JP2004172188A - Inductor component, manufacturing method thereof and switching power supply device using the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an inexpensive inductor component for a switching power supply device which is reduced in the variety of an inductance value even when a minute magnetic gap is formed, the manufacturing method thereof and the switching power supply device employing the inductor component. <P>SOLUTION: The inductor component is provided with a constitution wherein at least an abutting surface 4a between the central magnetic leg unit 4ct and an outside magnetic leg unit 4out is formed so as to be the same plane without any level difference, and so as to have a ground surface with recesses and protrusions. The magnetic core is formed by abutting the tops 9 of the recesses and protrusions of the abutting surfaces 4a, 5a to form a closed magnetic passage core, and a distance is provided between the bottom 10 of recesses and protrusions of the abutting surfaces 4a, 5a of one side cores 4, 5 and the other side cores 4, 5. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to an inductor component used for various electronic devices and the like, a method for manufacturing the same, and a switching power supply using the inductor component.
[0002]
[Prior art]
2. Description of the Related Art In recent years, as information communication infrastructure networks have greatly advanced, an increase in power consumption has become a social problem. In particular, high efficiency is an essential issue in a thin power supply used for a communication device and the like.
[0003]
These thin power supplies are equipped with many inductor components composed of a coil and a magnetic core, and there is a strong demand for inexpensive inductor components with high performance and small variations in performance that contribute to achieving higher power supply efficiency. .
[0004]
Hereinafter, a conventional inductor component will be described with reference to the drawings.
[0005]
7A is an assembly diagram showing a conventional inductor component, FIG. 7B is a schematic sectional view of the inductor component, FIG. 8A is an assembly diagram showing another example of the conventional inductor component, FIG. 9B is a schematic sectional view of the inductor component, FIG. 9A is an assembly view showing another example of the inductor component, and FIG. 9B is a schematic sectional view of the inductor component.
[0006]
7 to 9, 1 is a coil, 2 is an adhesive, 3 is gap paper, 4 is an E-shaped magnetic core, 4ct is a center magnetic leg, 4out is an outer leg magnetic leg, 5 is an I-shaped magnetic core, and 6 is a magnetic gap. , 7 are gap paper, 8 is an adhesive containing glass beads, and Gct, Gt1 and Gt2 are dimensions of the magnetic gap.
[0007]
First, a conventional inductor component will be described with reference to FIG.
[0008]
FIG. 7 shows that the magnetic gap is provided at the center magnetic leg 4ct of the E-shaped magnetic core 4, and the magnetic gap 6 is formed in advance at the tip of the center magnetic leg 4ct by a method such as grinding.
[0009]
At this time, the end butting surfaces of the center magnetic leg 4ct and the outer leg magnetic leg 4out were set so that a step could be formed by the gap dimension Gct.
[0010]
The coil 1 formed by applying a predetermined winding to the central magnetic leg 4ct of the E-shaped magnetic core 4 thus prepared in advance is incorporated, and an appropriate amount of the adhesive 2 is applied to the upper end of the central magnetic leg 4ct.
[0011]
Then, the gap paper 3 is inserted into the portion of the magnetic gap 6 of the center magnetic leg 4ct, and an appropriate amount of the adhesive 2 is applied to the upper surface of the gap paper 3 and the butting surface of the outer leg magnetic legs 4out. 5 were combined.
[0012]
Further, as shown in FIG. 7 (b), the inductor component is completed by pressing and assembling from above the I-shaped magnetic core 5 (indicated by a white arrow).
[0013]
Next, another conventional example will be described with reference to FIGS.
[0014]
8 (a) and 9 (a), a major difference from the conventional inductor component shown in FIG. 7 is that the center magnetic leg 4ct has a magnetic core without a magnetic gap Gct. In the schematic cross-sectional view showing the completion of the assembly of FIG. 9 (b), a uniform magnetic gap Gt1, Gt2 is provided in the center magnetic leg 4ct and the outer leg magnetic leg 4out.
[0015]
In FIG. 8, gap paper 7 having a thickness t1 is inserted into the butting surfaces of the upper and lower magnetic cores to provide a gap Gt1.
[0016]
Also, in FIG. 9, the gap paper 7 is not used, and the magnetic gap Gt2 is provided using an adhesive 8 containing glass beads of a predetermined size having a thickness t2.
[0017]
As prior art document information related to the invention of this application, for example, Patent Document 1 and Patent Document 2 are known.
[0018]
[Patent Document 1]
Japanese Patent Application Laid-Open No. 10-135554 [Patent Document 2]
JP-A-55-77115
[Problems to be solved by the invention]
In the above conventional configuration, since the magnetic gap 6 is formed only in the center magnetic leg 4ct in the configuration of FIG. 7A, the step size Gct of the outer leg magnetic leg 4out and the center magnetic leg 4ct is as small as 50 μm or less. When the gap value becomes large, there is a problem that the variation in the inductance value becomes large because the grinding accuracy is not high.
[0020]
Also, as shown in FIG. 7B, the pressing force when the upper and lower magnetic cores are combined also causes the central portion of the upper I-shaped magnetic core 5 to bend and the gap value to change, so that the variation in the inductance value further increases. There was a drawback in assembling.
[0021]
8 and 9 showing still another conventional example, extra members such as the gap paper 7 and the glass bead-containing adhesive 8 are required, so that the manufacturing cost is increased. In addition, when forming the minute gap size, it is difficult to set the optimum thickness of the gap paper 7 and the glass bead adhesive 8 in selecting the thickness t1 of the gap paper and the thickness t2 of the adhesive containing glass beads. Was.
[0022]
As described above, in the prior art, there is no small gap forming technique for providing an inductor component having a function of a high inductance and a small variation required to increase the efficiency of the power supply, and the efficiency of the power supply is not improved. Was a major bottleneck.
[0023]
The present invention solves the above-mentioned problems, and provides an inexpensive inductor component with a small variation in inductance value even when a minute magnetic gap of 50 μm or less is formed, a method of manufacturing the same, and a switching power supply using the inductor component. The purpose is to:
[0024]
[Means for Solving the Problems]
In order to achieve the above object, the present invention has the following configuration.
[0025]
In particular, the invention according to claim 1 of the present invention is characterized in that an abutting surface of the outer leg magnetic leg portion and the central magnetic leg portion of at least one of the magnetic cores is formed in the same plane with no step and has a ground surface having irregularities. The magnetic core has a configuration in which the tops of the projections and depressions of the butting surfaces are joined to form a closed magnetic path, and a gap is provided between the bottom of the projections and depressions of the joining surfaces of one core and the other magnetic core.
[0026]
According to the above configuration, since there is no magnetic gap in the center magnetic leg, the bending of the center of the magnetic core due to the pressing force when the upper and lower magnetic cores are combined does not occur. Further, since no extra member is arranged in the gap portion, the size of the magnetic gap is stabilized when the upper and lower magnetic cores are combined.
[0027]
As described above, since the magnetic gap size when the magnetic cores are combined is stabilized, the variation in the inductance value can be greatly reduced.
[0028]
In addition, since a magnetic gap corresponding to the size of the unevenness of the abutting surface can be formed on the abutting surface, an extra step of performing magnetic gap processing on the center magnetic leg can be eliminated.
[0029]
Further, extra materials such as gap paper and glass beads are not required, and the manufacturing cost can be greatly reduced. The setting of the minute gap is not affected by the gap processing accuracy, the thickness of the member, and the like, so that the degree of freedom in design is widened.
[0030]
As a result, even when a minute magnetic gap is formed, variation in inductance value can be reduced.
[0031]
The invention described in claim 2 of the present invention has a configuration in which the dimension from the top to the bottom of the unevenness of one magnetic core is larger than the dimension from the top to the bottom of the unevenness of the other magnetic core.
[0032]
According to the above configuration, if only one magnetic core is batch-processed, a new gap can be set when the magnetic cores are combined. Since the other magnetic core can be shared, inventory management and the like can be performed, and loss in production management is eliminated.
[0033]
The invention according to claim 3 of the present invention is particularly configured such that one of the magnetic cores is a butted surface having no irregularities.
[0034]
According to the above configuration, since one of the magnetic cores has a butted surface having no irregularities, a general grinding line can be used for one of the magnetic cores, and the cost of grinding the ferrite core can be reduced.
[0035]
The invention described in claim 4 of the present invention is particularly configured such that one of the magnetic cores is a mirror-like butted surface.
[0036]
According to the above configuration, since the butting surface of one of the magnetic cores is mirror-finished, the processing accuracy of the butting surfaces is stable, and the variation in the inductance value when combined can be further reduced.
[0037]
The invention described in claim 5 of the present invention is particularly configured such that the shape of the magnetic core to be combined is an EE type magnetic core.
[0038]
According to the above configuration, the magnetic cores to be abutted from both sides of the coil can be shared, so that the die investment can be reduced.
[0039]
The invention described in claim 6 of the present invention is particularly configured such that two or more coils to be incorporated are provided.
[0040]
With the above configuration, one can be configured as a primary coil for input and the other as a secondary coil for output, and used as a transformer for voltage conversion.
[0041]
According to the invention described in claim 7 of the present invention, since the inductance of the inductor component is high and the variation can be reduced, the exciting current which causes an increase in loss can be suppressed, and the variation can be reduced. Can be greatly reduced, and the efficiency can be improved.
[0042]
The invention according to claim 8 of the present invention is particularly directed to a method of manufacturing an inductor component including a coil having an air core, a magnetic core incorporated from both sides of the coil, and a closed magnetic circuit core formed by abutting the magnetic cores. A coil forming step of forming a coil having an air core, a grinding step of grinding a ground surface having irregularities on at least one abutting surface of the closed magnetic path cores, and projecting tops of the irregularities of the magnetic core from both sides of the coil. A closed magnetic path core assembly step of adjusting the distance between the bottom of the unevenness of one magnetic core and the other magnetic core and adjusting the inductance value by pressing together in the butting direction of the magnetic cores. .
[0043]
By the above method, a magnetic core having irregularities on the butted surface is prepared in advance so as to have a desired inductance value in the grinding process, and in the closed magnetic circuit core assembling process, the bottom of the irregularities of one magnetic core and the other magnetic core are further prepared. By adjusting the distance between the butting surface and the inductance value, it is possible to correct and absorb the variation in the single member in the previous process, and to reduce the variation in the inductance value to the ultimate.
[0044]
According to a ninth aspect of the present invention, in particular, the center magnetic leg portion and the outer leg magnetic leg portion of the magnetic core are formed on the same plane with no step, and the grinding step is performed by using the center magnetic leg portion and the outer leg magnetic leg. This is a method in which the butted surfaces of the portions are simultaneously ground.
[0045]
According to the above-described method, the abutting surfaces of the center magnetic leg portion and the outer leg magnetic leg portions can be simultaneously processed, so that the processing productivity of the abutting surface is also improved.
[0046]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be specifically described with reference to the drawings.
[0047]
(Embodiment 1)
A first embodiment of the present invention will be described with reference to FIG.
[0048]
FIG. 1A is an assembly view of the inductor component according to the first embodiment of the present invention, and FIG. 1B is a schematic sectional view of the inductor component.
[0049]
In FIG. 1, the same components as those in FIGS. 7 to 9 showing the conventional example are denoted by the same reference numerals, and detailed description is omitted. E-shaped magnetic core which is one magnetic core incorporated from both sides of the coil 1, 4 a is an E-shaped magnetic core abutting surface, 4 ct is a center magnetic leg of the E-shaped magnetic core 4, 4 out is an outer leg magnetic leg of the E-shaped magnetic core 4, 5 is a coil 1 The reference numeral 5a denotes an I-shaped magnetic core butting surface, which is the other magnetic core incorporated from both sides of the I-shaped magnetic core.
[0050]
7 is different from FIGS. 7 to 9 showing the conventional example in that the center magnetic leg 4ct of the E-shaped magnetic core 4 and the E-shaped magnetic core abutting surface 4a of the outer leg magnetic leg 4out are formed on the same plane without any step. The E-shaped magnetic core mating surface 4a and the I-shaped magnetic core mating surface 5a are ground surfaces having irregularities, and the E-shaped magnetic core 4 and the I-shaped magnetic core 5 are joined with the concave and convex tops 9 to form a closed magnetic circuit core. The point is that an interval is provided between the bottom portion 10 of the unevenness and the other magnetic core butted.
[0051]
That is, the center magnetic leg 4ct of the E-shaped core 4 does not have a magnetic gap (Gct in FIG. 7), the gap paper 7 for forming the magnetic gap, and the adhesive 8 containing glass beads are not used. Are greatly different from each other, and will be sequentially described below with reference to FIG.
[0052]
First, as shown in FIG. 1A, the E-shaped magnetic core mating surface 4a and the I-shaped magnetic core mating surface 5a are prepared by performing a grinding process so as to have a rough surface in advance so as to have an uneven step h1. .
[0053]
As a method of performing the grinding of the rough surface, it has not been possible to form the surface of the grinding wheel by selecting the mesh number of the grinding wheel so that the E-shaped magnetic core mating surface 4a and the I-shaped magnetic core mating surface 5a have a predetermined roughness. A minute gap can be easily formed.
[0054]
In addition, when selecting the mesh number for obtaining the predetermined roughness, a coil or the like dedicated to the magnetic core is used, and an inductance value that becomes a desired inductance value when the product is commercialized is set to the component standard value for the magnetic core. And the mesh number can be selected so as to satisfy the standard value.
[0055]
The coil 1 having an air core and formed by applying a predetermined winding is inserted into the center magnetic leg 4ct of the E-shaped core 4 prepared in advance in this way, and the upper end of the center magnetic leg 4ct and the upper end of the outer leg magnetic leg 4out are inserted. That is, an appropriate amount of the adhesive 2 is applied to the E-shaped magnetic core butting surface 4a, and the I-shaped magnetic core 5 is butted from above.
[0056]
Next, as shown in FIG. 1 (b), the assembling is performed by applying a pressing force from above the I-shaped core 5 (as indicated by a white arrow). The fine adjustment of the magnetic gap Gh1 may be performed while rubbing in the front, rear, left, and right directions so as to have a desired inductance as shown by.
[0057]
The desired inductance value referred to here is a standard value for process control for obtaining an inductance value required after the product is completed. The desired inductance value is used for correcting the grinding variation of the E-shaped magnetic core mating surface 4a and the I-shaped magnetic core mating surface 5a. By providing a process of re-adjusting also for absorption, variation in inductance value can be reduced to the ultimate, and a great effect is obtained particularly when a minute gap is formed.
[0058]
Then, an inductor component is completed through a final process such as curing of the adhesive 2.
[0059]
As described above, according to the configuration of FIG. 1 showing one embodiment of the inductor component of the present invention, since the center magnetic leg 4a has no magnetic gap (Gct in FIG. 7), the E-shaped core 4 and the I-shaped core 5 The bending of the central portion of the I-shaped magnetic core 5 due to the pressing force when combining the above is also prevented.
[0060]
Further, since no extra member is arranged between the E-shaped core 4 and the I-shaped core 5, the magnetic gap dimension Gh1 where the E-shaped core 4 and the I-shaped core 5 are butted is also stabilized.
[0061]
As described above, since the magnetic gap dimension Gh1 is stabilized, variation in the inductance value can be significantly reduced.
[0062]
In addition, since the step h1 of the unevenness according to the mesh number of the grinding wheel is formed on the E-shaped magnetic core mating surface 4a and the I-shaped magnetic core mating surface 5a, the E-shaped magnetic core mating surface 4a and the I-shaped magnetic core mating surface 5a are formed. The magnetic gap Gh1 can be formed by abutting the tops 9 of the concaves and convexes, and an extra step of performing magnetic gap processing on the center magnetic leg 4ct can be omitted.
[0063]
Further, extra materials such as the gap paper 7 and the glass bead-containing adhesive 8 are not required, and the manufacturing cost can be greatly reduced. Since the setting of the minute magnetic gap is not affected by the gap processing accuracy, the thickness of the members, and the like, the degree of freedom in design is widened.
[0064]
Furthermore, since the magnetic core abutting surfaces 4a and 5a are formed into a rough surface, the minute magnetic gap can be easily realized only by setting the mesh number of the grinding wheel to a predetermined roughness.
[0065]
As a result, a high inductance inductor component can be realized.
[0066]
1 showing the first embodiment of the present invention includes a coil forming step of forming a coil having an air core and having a predetermined winding, an E-shaped magnetic core mating surface 4a and an I-shaped magnetic core mating surface 5a. Then, a grinding step for grinding a ground surface having irregularities, and the E-type core 4 and the I-type core 5 are assembled by abutting the apex portions 9 of the E-type core 4 and the I-type core 5 from both sides of the coil 1. 5, the gap between the bottom 10 of the E-shaped core 4 and the I-shaped core 5 and the gap between the bottom 10 of the I-shaped core 5 and the E-shaped core 4 are adjusted. Then, the manufacturing method includes a closed magnetic path core assembly step of adjusting the magnetic gap Gh1 between the bottom 10 of the irregularities of the E-shaped core 4 and the bottom 10 of the I-shaped core and adjusting the inductance value.
[0067]
According to the above manufacturing method, the E-shaped magnetic core 4 and the I-shaped magnetic core 5 having irregularities on the E-shaped magnetic core mating surface 4a and the I-shaped magnetic core mating surface 5a are prepared in advance so as to have a desired inductance value in the grinding process. By adjusting the magnetic gap Gh1 between the uneven bottom 10 of the E-shaped core 4 and the uneven bottom 10 of the I-shaped core 5 and adjusting the inductance value in the closed magnetic circuit core assembling process, Variations in individual members can be corrected and absorbed, and variations in inductance values can be reduced to the ultimate.
[0068]
Further, the center magnetic leg 4ct and the outer leg magnetic leg 4out of the E-shaped magnetic core 5 are formed on the same plane without any level difference, and the center magnetic leg 4ct and the outer leg magnetic leg 4out are simultaneously ground in the grinding process. If processing is performed, the processing productivity of the butt surface is also improved.
[0069]
As a result, it is possible to provide an inexpensive inductor component with a small variation in inductance value even when a minute magnetic gap is formed, and a method for manufacturing the same.
[0070]
(Embodiment 2)
Next, a second embodiment of the present invention will be described with reference to FIG. FIG. 2A is an assembly diagram of an inductor component according to a second embodiment of the present invention, and FIG. 2B is a schematic sectional view of the inductor component.
[0071]
The basic configuration is the same as FIG. 1 showing the first embodiment of the present invention. The major difference is that the unevenness of the I-shaped magnetic core abutting surface 5b is made larger than that of the other E-shaped magnetic core abutting surface 4a, so that the dimension from the top 9 to the bottom 10 of the unevenness is increased, resulting in an extremely rough surface having a step h2. The point is that the surface is made rougher and combined.
[0072]
Hereinafter, description will be made sequentially with reference to FIG. As shown in FIG. 2 (a), the I-shaped magnetic core butting surface 5 b of the I-shaped magnetic core 5 to be combined has an extremely rough surface with a step h 2 as compared with the E-shaped magnetic core butting surface 4 a of the other E-shaped magnetic core 4. The surface is roughened and prepared, and as shown in FIG. 2B, a new gap Gh2 is formed by abutting the tops 9 of the irregularities of the E-shaped core 4 and the I-shaped core 5 so as to have a desired inductance. To complete it as an inductor component.
[0073]
Generally, the step h2 of the I-shaped magnetic core butting surface 5b is prepared in a separate step from the other E-shaped magnetic core butting surface 4a, but in some cases, the same step h1 as the E-shaped magnetic core 4 is processed. What has been set may be batch-processed in a post-process to newly process the step h2.
[0074]
As described above, according to the configuration of FIG. 2 showing the second embodiment of the present invention, one of the E-shaped magnetic core mating surface 4a and the I-shaped magnetic core mating surface 5b is made to be more coarse and extremely rough than the other. In this case, a new gap Gh2 can be set at the time of abutting only by batch-processing only one magnetic core. Since the other magnetic core can be shared, inventory management and the like can be performed, and loss in production management is eliminated.
[0075]
(Embodiment 3)
Next, a third embodiment of the present invention will be described with reference to FIGS.
[0076]
FIGS. 3A and 3B are assembly diagrams of an inductor component according to a third embodiment of the present invention, and FIGS. 4A and 4B are assembly diagrams showing another example of the inductor component.
[0077]
The basic configuration in FIG. 3 is the same as FIGS. 1 and 2 showing the first and second embodiments of the present invention. The major difference is that one of the E-shaped core 4 and the I-shaped core 5 is a butted surface having no irregularities.
[0078]
The basic configuration in FIG. 4 is the same as those in FIGS. 1 and 2 showing the first and second embodiments of the present invention, but the major difference is that the E-type core 4 and the I-type core 5 Is a mirror surface (in FIG. 4, the mirror surface state is indicated by a dotted line).
[0079]
As described above, according to FIG. 3 showing the third embodiment of the present invention, one of the E-shaped core 4 and the I-shaped core 5 has an E-shaped core butting surface 4c having no unevenness, and an I-shaped core butting. Since the surface 5c is used, the dimension from the top 9 to the bottom 10 of the unevenness is not set, and a general grinding line can be used, and the cost of grinding the ferrite core can be reduced.
[0080]
Further, according to FIG. 4 showing another example of the third embodiment of the present invention, according to FIG. 4, one of the E-shaped magnetic core 4 and the E-shaped magnetic core 5 is made into a mirror surface, and the E-shaped magnetic core butting surface 4d, The magnetic core abutting surface 5d is used, and since the processing accuracy of the mirror-finished abutting surface is stable, the variation in the inductance value when combined is further reduced.
[0081]
(Embodiment 4)
Next, a fourth embodiment of the present invention will be described with reference to FIG.
[0082]
FIG. 5 is a schematic sectional view of an inductor component according to a fourth embodiment of the present invention.
[0083]
The basic configuration in FIG. 5 is the same as that in FIG. 1 showing the first embodiment of the present invention. The major difference is that the magnetic core shapes to be combined are the same E-shaped magnetic core 4.
[0084]
As described above, according to FIG. 5 showing the fourth embodiment of the present invention, since the magnetic core shapes to be combined are both EE type having the same shape, the upper and lower magnetic cores can be shared, so that the die investment can be reduced.
[0085]
(Embodiment 5)
Next, a fifth embodiment of the present invention will be described with reference to FIG.
[0086]
FIG. 6 is a schematic sectional view of an inductor component according to a fifth embodiment of the present invention.
[0087]
The basic configuration in FIG. 6 is the same as that in FIG. 1 showing the first embodiment of the present invention. A major difference is that a primary coil 1a, a secondary coil 1b, and two or more coils 1 are incorporated.
[0088]
As described above, according to FIG. 6 showing the fifth embodiment of the present invention, since two or more coils 1 are incorporated, one is used as an input primary coil 1a and the other is used as an output secondary coil 1b. It is suitable as a main transformer for a switching power supply and the like that requires high inductance. Particularly, it is most suitable for a forward-type switching power supply device configured as an ON-ON type.
[0089]
In addition, the switching power supply device incorporating the inductor component of the present invention has a high inductance and has a high-performance inductor component of the present invention having a characteristic that the inductance value is less scattered. Excitation current can be suppressed and its variation can be reduced, and the loss can be greatly reduced as compared with a switching power supply device equipped with a conventional inductor component. As a result, a difference can be made in terms of efficiency.
[0090]
【The invention's effect】
According to the present invention as described above,
(1) The occurrence of deflection at the center of the magnetic core can be eliminated.
(2) Variation in inductance value can be greatly reduced.
(3) An extra step of performing gap processing can be eliminated.
(4) Extra materials such as gap paper and glass beads can be eliminated.
(5) Manufacturing costs can be significantly reduced.
(6) The degree of freedom in design can be expanded even when setting a minute gap.
(7) Variation in inductance value can be reduced to the ultimate.
(8) The excitation current of the switching power supply can be suppressed, and the variation can be reduced.
[0091]
As a result, it is possible to achieve the object of providing an inexpensive inductor component with a small variation in inductance value even when a minute magnetic gap of 50 μm or less is formed, a method of manufacturing the same, and a switching power supply device using the inductor component.
[Brief description of the drawings]
FIG. 1 (a) is an assembly diagram of an inductor component according to a first embodiment of the present invention; FIG. 1 (b) is a schematic sectional view thereof FIG. FIG. 3 (b) is a schematic cross-sectional view. FIG. 3 (a) is an assembly view of an inductor component according to a third embodiment of the present invention. FIG. 3 (b) is an assembly view of FIG. FIG. 5 (b) is an assembly drawing. FIG. 5 is a schematic sectional view of an inductor component according to a fourth embodiment of the present invention. FIG. 6 is a schematic sectional view of an inductor component according to a fifth embodiment of the present invention. (A) Assembly drawing showing a conventional inductor component (b) Schematic sectional view [FIG. 8] (a) Assembly drawing showing another example (b) Schematic sectional view [FIG. 9] (a) Other (B) Schematic cross-sectional view showing an example of [Description of reference numerals]
DESCRIPTION OF SYMBOLS 1 Coil 1a Primary coil 1b Secondary coil 2 Adhesive 3 Gap paper 4 E type magnetic core 4ct Center magnetic leg 4out Outer magnetic legs 4a, 4c, 4d E type magnetic core mating surface 5 I type magnetic cores 5a, 5b, 5c, 5d I-shaped magnetic core butting surface 6 Magnetic gap 7 Gap paper 8 Adhesive containing glass beads 9 Top 10 Bottom

Claims (9)

In an inductor component provided with a coil having an air core, a magnetic core incorporated from both sides of the coil, and a closed magnetic path magnetic core formed by abutting the magnetic cores, at least one of the magnetic core has an outer leg magnetic leg and a central magnetic leg. The abutting surfaces of the portions are formed in the same plane with no steps and are ground surfaces having irregularities, and the magnetic core abuts the tops of the irregularities of the abutting surfaces to form a closed magnetic path, and the abutting of one of the magnetic cores An inductor component having a space between the bottom of the surface irregularities and the other magnetic core. 2. The inductor component according to claim 1, wherein the dimension from the top to the bottom of the unevenness of one core is larger than the dimension from the top to the bottom of the unevenness of the other core. 2. The inductor component according to claim 1, wherein one of the magnetic cores is a butted surface having no irregularities. The inductor component according to claim 3, wherein one of the magnetic cores is a mirror-like butted surface. 2. The inductor component according to claim 1, wherein the shape of the magnetic core to be combined is an EE type magnetic core. 2. The inductor component according to claim 1, wherein two or more coils are provided. A switching power supply using the inductor component according to claim 1. In a method of manufacturing an inductor component including a coil having an air core, a magnetic core incorporated from both sides of the coil, and a closed magnetic path magnetic core formed by abutting the magnetic core, a coil forming step of forming a coil having an air core; A grinding step of grinding a ground surface having irregularities on the butting surface of at least one of the closed magnetic path cores; Pressurizing to adjust the distance between the bottom of the unevenness of one of the magnetic cores and the other of the magnetic cores and to adjust the inductance value. 9. The center magnetic leg portion and the outer leg magnetic leg portion of the magnetic core are formed on the same plane without a step, and in the grinding step, the butting surfaces of the center magnetic leg portion and the outer leg magnetic leg portion are simultaneously ground. 3. The method for manufacturing an inductor component according to claim 1.

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