JP2004327523A - Inductance component and electronic equipment using it - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an inductance component that has an insulating layer having a highly reliable insulation property in a coil formed by punching a metallic sheet. <P>SOLUTION: Since the insulating layer 10 is formed so that a fluidal resin material 9 may also be packed in a recessed section 8 provided in the intermediate section of the cut face 4 of the coil 3 formed by punching the metallic sheet 1, the recessed section 8 becomes the gathering section of the resin material 9, and the insulating layer 10 having a desired thickness can be formed certainly in a chamfered section 7 provided on the upside or underside of the cut face 4. Consequently, the insulation property of the insulating layer 10 becomes excellent as compared with the insulating layer formed on the conventional spherical cut face formed by deburring. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to an inductance component used for various electronic devices and an electronic device using the same.
[0002]
[Prior art]
In recent years, as electronic devices have become increasingly smaller and thinner, inductance components have become smaller and thinner. In addition, several to several tens of amps have been used in high-frequency regions corresponding to high speed and high integration of LSIs such as CPUs. What can withstand a large current is demanded.
[0003]
In response to such a demand, a conductor 30 is formed by cutting a metal plate such as copper or aluminum using a slitter as shown in FIG. It has been proposed to use a flat insulated wire 32 having a layer 31 formed thereon (for example, see Patent Document 1).
[0004]
[Patent Document 1]
JP-A-1-186714
[Problems to be solved by the invention]
However, in the above-described configuration, as shown in FIG. 24, burrs 33 are generated on the end surfaces of the contact sections, and even if the insulating layer 31 is formed in a state where the burrs 33 are formed, Is not formed, which causes dielectric breakdown.
[0006]
For this reason, as shown in FIG. 25, the burrs 33 of the conductor 30 formed by cutting from a metal plate with a slitter are removed by etching, the cut surface is processed into a spherical shape, and the insulating layer 31 is also formed on that surface. It has been proposed to form.
[0007]
However, when the cut surface of the conductor 30 is processed into a spherical shape by performing the etching process of the burr 33, the thickness of the insulating layer 31 formed on the cut surface is reduced or the conductor 30 itself is exposed. However, there is a risk that sufficient reliability cannot be obtained in terms of insulation.
[0008]
An object of the present invention is to provide an inductance component that eliminates the above-described conventional drawbacks and that is obtained by stamping out a metal plate and that has sufficient reliability in terms of insulating properties, and an electronic device using the same. The purpose is.
[0009]
[Means for Solving the Problems]
In order to solve the above problems, the present invention provides an inductance having a configuration in which a concave portion is provided in an intermediate portion of a cut surface of a coil portion formed by punching a metal plate, and an insulating layer is provided so as to fill the concave portion. Parts.
[0010]
With this configuration, the concave portion of the cut surface becomes a reservoir for the resin material forming the insulating layer, and the insulating layer is necessarily thickly and surely formed on the upper and lower cut surfaces. In this way, it is possible to obtain an inductance component with sufficient reliability.
[0011]
BEST MODE FOR CARRYING OUT THE INVENTION
The invention according to claim 1 of the present invention provides a linear, meandering, spiral, ring, frame, and a plurality of ring and frame shapes in which terminals are integrally formed at least at both ends by punching a metal plate. A coil portion formed by folding a continuous body to form a coil of several turns, and a concave portion provided in an intermediate portion of a cut surface of the coil portion, and an insulating layer so that the coil portion excluding the terminals is filled in the concave portion of the cut surface. With this configuration, the concave portion of the cut surface serves as a reservoir for the resin material forming the insulating layer, and a thick and reliable insulating layer can be formed on the cut surface. In addition to being excellent, the bonding strength of the insulating layer to the coil portion can be increased and peeling can be prevented.
[0012]
According to the second aspect of the present invention, the concave portion of the cut surface of the coil portion is formed by chamfering the corners of the upper side and the lower side of the cut surface. Will be obtained.
[0013]
According to a third aspect of the present invention, the concave portion provided in the cut surface of the coil portion is configured to protrude outward from below the wall surface forming the concave portion, and the insulating layer is formed by this configuration. In this case, the resin material hits below the wall surface forming the concave portion and flows into the concave portion, so that the resin material is reliably filled in the concave portion, and as a result, the wall surface on the upper side and the lower side of the concave portion is also reliably thickened. Can be formed.
[0014]
According to a fourth aspect of the present invention, the coil portion is buried in a magnetic material, and the use of the magnetic material improves the characteristics as an inductance component, and at the time of burying, the coil portion has a cut surface. Thus, damage to the insulating layer can be reduced.
[0015]
According to a fifth aspect of the present invention, a magnetic material is incorporated in the coil portion. This also improves the characteristics as an inductance component by using the magnetic material, and also enhances the characteristics of the coil portion that comes into contact when the magnetic material is incorporated. Since the insulating layer on the cut surface is formed thick, breakage of the insulating layer can be reduced.
[0016]
According to a sixth aspect of the present invention, the coil portion is sandwiched by a magnetic material, which also improves the characteristics as an inductance component by the magnetic material, and cuts the coil portion in contact with the magnetic material. Insulation at the upper side and the lower side can be reliably ensured.
[0017]
According to a seventh aspect of the present invention, the coil portion is formed by arranging the coil portion on any one of an insulator, a dielectric, and a magnetic material. Sufficient insulation from components and the like can be ensured.
[0018]
An invention according to claim 8 is an electronic device using the inductance component according to any one of claims 1 to 7 in combination with another electronic component so as to form a predetermined circuit. The improvement in reliability is directly reflected in electronic devices.
[0019]
Hereinafter, the inductance component of the present invention will be described with reference to the drawings. First, a basic configuration of the inductance component of the present invention, including a method of manufacturing the same, will be described with reference to FIGS.
[0020]
First, a metal plate 1 made of copper or silver is cut by a press die 2 as shown in FIG. 1 to form a coil portion 3 having a predetermined shape as shown in FIG. At this time, it is assumed that the coil portion 3 has terminals integrally formed at least at both ends thereof. Burrs 5 are formed on the lower side of the cut surface 4 of the coil portion 3 as shown in FIG.
[0021]
In the case where the burr 5 is formed as described above, even if an insulating layer described later is formed, it is difficult to form an insulating layer at the burr 5 and the coil portion 3 lacks insulation. As shown in FIG. 4, the coil portion 3 is pressed by a chamfering die 6, and a chamfered portion 7 is formed at the upper and lower corners of the cut surface 4 of the coil portion 3 as shown in FIG.
[0022]
By performing this chamfering process, a concave portion 8 is formed at an intermediate portion of the cut surface of the coil portion 3 as shown in FIG. Moreover, the recess 8 is formed such that the wall surface below the cut surface 4 forming the recess 8 protrudes outward. This is because the above-mentioned burrs 5 at the time of cutting are formed on the lower side of the cut surface 4, and the burrs 5 are chamfered together with the burrs 5 to obtain the above-described configuration.
[0023]
Next, as shown in FIG. 6, a resin material 9 such as an epoxy resin or a polyimide resin for forming an insulating layer is applied to the upper surface of the coil unit 3. At this time, the resin material 9 is applied so as to be formed also on the cut surface 4 of the coil portion 3, and is sufficiently filled in the concave portion 8 of the cut surface 4 so as to overflow from the concave portion 8.
[0024]
Thereafter, the resin material 9 applied to the upper surface of the coil portion 3 is set to a semi-cured state, and then the coil portion 3 is turned over, and the resin material 9 is applied to the lower surface of the coil portion 3 as shown in FIG. A resin material 9 is formed on the entire surface, and the resin material 9 is completely cured to form an insulating layer 10 to obtain an inductance component.
[0025]
It is preferable that the insulating layer 10 is not formed on the terminals at both ends of the coil section 3, which is advantageous when mounting the inductance component on the printed wiring board. Further, the resin material 9 may be formed by printing, spraying, or transferring other than coating.
[0026]
As described above, the concave portion 8 is provided in the middle of the cut surface 4 of the coil portion 3 formed by punching the metal plate 1, and the insulating layer 10 is formed so that the concave portion 8 is filled with the resin material 9. Thereby, the concave portion 8 becomes a pool portion of the resin material 9 having fluidity, and the insulating layer 10 having a desired thickness can be reliably formed on the chamfered portion 7 on the upper side and the lower side of the cut surface 4, Insulation can be improved as compared to an insulating layer formed on a cut surface formed into a spherical shape by conventional deburring.
[0027]
As the shape of the inductance component having the above configuration, various shapes can be considered depending on the use and purpose. For example, a linear inductance component having terminals 11 at both ends as shown in FIG. 8, a meandering inductance component having terminals 11 at both ends as shown in FIG. 9, and a terminal 11 at both ends as shown in FIG. As shown in FIG. 13, a spiral inductance component, a ring-shaped inductance component having terminals 11 at both ends as shown in FIG. 11, a frame-shaped inductance component having terminals 11 at both ends as shown in FIG. Inductance components having terminals 11 at both ends and bending a ring-shaped continuum to form a coil 12 of several turns are conceivable.
[0028]
What is shown here is only a typical one that is put into practical use, and various other ones are also conceivable. For example, one having an intermediate tap provided in the configuration shown in FIG. Instead of the continuum, a framed continuum may be bent.
[0029]
Although the coil portion 3 formed by punching from the metal plate on which the insulating layer 10 is formed as described above can perform a sufficient function as an inductance component depending on the application, however, in order to further improve the characteristics as the inductance component, it is necessary to use a magnetic material. Combination with such is required.
[0030]
Hereinafter, typical examples will be described with reference to FIGS. 14 to 16. In this example, a choke coil used for a power supply circuit of an electronic device is assumed. As shown in FIG. 14A, three ring-shaped continuous bodies 13 are punched out of a metal plate made of copper, and a terminal-integrated coil part 3 in which terminals 11 are integrally formed at both ends of the continuous body 13 is used. . The coil portion 3 has the cut surface 4 subjected to the above-described chamfering process, and has a concave portion 8 at an intermediate portion of the cut surface. A resin material 9 is applied so that the concave portion 8 is filled. Is formed. The insulating layer 10 is not formed on the bent portion 14 of the ring-shaped continuum 13.
[0031]
This is to prevent the insulating layer 10 from being torn due to a difference in the degree of expansion and contraction between the outside and the inside of the bent portion 14 when the ring-shaped continuous body 13 is bent.
[0032]
This is bent using the bent portion 14 so that the center points overlap each other as shown in FIG. 14 (b) to form the coil portion 3 having several turns. And project radially outward.
[0033]
The coil unit 3 configured as described above, except for the terminal 11, is buried in the magnetic body 15 as shown in FIG. The magnetic material 15 is prepared by adding 3.3 parts by weight of a silicone resin to a soft magnetic material alloy powder, mixing the mixture, and passing through a mesh to use a composite magnetic material as a rectifying powder. The metal magnetic powder is a soft magnetic alloy powder of Fe (50) Ni (50) having an average particle diameter of 13 μm manufactured by a water atomizing method.
[0034]
By using such a magnetic material 15, each particle of the soft magnetic alloy powder is covered with an insulating resin, and can have an excellent saturation magnetic flux density and a small eddy current loss. It can correspond to. The composition of the metal magnetic powder contains Fe, Ni, and Co in a total amount of 90% by weight or more. By setting the filling rate of the metal magnetic powder to 65 to 90% by volume, a composite having a high saturation magnetic flux density and a high magnetic permeability is provided. It can be a magnetic material. Further, when the average particle size of the metal magnetic powder is 1 to 100 μm, it is effective to reduce the eddy current.
[0035]
The same effect can be obtained even when the magnetic material 15 is a ferrite magnetic material or a composite of a ferrite magnetic powder and an insulating resin. The resistance is higher than that of the metal magnetic powder, but the resistance prevents eddy current from being generated. It is possible to respond to high frequencies.
[0036]
In manufacturing this inductance component, semi-hardened magnetic pellets formed along the shape of the coil portion 3 are arranged above and below the coil portion 3 having the terminal 11, and these are applied with a pressure of 3 ton / cm ² . The coil portion 3 is embedded in the magnetic material 15 by performing a heat treatment at 150 ° C. for about 1 hour to completely cure the semi-cured magnetic material. It is bent from the side to the bottom to obtain an inductance component as shown in FIG.
[0037]
The terminal 11 protruding from the magnetic body 15 is provided with a surface layer 17 of solder or Sn or Pb to prevent oxidation of the Ni underlayer 16 and to prevent the oxidation of the Ni underlayer and to improve solder wettability. Is done.
[0038]
In addition, the magnetic body 15 must be formed in a square shape, and the upper surface needs to be a flat surface so as to be easily sucked by the nozzle at the time of automatic mounting. It can also be.
[0039]
By embedding the coil portion 3 in the magnetic body 15 as described above, the inductance characteristics as an inductance component can be remarkably improved, and the coil portion 3 can be protected, which is advantageous for automatic mounting. Can be. Further, even if the insulating layer 10 of the coil portion 3 causes friction with the magnetic pellet when the magnetic material pellets are arranged vertically and pressurized in the manufacturing process, the insulating layer 10 is firmly attached to the cut surface 4 of the coil portion 3. Are formed, and the insulation becomes excellent.
[0040]
As an inductance component having another configuration of the present invention, one shown in FIGS. 17 and 18 can be considered. The coil portion 3 is the same as that buried in the magnetic body 15. The T-shaped magnetic body 18 made of ferrite or the like having a columnar portion formed in the center of the upper surface of the plate-like body is used as the magnetic body. Using a cap-shaped magnetic body 20 made of ferrite or the like provided with a cutout portion 19 from which the terminal 11 of the portion 3 is drawn out, incorporated into the cylindrical portion of the T-shaped magnetic body 18 so as to fit the hollow portion of the coil portion 3, The cap-shaped magnetic body 20 is put on the T-shaped magnetic body 18 in which the coil portion 3 is incorporated, and the joining surfaces of the magnetic bodies 18 and 20 are joined with an adhesive.
[0041]
Even with this configuration, the inductance part can be made to have excellent inductance characteristics, and even if the coil part 3 is slightly rubbed when the coil part 3 is assembled into the magnetic body 18 or when the magnetic body 20 is assembled, the coil part 3 can be used. Since the insulating layer 10 is firmly formed on the cut surface 4, the insulating layer 10 can be prevented from being damaged or peeled off, and the insulation is highly reliable.
[0042]
An inductance component having still another configuration will be described with reference to FIGS. The coil unit 3 has the same configuration as that of the above-described two configurations, and uses two plate-shaped magnetic members 21 and 22 as the magnetic members. The coil unit 3 is disposed between the two magnetic members 21 and 22. Are sandwiched. The magnetic bodies 21 and 22 and the coil section 3 are joined by an adhesive to be integrated.
[0043]
Instead of bonding with an adhesive, a resin material may be filled around the coil portion 3 to integrate the magnetic members 21 and 22 with the coil portion 3.
[0044]
Also in this configuration, the inductance characteristics can be improved as an inductance component, and the exposed coil portion 3 is completely covered with the insulating layer 10 depending on the configuration. Even if they come into contact with each other, sufficient insulation can be maintained.
[0045]
Another configuration of the inductance component will be described with reference to FIG. The coil section 3 used here has terminals 11 at both ends shown in FIG. 9, and a meandering coil section in which an insulating layer 10 is also formed on the recess 8 of the cut surface 4 of the coil section 3 except for the terminals 11. 3. The coil portion 3 is configured to be bonded to a plate-like body 23 made of an insulator, a dielectric or a magnetic material using an adhesive or the like.
[0046]
The reason why an insulator is selected as the plate-shaped member 23 is that the plate-shaped member 23 can be a printed wiring board, and the inductance component is coupled to the surface of the printed wiring board to form another circuit pattern. A predetermined circuit can be configured with various electronic components to be mounted.
[0047]
The reason why the dielectric is selected as the plate-like member 23 is that a capacitor is built in a laminated body of a thin dielectric layer and a metal layer, and the coil part 3 is provided on the surface of the capacitor, so that an LC composite component or filter is provided. A circuit can be configured.
[0048]
The reason why the magnetic material is selected as the plate-like body 23 is to improve the characteristics as an inductance component.
[0049]
Regardless of which plate-like body 23 is selected, other electronic components, conductors, and the like are often provided in the vicinity of the coil unit 3, but even in such a case, the coil unit 3 excluding the terminal 11 is provided. Since the insulating layer 10 is firmly provided, the insulating property can be made highly reliable.
[0050]
Although various examples of combinations of the coil portion 3 and a magnetic material have been shown, only those using one coil portion 3 have been described. It can be an inductance component or an inductance component such as a transformer. That is, two or more coil portions 3 are buried in the magnetic body 15, incorporated into the magnetic bodies 18 and 20, sandwiched between the magnetic bodies 21 and 22, or connected to the plate 23. By doing so, an inductance component such as a multiple inductance component described above or a transformer having another function can be obtained.
[0051]
An example of application to an electronic device using a double choke coil as an example of such a multiple inductance component will be described with reference to FIG.
[0052]
FIG. 22 shows a power supply circuit of a multi-phase electronic device. An integration circuit is formed by a choke coil 24 and a capacitor 25. The integration circuit includes an input power supply 26, a switching element 27, and an output side such as a CPU. The load 28 is connected to form a power supply circuit.
[0053]
The choke coil 24 has a structure in which two terminal-integrated coil portions 3 are embedded in the magnetic body 15, and these two coil portions 3 control a plurality of DC / DC converters. And operate in parallel. With this circuit configuration, it is possible to increase the frequency and the current, and in particular, by mounting the choke coil 24 of the present invention, the insulation reliability is improved.
[0054]
Note that the inductance component according to the present invention is not limited to the above-described multi-phase power supply circuit, and can be used in power supply circuits of other electronic devices that can cope with higher frequencies and higher currents. Personal computers and mobile phones are typical examples of electronic devices.
[0055]
【The invention's effect】
As described above, since the inductance component of the present invention is configured, the concave portion formed in the middle portion of the cut surface of the coil portion is filled with the resin material forming the insulating layer, and the cut surface that is chamfered is also thick. The layer is formed, and the concave portion can increase the binding force of the insulating layer to the coil portion, so that the insulating layer is not easily peeled off, and the insulating property can be highly reliable.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing a state in which a coil portion is formed by punching from a metal plate according to an embodiment of the present invention; FIG. 2 is a cross-sectional view of a main part of the coil portion formed by punching; FIG. 3 is a cross-sectional view of a main part showing a state where the coil portion formed by punching is chamfered. FIG. 4 is a cross-sectional view of a main part in a state where the chamfering processing is performed. FIG. 6 is a cross-sectional view showing a cut surface of the coil part. FIG. 6 is a cross-sectional view of a main part showing a state in which an insulating layer is formed on the upper surface of the coil part. FIG. 8 is a perspective view showing a linear inductance component as an example of the inductance component of the present invention. FIG. 9 is a perspective view showing the meandering inductance component. FIG. 10 is a view showing the spiral inductance component. FIG. 11 is a perspective view showing the same ring shape. Perspective view showing an inductance component 12 is a perspective view of the inductance component constitutes a coil of several turns by bending a perspective view [13] the ring-like continuous body, showing the frame-shaped inductance part [14]
(A) A plan view of a coil portion before bending of an inductance component formed by the ring-shaped continuum (b) A perspective view after bending (FIG. 15) shows an inductance component having the coil portion embedded in a magnetic material. FIG. 16 is an exploded perspective view of an inductance component configured by incorporating a magnetic material into the coil portion. FIG. 18 is a perspective view of the inductance component after the assembly. FIG. 20 is an exploded perspective view of an inductance component having a coil portion sandwiched between magnetic materials. FIG. 20 is a perspective view of the inductance component after the assembly. FIG. FIG. 22 is a perspective view of an inductance component. FIG. 22 is a circuit diagram showing an example in which the inductance component is used in a power supply circuit of an electronic device. FIG. 23 is a diagram illustrating an inductance component formed by punching a conventional metal plate. Sectional view of a main part showing a cross-sectional view state [25] was removed the burr of a main part showing the problems due to cross-sectional view and FIG. 24 the burrs EXPLANATION OF REFERENCE NUMERALS
REFERENCE SIGNS LIST 1 metal plate 2 press die 3 coil portion 4 cut surface 5 burr 6 beveling die 7 chamfered portion 8 concave portion 9 resin material 10 insulating layer 11 terminal 12 coil 13 ring-shaped continuum 14 bent portion 15 magnetic body 18, 20, 21, 22 Magnetic body 23 Plate body 24 Choke coil 25 Capacitor 26 Input power supply 27 Switching element 28 Load

Claims (8)

A linear, meandering, spiral, ring, frame, and a plurality of ring-shaped or frame-shaped continuous bodies in which terminals were integrally formed at least at both ends by punching a metal plate were bent to form a coil of several turns. An inductance component comprising: a coil portion; and a concave portion provided at an intermediate portion of a cut surface of the coil portion, and an insulating layer formed on the coil portion except for the terminals so as to fill the concave portion of the cut surface. 2. The inductance component according to claim 1, wherein the concave portion of the cut surface of the coil portion is formed by chamfering a corner of an upper side and a lower side of the cut surface. 2. The inductance component according to claim 1, wherein the recess provided on the cut surface of the coil portion is configured to protrude outward below a wall surface forming the recess. 3. 2. The inductance component according to claim 1, wherein the coil part is embedded in a magnetic material. 2. The inductance component according to claim 1, wherein a magnetic material is incorporated in the coil portion. 2. The inductance component according to claim 1, wherein the coil part is sandwiched between magnetic materials. 2. The inductance component according to claim 1, wherein the coil portion is configured by being arranged on a plate-shaped body of any one of an insulator, a dielectric, and a magnetic body. An electronic device using the inductance component according to any one of claims 1 to 7 in combination with another electronic component so as to form a predetermined circuit.

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