on the non-coated portion of the adhesive, laminating another flat magnetic member so as to sandwich the non-magnetic material sheet, and bonding these flat magnetic members, Forming the wiring terminal by bending the terminal portion of the metal conductor to thereby easily manufacture the inductor.

According to a twenty-first aspect of the present invention, the concave portion is formed so as to surround a central portion of the main surface of the flat magnetic member, and the non-magnetic material sheet is provided at a central portion of the main surface of the flat magnetic member. Placed.

In the invention, the recess is formed so as to surround a central portion of the main surface of the flat magnetic member, and the non-magnetic sheet is arranged outside the recess.

[0023]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings.

FIG. 1 is an external perspective view showing an inductor according to a first embodiment of the present invention, FIG. 2 is an exploded perspective view thereof, and FIG. 3 is a side view. In the figure, reference numeral 10 denotes an inductor, a strip-shaped metal conductor 13 and an insulating material sheet between two first and second plate-shaped magnetic members (hereinafter, referred to as magnetic members) 11 and 12 having a square main surface. 14 is sandwiched between them. These two magnetic members 11 and 12 and metal conductor 13
The magnetic material sheet 14 is bonded using a resin.

Each of the magnetic members 11 and 12 has a thickness of, for example, 0.5 mm to 1.0 mm and a side of 5 mm to 15 m.
m of a ferrite plate. In addition, a concave portion 11a for disposing the metal conductor 13 is formed on an upper main surface (hereinafter, referred to as an upper surface) of the magnetic member 11. This recess 1
Reference numeral 1a denotes a main portion having an annular shape and four outwardly directed radial portions, each having a predetermined depth and width.
Here, the depth of the concave portion 11a corresponds to the thickness of the metal conductor 13, and the width is set slightly larger than the width of the metal conductor 13.

The metal conductor 13 has a thickness of, for example, 10
It is made of copper having a thickness of 0 μm and a width of 1 mm to 2 mm, and is formed by punching a copper plate. In addition, the metal conductor 13
Are provided with three terminal portions 13a to 13c including both ends thereof, and a main portion 13d excluding these terminal portions 13a to 13c has an arc shape. In addition, the metal conductor 13
The terminal portions 13a to 13c are exposed to the outside and bent into a predetermined shape to form wiring terminals.

The inductor 10 was manufactured as follows.

That is, the metal conductor 13 is bonded in the concave portion 11a using an epoxy resin, and the nonmagnetic material sheet 14 and the magnetic member 12 serving as the upper plate are further bonded thereon using the resin. Next, the terminal portion 13 exposed to the outside
The terminals a to 13c are bent according to the shape of the magnetic member 11 serving as the lower plate to form wiring terminals. After this, 150 ~
It is dried at a temperature of 200 degrees to cure the resin for bonding. Thereby, the inductor 10 is completed.

According to the inductor 10 having the above-described structure, the nonmagnetic material sheet 14 is sandwiched between the magnetic members 11 and 12 so that the two magnetic members 1 are formed depending on the thickness of the sheet 14.
A nonmagnetic layer is formed between 1 and 12. Further, since the thickness of the nonmagnetic material sheet 14 can be accurately set in advance, the thickness of the nonmagnetic layer can be accurately set.

The non-magnetic layer increases the magnetic field intensity at which magnetic saturation occurs, so that magnetic saturation can be avoided.

Further, the terminal portions 13a to 13
c, and the terminal portions 13a to 13c are connected to the magnetic member 11,
Since the wiring terminal is exposed to the outside from the gap between the wirings 12, the manufacturing process can be simplified. In addition, since the band-shaped metal conductor 13 having a relatively large cross-sectional area is used,
In addition to being easy to manufacture, the DC resistance can be reduced and a large inductance value can be obtained.

In this embodiment, two magnetic members 11 and
Although a ferrite plate having the same magnetic characteristics is used as 12, two flat magnetic members 11 and 12 having different magnetic characteristics are used.
, An inductor having both these two magnetic characteristics can be formed. For example, when ferrite having high magnetic permeability is used as the plate-shaped magnetic members 11 and 12, loss at high frequencies is reduced, and when metal powder or an amorphous alloy is used, DC superimposition characteristics are excellent. An inductor having both characteristics can be configured.

Further, by forming the plate-like magnetic members 11 and 12 from a mixture of a resin and a magnetic material, the manufacturing process can be further simplified.

Further, the two flat magnetic members 11 and 12
The inductance value can be arbitrarily set by changing the arrangement and shape of the metal conductor 13 between them.

Further, the terminal portions 13a to 13c may be made longer by bending them so as to protrude in a direction perpendicular to the side surface of the magnetic member 11 as shown in FIG.
Alternatively, the magnetic member 11 may be bent toward the bottom side as shown in FIG. Also, as shown in FIG. 4 and FIG.
6 and 7, the terminal portions 13a to 13c can be neatly formed by first bending the distal ends thereof and then bending the roots thereof as shown in FIGS.

As the metal conductor 13, phosphor bronze, iron, or the like may be used in addition to copper.

Next, a second embodiment of the present invention will be described.

FIG. 8 is an exploded perspective view showing an inductor according to a second embodiment of the present invention. In the figure, the same components as those in the above-described first embodiment are denoted by the same reference numerals, and description thereof is omitted. The difference between the second embodiment and the first embodiment is the shape of the metal conductor and the concave portion.

That is, in the second embodiment, the metal conductor 13
A is made of copper having a thickness of, for example, 100 μm and a width of 1 mm to 2 mm, and is formed in a shape in which terminal portions 13a to 13c are continuously provided at predetermined positions at both ends and a center of the arc-shaped portion 13d. Further, the arc-shaped portion 13d of the metal conductor 13A is formed slightly longer than in the first embodiment. By this. The terminal portions 13a and 13c at both ends can be exposed along the same side of the magnetic member 11A.

A concave portion 21a having a shape corresponding to this
Are formed on the upper surface of the magnetic member 11A. here,
In the concave portion 21a, the portion where the terminal portions 13a and 13c are arranged is cut out continuously, and the terminal portions 13a and 1c are notched.
The portion where 3c does not exist is filled with an adhesive resin, and a non-magnetic layer is formed.

Next, a third embodiment of the present invention will be described.

FIG. 9 is an external perspective view showing an inductor 10B according to a third embodiment of the present invention, FIG. 10 is an exploded perspective view thereof, and FIG. 11 is a side sectional view. In the figure, the same components as those in the first embodiment described above are denoted by the same reference numerals, and description thereof is omitted. The difference between the third embodiment and the first embodiment is that the concave portions 11b are formed from the upper surface to the side surfaces of the magnetic member 11B, and the tip portions of the terminal portions 13a to 13c exposed to the outside of the metal conductor 13 are also different. Side recess 11b
It is to be arranged in.

Accordingly, the protrusion of the metal conductor 13 on the side surface of the magnetic member 11B can be eliminated, and the size can be reduced.

It is to be noted that, as shown in FIGS. 4 and 5, when the tip portions of the terminal portions 13a to 13c are further bent,
As shown in FIGS. 12 and 13, the protruding portions in the terminal portions 13 a to 13 c can be reduced. Further, when the distal end portions of the terminal portions 13a to 13c are bent toward the bottom surface of the magnetic member 11B, as shown in FIG.
On the bottom surface of 1B, concave portions corresponding to the tip portions of the terminal portions 13a to 13c may be formed.

As shown in FIGS. 14 to 16, a concave portion in which the tip portions of the terminal portions 13a to 13c of the metal conductor 13 are arranged may be formed in the magnetic member 12 serving as the upper plate.

Next, a fourth embodiment of the present invention will be described.

FIG. 17 is an exploded perspective view showing an inductor according to a fourth embodiment of the present invention, and FIG. 18 is a side sectional view thereof. In the figure, the same components as those of the above-described third embodiment are denoted by the same reference numerals, and description thereof is omitted. Also,
The difference between the fourth embodiment and the third embodiment is that an inductor 10C is formed using an insulating material sheet 14C in which a region surrounded by an arc-shaped portion 13d of a metal conductor 13 is hollowed out.

The insulating material sheet 14C is used for the magnetic member 11
B, 12 without adhering to these magnetic members 11
B, 12 between. When the magnetic member 12 serving as the upper plate is bonded to the magnetic member 11B, the magnetic member 11
The resin 15 is applied to a position corresponding to the hollowed portion at the center of the insulating material sheet 14C on the facing surfaces of the magnetic members 11B and 12 so that the magnetic members 11B and 12 are bonded to each other.

As a result, since the resin 15 is not interposed between the magnetic material sheet 14C and the magnetic members 11B and 12, errors in the thickness of the non-magnetic layer caused by the resin can be eliminated, and the thickness of the non-magnetic layer can be reduced. Can be set more accurately.

Next, a fifth embodiment of the present invention will be described.

FIG. 19 is an exploded perspective view showing an inductor according to a fifth embodiment of the present invention, and FIG. 20 is a sectional side view thereof.
In the figure, the same components as those of the above-described fourth embodiment are denoted by the same reference numerals, and description thereof will be omitted. In addition, the fifth
The fourth embodiment differs from the fourth embodiment in that the metal conductor 1
That is, the inductor 10D in which the nonmagnetic material sheet 14D is arranged only in the region surrounded by the third arc-shaped portion 13d is formed.

The insulating material sheet 14D is used for the magnetic member 11
B, 12 without adhering to these magnetic members 11
B, 12 between. When the magnetic member 12 serving as the upper plate is bonded to the magnetic member 11B, the magnetic member 11
The resin 15 is applied to a portion of the opposing surface of the magnetic members 11B, 12B where the insulating material sheet 14D does not contact.
12 are bonded.

Thus, since the resin 15 is not interposed between the magnetic material sheet 14D and the magnetic members 11B and 12, the error in the thickness of the non-magnetic layer caused by the resin can be eliminated, and the thickness of the non-magnetic layer can be reduced. Can be set more accurately.

Next, a sixth embodiment of the present invention will be described.

FIG. 21 is an exploded perspective view showing an inductor according to a sixth embodiment, and FIG. 22 is a side sectional view thereof. In the figure, the same components as those of the above-described third embodiment are denoted by the same reference numerals, and description thereof is omitted. The difference between the sixth embodiment and the third embodiment is that four small protrusions 11c are formed at the four corners of the upper surface of the magnetic member 11E, and the thickness of the nonmagnetic layer is determined by the height of these protrusions 11c. Is to be set.

That is, the inductor 10E of the sixth embodiment.
Does not use the non-magnetic material sheet 14. Metal conductor 1
Reference numeral 3 is disposed in and bonded to the recess 11b. A non-magnetic layer is formed between the magnetic member 11E and the magnetic member 12 by filling with an adhesive resin 15, and the thickness thereof is set by the protrusion 11c.

According to the present embodiment, when forming the magnetic member 11E, the height of the protrusion 11c can be set accurately, so that the thickness of the nonmagnetic layer can be set accurately.

Next, a seventh embodiment of the present invention will be described.

FIG. 23 is an exploded perspective view showing an inductor according to a seventh embodiment, and FIG. 24 is a side sectional view thereof. In the figure, the same components as those of the above-described third embodiment are denoted by the same reference numerals, and description thereof is omitted. The difference between the seventh embodiment and the third embodiment is that a region surrounded by the arc-shaped portion 13d of the metal conductor 13 on the upper surface of the magnetic member 11F is formed higher than other portions, and the height is determined by this height. That is, the thickness of the nonmagnetic layer is set.

That is, the inductor 10F of the seventh embodiment
Does not use the non-magnetic material sheet 14. The metal conductor 13 is disposed in and bonded to the recess 11b. In addition, a central portion of the upper surface of the magnetic member 11F, that is, a portion surrounded by the annular concave portion 11b is formed to be higher by a predetermined amount than other regions of the upper surface, thereby forming the protrusion 11d. When bonding the magnetic member 12 to the magnetic member 11F,
Resin is applied to a region excluding the protrusion 11d, and the upper surface of the protrusion 11d is brought into contact with and bonded to the opposing surface of the magnetic member 12.

Thus, the magnetic member 11F and the magnetic member 1
2, a nonmagnetic layer is formed by filling the adhesive resin 15 except for the central protrusion 11d, and the thickness thereof is set by the protrusion 11d.

According to the present embodiment, when forming the magnetic member 11F, the height of the protrusion 11d can be set accurately, so that the thickness of the nonmagnetic layer can be set accurately.

Next, an eighth embodiment of the present invention will be described.

FIG. 25 is an exploded perspective view showing an inductor according to the eighth embodiment, and FIG. 26 is a side sectional view thereof. In the figure, the same components as those of the above-described third embodiment are denoted by the same reference numerals, and description thereof is omitted. The difference between the eighth embodiment and the third embodiment is that the thickness of the metal conductor 13G is set to be larger than the depth of the concave portion 11b of the magnetic member 11B, and the depth of the concave portion 11b and the thickness of the metal conductor 13G are set. The difference is that the thickness of the nonmagnetic layer is set.

That is, the inductor 10G of the eighth embodiment
Does not use the non-magnetic material sheet 14. The metal conductor 13G is arranged and bonded in the recess 11b,
The upper surface is located higher than the upper surface of the magnetic member 11B. When the magnetic member 12 is bonded to the magnetic member 11B, a resin is applied to a region excluding the metal conductor 13G, and the upper surface of the metal conductor 13G is brought into contact with the opposing surface of the magnetic member 12 and bonded.

Thus, the magnetic member 11B and the magnetic member 1
2 and the adhesive resin 1 except for the metal conductor 13G.
5 is filled to form a non-magnetic layer, the thickness of which is set by the protruding height of the metal conductor 13G.

According to the present embodiment, when forming the magnetic member 11B, the depth of the recess 11b can be set accurately, and the thickness of the metal conductor 13G can be set accurately. Can be set to

Next, a ninth embodiment of the present invention will be described.

FIG. 27 is an exploded perspective view showing an inductor according to a ninth embodiment, and FIG. 28 is a side sectional view thereof. In the figure, the same components as those of the above-described third embodiment are denoted by the same reference numerals, and description thereof is omitted. The difference between the ninth embodiment and the third embodiment is that a plurality of protrusions 13e for setting the thickness of the nonmagnetic layer are provided on the metal conductor 13H.

That is, the inductor 10H of the ninth embodiment
Does not use the non-magnetic material sheet 14. The metal conductor 13H is arranged and bonded in the recess 11b,
The projection 13e is located outside the recess 11b, and the lower surface of the projection is in contact with the upper surface of the magnetic member 11B. When bonding the magnetic member 12 to the magnetic member 11B,
Resin is applied to a region excluding the metal conductor 13H, and the upper surface of the protrusion 13e of the metal conductor 13H is brought into contact with and adhered to the opposing surface of the magnetic member 12.

Thus, the magnetic member 11B and the magnetic member 1
2 and the adhesive resin 1 except for the metal conductor 13H.
5 is filled to form a nonmagnetic layer, the thickness of which is set by the thickness of the protrusion 13e of the metal conductor 13H.

According to the present embodiment, when forming the magnetic member 11B, the thickness of the protrusion 13e of the metal conductor 13H can be set accurately, so that the thickness of the nonmagnetic layer can be set accurately.

Next, a tenth embodiment of the present invention will be described.

FIG. 29 is an external perspective view showing an inductor according to a tenth embodiment, and FIG. 30 is an exploded perspective view thereof. In the figure, the same components as those in the above-described first embodiment are denoted by the same reference numerals, and description thereof is omitted. In addition, the tenth
The difference between this embodiment and the first embodiment is that the metal conductor 1
3 is provided with a fixing bracket 31 for each of the terminal portions 13a to 13c, and is electrically connected to the fixing bracket 31 without bending the end portions of the terminal portions 13a to 13c of the metal conductor 13.

That is, the inductor 10 according to the tenth embodiment
In J, the distal end portions of the terminal portions 13a to 13c are
One of the insertion holes 31a is inserted and soldered.

The fixing bracket 31 is formed, for example, by forming an insertion hole 31a in the center of a rectangular copper plate into which the terminal portions 13a to 13c can be inserted, and then stacking the magnetic members 11,1.
It is formed by bending into a U-shape that sandwiches 2. For this reason, the terminal portions 13a to 13
Since the magnetic members 11 and 12 are sandwiched by the fixing fittings 31 at the same time as the insertion of the distal end portion 13c, the durability can be improved and the fixing fittings 31 can be used as connection terminals.

Next, an eleventh embodiment of the present invention will be described.

FIG. 31 is an external perspective view showing an inductor according to an eleventh embodiment, and FIG. 32 is an exploded perspective view thereof. In the figure, the same components as those of the above-described tenth embodiment are denoted by the same reference numerals, and description thereof is omitted. Also, the first
The difference between the first embodiment and the tenth embodiment is that a fixing bracket 31A provided with a stopper 31b for setting the thickness of the nonmagnetic layer between the magnetic members 11 and 12 is used.

Thus, in the inductor 10 K of the eleventh embodiment, the non-magnetic layer is formed by the bonding resin 15 without using the insulating material sheet 14.

The fixing member 31A has substantially the same shape as the fixing member 31 of the tenth embodiment. However, a stopper portion 31b projects substantially in the center so as to be sandwiched between the magnetic members 11 and 12. Is provided.

For this reason, the insertion hole 31a of the fixing bracket 31A
The stoppers 31b are sandwiched between the magnetic members 11 and 12 at the same time as the distal ends of the terminals 13a to 13c are inserted into the terminals 13a to 13c. Thus, a nonmagnetic layer having a thickness corresponding to the thickness of the stopper portion 31b is formed between the magnetic members 11 and 12.

Therefore, according to the present embodiment, the fixture 3
Since the thickness of the stopper portion 31b can be set accurately when forming 1A, the thickness of the nonmagnetic layer can be set accurately.

Next, a twelfth embodiment of the present invention will be described.

FIG. 33 is an exploded perspective view showing the inductor of the twelfth embodiment, and FIG. 34 is a plan view showing the metal conductor. In the figure, the same components as those in the above-described first embodiment are denoted by the same reference numerals, and description thereof is omitted. The difference between the twelfth embodiment and the first embodiment is that
The magnetic member 11L is formed with a through hole 11e through which the terminal portions 13a to 13c of the metal conductor 13L are inserted.
Are exposed at the bottoms of the terminals 13a to 13c.

With the above configuration, the same effects as those of the above embodiments can be obtained. In addition, the metal conductor 13L
Other shapes are possible as shown in FIGS. 35 and 36.
The thirteenth embodiment shown in FIG.
The same applies to the shape of the fourth embodiment.

Next, a fifteenth embodiment of the present invention will be described.

FIG. 39 is an external perspective view showing an inductor according to a fifteenth embodiment, and FIG. 40 is an exploded perspective view thereof. In the drawing, reference numeral 40 denotes an inductor, a magnetic member 41 having a circular main surface and a circular concave portion 41a on one main surface (hereinafter referred to as an upper surface), a substantially cylindrical magnetic member 42 fitted into the concave portion 41a, and It is composed of a metal conductor 43.

The magnetic member 41 has a thickness of, for example, 1.0 mm.
It is made of a cylindrical ferrite plate having a diameter of 5 to 15 mm and a diameter of 2.0 mm. The magnetic member 42 has, for example, a thickness of 0.5
It is made of a cylindrical ferrite plate having a diameter of 2.5 mm to 1.0 mm and a diameter of 2.5 mm to 10 mm.

Further, a concave portion 41 a for disposing the metal conductor 43 is formed on the upper surface of the upper side of the magnetic member 41. The recess 41a has a cylindrical shape.

On the side surface of the magnetic member 42, a groove 42a into which terminal portions 43a to 43c described later are fitted is formed.

The metal conductor 43 is made of copper having a thickness of, for example, 100 μm and a width of 1 mm to 2 mm, similarly to the above-described embodiment, and is formed by punching a copper plate. The metal conductor 43 is provided with three terminal portions 43a to 43c including both ends thereof.
The main part 43d excluding a to 43c has an arc shape.

The metal conductor 43 is disposed in the concave portion 41a, and is sandwiched between the magnetic members 41 and 42, and has a terminal portion 43a.
43c are exposed to the outside and bent into a predetermined shape to form wiring terminals. The two magnetic members 41 and 42 and the metal conductor 43 are bonded using a resin.

According to the above configuration, a non-magnetic layer having the same thickness as that of the metal conductor 43 is formed between the magnetic members 41 and 42, and this non-magnetic layer is made of a filled resin.

Therefore, the same effects as those of the other embodiments can be obtained by the above configuration.

Next, a sixteenth embodiment of the present invention will be described.

FIG. 41 is an external perspective view showing an inductor according to a sixteenth embodiment, and FIG. 42 is an exploded perspective view thereof. In the figure, 50 is an inductor whose main surface is rectangular,
The magnetic member 51 includes a magnetic member 51 having a rectangular concave portion 51a on one main surface (hereinafter, referred to as an upper surface), a rectangular parallelepiped magnetic member 52 fitted into the center of the concave portion 51a, and a metal conductor 53.

The magnetic member 51 has a thickness of, for example, 1.0 mm.
It is made of a rectangular parallelepiped ferrite plate having a side length of 5 mm to 15 mm and a length of 2.0 mm. The magnetic member 52 has, for example, a thickness of 0.5 mm to 1.0 mm and a side of 2.5 mm to 10 mm.
Made of a rectangular parallelepiped ferrite plate.

Further, a concave portion 51 a for disposing the metal conductor 53 is formed on the upper surface of the upper side of the magnetic member 51. Further, the recess 51a is opened on two opposing side surfaces of the magnetic member 51.

The metal conductor 53 is made of copper having a thickness of, for example, 100 μm and a width of 1 mm to 2 mm, and is formed by punching a copper plate, similarly to the above-described embodiment. The metal conductor 5 is formed in a substantially Y-shape.
The two ends constitute terminal portions 53a to 53c. The portion excluding these terminal portions 43a to 43c is arranged in the concave portion 51a, is sandwiched between the magnetic members 51 and 52, and the distal ends of the terminal portions 53a to 53c are exposed to the outside, and are bent into a predetermined shape. It is a wiring terminal.

The two magnetic members 51 and 52 and the metal conductor 53 are bonded using a resin.

According to the above configuration, a non-magnetic layer having the same thickness as that of the metal conductor 53 is formed between the magnetic members 51 and 52, and this non-magnetic layer is made of a filled resin.

Therefore, the same effects as those of the other embodiments can be obtained by the above configuration.

The embodiments described above are merely specific examples of the present invention, and the present invention is not limited to only these. For example, it goes without saying that a thin inductor can be formed in which substantially the same effects can be obtained by combining the embodiments.

[0104]

As described above, according to the inductor of the present invention, a thin power supply can be realized by using the inductor as an output smoothing inductor of a CPU core power supply. It can sufficiently satisfy the demand for thin electronic devices such as personal computers, and greatly contributes to the development of industry. Further, since the thickness of the non-magnetic layer can be set accurately, the magnetic field intensity at which magnetic saturation occurs due to the non-magnetic layer can be increased, and magnetic saturation can be avoided. Further, since the structure is relatively simple, the manufacturing cost can be reduced, which can greatly contribute to the cost reduction of electronic devices.

Further, according to the method of manufacturing an inductor according to the nineteenth to twenty-second aspects, since it is easy to mold the inductor into a desired shape, an inductor having an inductance value according to a demand can be easily manufactured at low cost. be able to. Furthermore, an inductor having a thin shape and a small size can be easily manufactured.

[Brief description of the drawings]

FIG. 1 is an external perspective view showing an inductor according to a first embodiment of the present invention.

FIG. 2 is an exploded perspective view showing the inductor according to the first embodiment of the present invention.

FIG. 3 is a side sectional view showing the inductor according to the first embodiment of the present invention;

FIG. 4 is a view showing another shape of the terminal end portion of the metal conductor according to the first embodiment of the present invention.

FIG. 5 is a diagram showing another shape of the terminal end portion of the metal conductor according to the first embodiment of the present invention.

FIG. 6 is a view for explaining how to bend a terminal end portion of the metal conductor according to the first embodiment of the present invention.

FIG. 7 is a view for explaining how to bend the tip of the terminal portion of the metal conductor according to the first embodiment of the present invention.

FIG. 8 is an exploded perspective view showing an inductor according to a second embodiment of the present invention.

FIG. 9 is an external perspective view showing an inductor according to a third embodiment of the present invention.

FIG. 10 is an exploded perspective view showing an inductor according to a third embodiment of the present invention.

FIG. 11 is a side sectional view showing an inductor according to a third embodiment of the present invention.

FIG. 12 is a view showing another shape of a terminal end portion of the metal conductor according to the third embodiment of the present invention.

FIG. 13 is a view showing another shape of a terminal end portion of the metal conductor according to the third embodiment of the present invention.

FIG. 14 is a diagram showing another configuration according to the third embodiment of the present invention.

FIG. 15 is a diagram showing another configuration according to the third embodiment of the present invention.

FIG. 16 is a diagram showing another configuration according to the third embodiment of the present invention.

FIG. 17 is an exploded perspective view showing an inductor according to a fourth embodiment of the present invention.

FIG. 18 is a side sectional view showing an inductor according to a fourth embodiment of the present invention.

FIG. 19 is an exploded perspective view showing an inductor according to a fifth embodiment of the present invention.

FIG. 20 is a side sectional view showing an inductor according to a fifth embodiment of the present invention.

FIG. 21 is an exploded perspective view showing an inductor according to a sixth embodiment of the present invention.

FIG. 22 is a side sectional view showing an inductor according to a sixth embodiment of the present invention.

FIG. 23 is an exploded perspective view showing an inductor according to a seventh embodiment of the present invention.

FIG. 24 is a side sectional view showing an inductor according to a seventh embodiment of the present invention.

FIG. 25 is an exploded perspective view showing an inductor according to an eighth embodiment of the present invention.

FIG. 26 is a side sectional view showing an inductor according to an eighth embodiment of the present invention.

FIG. 27 is an exploded perspective view showing an inductor according to a ninth embodiment of the present invention.

FIG. 28 is a side sectional view showing an inductor according to a ninth embodiment of the present invention.

FIG. 29 is an external perspective view showing an inductor according to a tenth embodiment of the present invention.

FIG. 30 is an exploded perspective view showing an inductor according to a tenth embodiment of the present invention.

FIG. 31 is an external perspective view showing an inductor according to an eleventh embodiment of the present invention.

FIG. 32 is an exploded perspective view showing an inductor according to an eleventh embodiment of the present invention.

FIG. 33 is an exploded perspective view showing an inductor according to a twelfth embodiment of the present invention.

FIG. 34 is a plan view showing a metal conductor according to a twelfth embodiment of the present invention.

FIG. 35 is an exploded perspective view showing an inductor according to a thirteenth embodiment of the present invention.

FIG. 36 is a plan view showing a metal conductor according to a thirteenth embodiment of the present invention.

FIG. 37 is an exploded perspective view showing an inductor according to a fourteenth embodiment of the present invention.

FIG. 38 is a plan view showing a metal conductor according to a fourteenth embodiment of the present invention.

FIG. 39 is an external perspective view showing an inductor according to a fifteenth embodiment of the present invention.

FIG. 40 is an exploded perspective view showing an inductor according to a fifteenth embodiment of the present invention.

FIG. 41 is an external perspective view showing an inductor according to a sixteenth embodiment of the present invention.

FIG. 42 is an exploded perspective view showing an inductor according to a sixteenth embodiment of the present invention.

[Explanation of symbols]

10, 10A, 10B, 10C, 10D, 10E, 10
F, 10G, 10H, 10J, 10K, 10L, 40,
50 ... Inductor, 11, 11A, 11B, 11E, 1
1F, 12, 41, 42, 51, 52 ... magnetic member, 11
a, 11b, 11f, 41a, 51a ... recess, 11c ...
Projection, 11d Projection, 11e Through hole, 13, 13A
~ 13D, 43, 53 ... metal conductors, 13a ~ 13c, 4
3a to 43c, 53a to 53c: terminal portion, 13e: projecting portion, 14, 14C, 14D: non-magnetic material sheet, 15:
Resin, 31, 31A: fixing bracket, 31a: insertion hole, 31
b ... Stopper part.

Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat II (reference) H01F 41/12 H01F 41/12 E

Claims (22)

[Claims] 1. A metal conductor having a band shape or a string shape having a predetermined length and having two or more terminal portions including both ends, a first main surface facing each other, and the metal conductor being provided between the two main surfaces. A first and a second flat magnetic member sandwiching a conductor; and a non-magnetic layer provided between the two flat magnetic members. The first main surface of the first flat magnetic member and the first 2
An inductor, wherein a recess for arranging the metal conductor is formed on at least one of the first main surfaces of the plate-shaped magnetic member. 2. A non-magnetic material sheet is provided between the first flat magnetic member and the second flat magnetic member, and at least a part of the non-magnetic layer is formed of the non-magnetic material. The inductor according to claim 1, wherein the inductor is formed of a sheet. 3. A projection is formed on at least one of the first main surface of the first flat magnetic member and the first main surface of the second flat magnetic member. A gap between the first plate-shaped magnetic member and the second plate-shaped magnetic member formed in a portion other than the protrusion is filled with a non-magnetic member to form the non-magnetic layer. The inductor according to claim 1, wherein 4. The metal conductor has a thickness at least partially greater than a depth of the recess, and is formed in a portion other than the metal conductor due to a difference between the depth of the recess and the thickness of the metal conductor. The inductor according to claim 1, wherein the non-magnetic layer is formed by filling a gap between the first and second flat-plate magnetic members with a non-magnetic member. . 5. The first metal conductor protrudes from the inside of the recess in a width direction of the recess at a portion other than both end portions thereof.
And one or more protrusions sandwiched between the first main surfaces of each of the first and second plate-like magnetic members, and a gap between the first and second plate-like magnetic members formed by the protrusions 2. The inductor according to claim 1, wherein the non-magnetic layer is formed by filling the non-magnetic member. 6. The inductor according to claim 1, wherein the metal conductor is formed by stamping a metal plate into a predetermined shape. 7. A portion of the metal conductor excluding the terminal portion is arranged in an arc shape having a winding center axis substantially coinciding with a perpendicular to a main surface of the plate-shaped magnetic member. Item 2. The inductor according to Item 1. 8. A recess connected to the recess is formed on one of the side surfaces of the first and second plate-shaped magnetic members, and a terminal portion of the metal conductor is exposed on the side surface and The inductor according to claim 1, wherein the inductor is fitted in a concave portion on a side surface. 9. A recess connected to the recess on the side surface is formed on the second main surface of the plate-shaped magnetic member having the recess on the side surface, and is formed on the second main surface. 9. The inductor according to claim 8, wherein a tip of a terminal portion of the metal conductor is fitted in the recess. 10. The inductor according to claim 8, wherein a concave portion on the side surface is formed in a flat magnetic member having a concave portion for disposing the metal conductor. 11. A terminal portion of the metal conductor is exposed on the side surface, and a metal member sandwiching the first and second plate-shaped magnetic members is provided for each of the terminal portions. The inductor according to claim 1, wherein a terminal portion of a metal conductor is connected to the metal member. 12. The metal member is formed with an opening through which a terminal of the metal conductor is inserted, and is soldered in a state where the terminal is inserted through the opening. The inductor according to claim 11, wherein 13. The metal plate has a protrusion inserted between the first plate-like magnetic member and the second plate-like magnetic member, and the first plate-like magnetic member formed by the protrusion. The inductor according to claim 11, wherein the nonmagnetic layer is formed by filling a gap between the member and the second plate-shaped magnetic member with a nonmagnetic member. 14. An insertion hole through which a terminal portion of the metal conductor is inserted is formed in one of the first and second plate-shaped magnetic members, and the terminal portion of the metal conductor is formed in the insertion hole. 2. The inductor according to claim 1, wherein the inductor is exposed to the second main surface of the formed flat magnetic member to form an external connection terminal. 15. A first magnetic member having a concave portion of a predetermined shape, a second magnetic member fitted in the concave portion, and two or more terminal portions including both ends, and the terminal portion is externally provided. An inductor comprising a metal conductor sandwiched between the first magnetic member and the second magnetic member so as to be exposed to the outside. 16. The inductor according to claim 15, wherein an opening surface of the concave portion has a circular shape, and a portion of the metal conductor other than the terminal portion has an arc shape. 17. The inductor according to claim 1, wherein the first and second plate-shaped magnetic members have different magnetic characteristics. 18. The inductor according to claim 1, wherein the flat magnetic member is made of a mixture of a magnetic material and a resin. 19. A band-shaped or string-shaped metal conductor having two or more terminals including both ends is sandwiched between flat magnetic members,
A method of manufacturing an inductor, wherein a nonmagnetic layer is formed at least in a portion other than a metal conductor between the plate-shaped magnetic members, wherein the metal conductor is arranged such that a terminal portion of the metal conductor is located outside a main surface. Forming a concave portion to be formed on the main surface of the flat magnetic member; arranging and bonding a portion of the metal conductor other than the terminal end portion to the concave portion; and a main surface side of the flat magnetic member A step of laminating another metal plate-like member with a nonmagnetic material sheet having a predetermined thickness sandwiched between the metal conductor and the non-magnetic material sheet and bonding them together; and forming a wiring terminal by bending the terminal portion of the metal conductor. And a method for manufacturing an inductor. 20. A band-shaped or string-shaped metal conductor having two or more terminal portions including both ends is sandwiched between plate-shaped magnetic members,
A method of manufacturing an inductor, wherein a non-magnetic layer is formed at least in a portion other than a metal conductor between the plate-shaped magnetic members, wherein the metal conductor is arranged such that a terminal end portion of the metal conductor is located outside a main surface. Forming a recess on the main surface of the plate-shaped magnetic member, and arranging and bonding a portion of the metal conductor other than the terminal end portion to the recess, An adhesive is applied except for a part of the surface, a non-magnetic material sheet having a predetermined thickness is stacked on a non-application portion of the adhesive, and another flat magnetic member is stacked so as to sandwich the non-magnetic material sheet. A method for manufacturing an inductor, comprising: bonding a flat magnetic member; and bending a terminal portion of the metal conductor to form a wiring terminal. 21. The flat magnetic member, wherein the recess is formed so as to surround a central portion of a main surface of the flat magnetic member, and the non-magnetic material sheet is arranged at a center of the main surface of the flat magnetic member. The method for manufacturing an inductor according to claim 20, wherein 22. The inductor according to claim 20, wherein the recess is formed so as to surround a central portion of the main surface of the flat magnetic member, and the non-magnetic sheet is disposed outside the recess. Manufacturing method.