JP2012049435A - Coil enclosing dust core - Google Patents

Coil enclosing dust core Download PDF

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JP2012049435A
JP2012049435A JP2010192121A JP2010192121A JP2012049435A JP 2012049435 A JP2012049435 A JP 2012049435A JP 2010192121 A JP2010192121 A JP 2010192121A JP 2010192121 A JP2010192121 A JP 2010192121A JP 2012049435 A JP2012049435 A JP 2012049435A
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terminal
dust core
lead
coil
core
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JP5403823B2 (en
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Kyoichi Kawase
恭一 川瀬
Masaru Sakurai
勝 桜井
Shuji Izawa
周治 井澤
Takao Mizushima
隆夫 水嶋
Yoichi Abiko
世一 安彦
Keiichi Araki
慶一 荒木
Eiichiro Matsuyama
英一郎 松山
Yutaka Naito
豊 内藤
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Alps Green Devices Co Ltd
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Abstract

PROBLEM TO BE SOLVED: To provide a coil enclosing dust core capable of simplifying coiling process, fully maintaining strength of a dust core and promoting miniaturization.SOLUTION: A first drawing part 8 is drawn out from the upper surface side of a winding part 2a, and a second drawing part 9 is drawn out from the lower surface side of the winding part 2a. The first drawing part 8 has a ramp 8b inclining downward and toward the direction of a side surface 3a of a dust core 3. The lowest position of the ramp 8b is located on the same height as that of the lower surface of the winding part 2a or thereunder, and the lowest position of the ramp 8b and the lower surface of the second drawing part 9 are located above the lower surface of the dust core 3. The first drawing part 8 and the second drawing part 9 are embedded in the dust core 3. A first terminal part 6 and a second terminal part 7 are projected in an orthogonal direction outside from the side surface 3a of the dust core 3 located above the lower surface of the dust core 3.

Description

本発明は、パワーインダクタや、その他の電子部品に用いられるコイル封入圧粉コアの端子構造に関する。   The present invention relates to a terminal structure of a coil-embedded dust core used for power inductors and other electronic components.

電子部品等に適用されるコイル封入圧粉コアは、圧粉コアの内部にコイルを封入した構造である。   A coil-enclosed dust core applied to electronic components or the like has a structure in which a coil is enclosed inside a dust core.

特許文献１〜３に記載された発明では、コイルの巻回部から引き出された２本の引き出し端子が圧粉コアの側面で直角に折り曲げられている。   In the inventions described in Patent Documents 1 to 3, the two lead terminals drawn out from the winding portion of the coil are bent at a right angle on the side surface of the dust core.

しかしながら、コイル封入圧粉コアの小型化に伴って、コイルの小型化とともに所定のインダクタンスとなるよう調整すべく、導線厚はある程度の厚みを確保しつつ導線幅を狭くして、導線厚に対する導線幅のアスペクト比を小さくすると、直角に折り曲げ加工することが困難になった。またコイルの小型化に対して直角曲げを行うと断線等の電気的不安定を引き起こすリスクがあった。   However, along with the miniaturization of the coil-embedded dust core, in order to adjust the coil to have a predetermined inductance along with the miniaturization of the coil, the conductor thickness is reduced to a certain extent while ensuring a certain thickness. When the aspect ratio of the width is reduced, it becomes difficult to bend at a right angle. Also, there is a risk of causing electrical instability such as wire breakage when bending at right angles to the miniaturization of the coil.

また特許文献４に記載された発明では、コイルの巻回部から引き出された２本の引き出し端子を傾斜させて圧粉コアの側面から突出させている構造が開示されている。   The invention described in Patent Document 4 discloses a structure in which two lead terminals drawn out from a coil winding portion are inclined and protruded from the side surface of the dust core.

特許文献４の図２に示すように引き出し端子の傾斜した部分が圧粉コアの側面から外部に飛び出している。   As shown in FIG. 2 of Patent Document 4, the inclined portion of the lead terminal protrudes from the side surface of the dust core to the outside.

しかしながら、このような形態であると、引き出し端子の傾斜して飛び出した周辺部分の圧粉コアの強度が弱くなり、また引き出し端子に強い力が加わった際に圧粉コアに強い応力が加わりやすい構造であり、これにより圧粉コアが割れる等の不具合が生じやすくなっていた。   However, in such a form, the strength of the dust core in the peripheral portion that protrudes from the inclined terminal terminal becomes weak, and when a strong force is applied to the drawer terminal, a strong stress is easily applied to the dust core. Due to the structure, it was easy to cause problems such as cracking of the powder core.

特開２００６−２９４７７５号公報JP 2006-294775 A 特開２００４−１１１４５６号公報JP 2004-111456 A 特開２００７−６７２８３号公報JP 2007-67283 A 特開２００３−２８２３４６号公報JP 2003-282346 A

そこで本発明は、上記の従来課題を解決するためのものであり、特に、コイル加工を簡単にでき、また圧粉コアの強度を十分に保ちつつ、小型化を促進することができるコイル封入圧粉コアを提供することを目的とする。   Therefore, the present invention is to solve the above-described conventional problems, and in particular, coil filling pressure that can simplify coil processing and can promote downsizing while maintaining sufficient strength of the dust core. The object is to provide a powder core.

本発明におけるコイル封入圧粉コアは、
圧粉コアと、コイルと、を有し、
前記コイルは、前記圧粉コア内に埋設される巻回部と、前記巻回部から引き出される第１引き出し端子と第２引き出し端子とを備え、
前記第１引き出し端子及び前記第２引き出し端子は、夫々前記圧粉コアの側面から外部に露出する第１端子部及び第２端子部と、前記第１端子部と前記巻回部との間、及び前記第２端子部と前記巻回部との間に位置して前記圧粉コア内に埋設された第１引き出し部及び第２引き出し部とを備えており、
前記第１引き出し部における前記巻回部からの第１引き出し位置は、前記巻回部の上面側に位置し、前記第２引き出し部における前記巻回部からの第２引き出し位置は、前記巻回部の下面側に位置しており、
前記圧粉コア内に埋設された前記第１引き出し部は、前記第１引き出し位置から引き出されて下方且つ前記圧粉コアの側面方向に向けて傾く傾斜部を有しており、
前記傾斜部の最下位置は、前記巻回部の下面と同一高さあるいは前記下面よりも下方に位置するとともに、前記傾斜部の最下位置及び前記第２引き出し部の下面は、前記圧粉コアの下面よりも上方に位置しており、
前記第１端子部及び前記第２端子部は、前記圧粉コアの下面よりも上方に位置する前記圧粉コアの側面から直交方向にて外部に突出していることを特徴とするものである。 The coil-embedded dust core in the present invention is
A dust core and a coil;
The coil includes a winding part embedded in the dust core, a first lead terminal and a second lead terminal drawn from the winding part,
The first lead terminal and the second lead terminal are respectively exposed between the first terminal portion and the second terminal portion exposed from the side surface of the dust core, and between the first terminal portion and the winding portion, And a first drawer part and a second drawer part that are located between the second terminal part and the winding part and are embedded in the dust core,
The first drawer position from the winding part in the first drawer part is located on the upper surface side of the winding part, and the second drawer position from the winding part in the second drawer part is the winding position. Located on the lower surface side of the part,
The first drawer portion embedded in the dust core has an inclined portion that is pulled out from the first drawer position and tilts downward and toward the side surface of the dust core;
The lowest position of the inclined portion is located at the same height as the lower surface of the winding portion or below the lower surface, and the lowest position of the inclined portion and the lower surface of the second lead-out portion are Located above the lower surface of the core,
The first terminal portion and the second terminal portion protrude outward from the side surface of the dust core located above the lower surface of the dust core in an orthogonal direction.

本発明では、巻回部の上面側から引き出される第１引き出し端子と、下面側から引き出される第２引き出し端子とを有し、各引き出し端子は、圧粉コアの側面から外部に突出する各端子部と、巻回部と各端子部との間に位置して圧粉コア内に埋設される各引き出し部とを有している。   In this invention, it has the 1st lead terminal pulled out from the upper surface side of a winding part, and the 2nd lead terminal pulled out from the lower surface side, and each lead terminal protrudes outside from the side of a dust core Part, and each drawer | drawing-out part which is located between a winding part and each terminal part, and is embed | buried in a compacting core.

巻回部の上面側から引き出される第１引き出し部は、圧粉コア内にて傾斜する傾斜部により斜めに折り曲げられている。従来のように直角曲げを行う場合等に比べてコイルの小型化に応じて、コイル加工を簡単にできる。また傾斜部は圧粉コア内に埋設され、第１端子部及び第２端子部は圧粉コアの側面にて直交方向から外部に突出している。このように圧粉コアの側面から直交方向へ各端子部を引き出すことで、傾斜部の一部が外部に突出する形態に比べて圧粉コアの強度を高めることができる。   The 1st drawer | drawing-out part pulled out from the upper surface side of a winding part is bend | folded diagonally by the inclination part which inclines in a powder core. Coil machining can be simplified according to the downsizing of the coil as compared to the case of performing a right-angle bending as in the prior art. The inclined portion is embedded in the dust core, and the first terminal portion and the second terminal portion protrude outward from the orthogonal direction on the side surface of the dust core. In this way, by pulling out each terminal portion in the orthogonal direction from the side surface of the dust core, the strength of the dust core can be increased as compared with a form in which a part of the inclined portion protrudes to the outside.

また、本発明では、第１引き出し部の傾斜部の最下位置は、巻回部の下面と同一高さあるいは前記下面よりも下方に位置している。これにより、第１引き出し部の傾斜部を長く形成でき、第１引き出し部を直角曲げするような場合に比べて、第１引き出し部全体の引き出し長さを短くでき、直流抵抗を低下させることができる。またこのとき、第１引き出し部の傾斜部の最下位置及び第２引き出し部の下面を、圧粉コアの下面よりも上方に位置させているため、第１引き出し部及び第２引き出し部が圧粉コアの下面から露出することなく、圧粉コア内に適切に埋設でき、圧粉コアの強度を高めることができる。   In the present invention, the lowest position of the inclined portion of the first drawer portion is located at the same height as the lower surface of the winding portion or below the lower surface. Accordingly, the inclined portion of the first lead portion can be formed long, and the lead length of the entire first lead portion can be shortened and the direct current resistance can be reduced as compared with the case where the first lead portion is bent at a right angle. it can. At this time, since the lowermost position of the inclined portion of the first drawer and the lower surface of the second drawer are positioned above the lower surface of the dust core, the first drawer and the second drawer are pressed. Without being exposed from the lower surface of the powder core, it can be appropriately embedded in the powder core, and the strength of the powder core can be increased.

以上により本発明によれば、コイル封入圧粉コアの小型化において、コイル加工を簡単にできるとともに、圧粉コアの強度の向上及び直流抵抗の低減等を図ることが可能になる。   As described above, according to the present invention, in the downsizing of the coil-embedded dust core, coil processing can be simplified, and the strength of the dust core can be improved and the direct current resistance can be reduced.

本発明では、前記第１端子部及び前記第２端子部は、前記圧粉コアの側面に対して同一高さ位置から外部に突出していることが好ましい。   In this invention, it is preferable that the said 1st terminal part and the said 2nd terminal part protrude outside from the same height position with respect to the side surface of the said powder core.

また本発明では、前記圧粉コア内に埋設された前記第１引き出し部は、前記第１引き出し位置から前記圧粉コアの側面方向に向けて引き出された上層部と、前記上層部から傾く傾斜部と、前記傾斜部から前記第１端子部に繋がる下層部とを有しており、
前記第１引き出し部の下層部及び前記第２引き出し部は、前記圧粉コアの側面に対して直交した方向に延出して、夫々、前記第１端子部及び前記第２端子部に繋がっていることが好ましい。これにより、コイル加工をより効果的に簡単にできる。 In the present invention, the first drawer portion embedded in the dust core includes an upper layer portion that is drawn from the first drawer position toward the side surface of the dust core, and an inclination that is inclined from the upper layer portion. And a lower layer part connected to the first terminal part from the inclined part,
The lower layer portion of the first lead portion and the second lead portion extend in a direction perpendicular to the side surface of the dust core, and are connected to the first terminal portion and the second terminal portion, respectively. It is preferable. Thereby, coil processing can be simplified more effectively.

また本発明では、前記第１引き出し部の下層部と、前記第２引き出し部とは同一高さで形成されて、前記第１端子部と前記第２端子部とが、前記圧粉コアの前記側面に対して同一高さ位置から外部に突出していることが好ましい。   In the present invention, the lower layer portion of the first lead portion and the second lead portion are formed at the same height, and the first terminal portion and the second terminal portion are formed on the dust core. It is preferable to protrude outside from the same height position with respect to the side surface.

このように、第１引き出し部の下層部の高さ位置を、第２引き出し部の高さ位置に合わせることで、各端子部の高さ位置を揃えることができるとともに、圧粉コアの側面から突出する第１端子部及び第２端子部の突出量を同じにできる。よって、前記圧粉コアの側面から外部に突出した前記第１端子部及び前記第２端子部の先端を、下方に折り曲げて、各端子部の先端を同一高さ位置（ただし、前記圧粉コアの下面と同一高さあるいは前記下面よりも下方に位置している）に揃える場合に、同じように、各端子部の先端を折り曲げ加工すればよく、より効果的に、コイル加工を簡単にすることができる。   In this way, by adjusting the height position of the lower layer portion of the first lead portion to the height position of the second lead portion, the height positions of the respective terminal portions can be aligned, and from the side surface of the dust core. The protruding amounts of the protruding first terminal portion and second terminal portion can be made the same. Therefore, the tips of the first terminal portion and the second terminal portion that protrude outward from the side surface of the dust core are bent downward, and the tips of the terminal portions are at the same height position (however, the dust core In the same manner, it is only necessary to bend the tip of each terminal portion to make the coil processing more effective. be able to.

また本発明では、前記第１引き出し端子及び前記第２引き出し端子は、前記巻回部から同方向に引き出されており、前記巻回部の中心から見て、各引き出し端子が引き出される側での前記巻回部の側面と前記圧粉コアの側面間の幅寸法に比べて、各引き出し端子が引き出される側以外の領域での前記巻回部の側面と前記圧粉コアの側面間の幅寸法が小さく形成されていることが好ましい。   Further, in the present invention, the first lead terminal and the second lead terminal are drawn in the same direction from the winding part, and viewed from the center of the winding part, on the side where each lead terminal is drawn. Compared with the width dimension between the side surface of the winding part and the side surface of the dust core, the width dimension between the side surface of the winding part and the side surface of the dust core in a region other than the side from which each lead terminal is drawn out Is preferably formed small.

第１引き出し端子及び第２引き出し端子を同方向に引き出すことで、巻回部の側面と圧粉コアの側面間における圧粉コアの薄肉領域を増やすことができ、コイル封入圧粉コアの小型化をより効果的に促進することができる。   By pulling out the first lead terminal and the second lead terminal in the same direction, the thin area of the dust core between the side surface of the winding part and the side surface of the dust core can be increased, and the coil-embedded dust core can be downsized. Can be promoted more effectively.

本発明のコイル封入圧粉コアによれば、コイル封入圧粉コアの小型化において、コイル加工を簡単にできるとともに、圧粉コアの強度の向上及び直流抵抗の低減等を図ることが可能になる。   According to the coil-embedded dust core of the present invention, it is possible to simplify the coil processing and to improve the strength of the dust-core and reduce the direct current resistance in reducing the size of the coil-embedded dust core. .

本発明を適用したコイル封入圧粉コアの第１実施形態を透視して示す斜視図、1 is a perspective view showing a first embodiment of a coil-embedded dust core to which the present invention is applied, 図１に示すコイル封入圧粉コアの透視平面図、FIG. 1 is a perspective plan view of the coil-embedded dust core shown in FIG. 図１及び図２をＡ方向から見たときのコイル封入圧粉コアの透視側面図、A perspective side view of the coil-embedded dust core when FIG. 1 and FIG. 2 are viewed from the direction A, 図１及び図２をＢ方向から見たときのコイル封入圧粉コアの透視側面図、A perspective side view of the coil-embedded dust core when FIG. 1 and FIG. 2 are viewed from the B direction, 第２実施形態のコイル封入圧粉コアの透視平面図、A perspective plan view of the coil-embedded dust core of the second embodiment, 比較例のコイル封入圧粉コアの透視側面図。The perspective side view of the coil enclosure powder core of a comparative example.

図１は、本発明を適用したコイル封入圧粉コアの第１実施形態を透視して示す斜視図、図２は、図１に示すコイル封入圧粉コアの透視平面図、図３は、図１及び図２をＡ方向から見たときのコイル封入圧粉コアの透視側面図、図４は、図１及び図２をＢ方向から見たときのコイル封入圧粉コアの透視側面図、図５は、第２実施形態のコイル封入圧粉コアの透視平面図、図６は、比較例のコイル封入圧粉コアの透視側面図、である。   FIG. 1 is a perspective view showing a first embodiment of a coil-embedded dust core to which the present invention is applied, FIG. 2 is a perspective plan view of the coil-embedded dust core shown in FIG. 1, and FIG. 1 and 2 are perspective side views of the coil-embedded dust core when viewed from the A direction, FIG. 4 is a perspective side view of the coil-embedded dust core when FIGS. 1 and 2 are viewed from the B direction, and FIG. 5 is a see-through plan view of the coil-embedded dust core of the second embodiment, and FIG. 6 is a see-through side view of the coil-embedded dust core of the comparative example.

図１ないし図４に示すコイル封入圧粉コア１は、圧粉コア３と、圧粉コア３に覆われる空芯コイル２とを備えて構成される。   A coil-embedded dust core 1 shown in FIGS. 1 to 4 includes a dust core 3 and an air-core coil 2 covered with the dust core 3.

空芯コイル２は、絶縁被膜された導線を螺旋状に巻回して形成されたものである。空芯コイル２は、巻回部２ａと、巻回部２ａから引き出された第１引き出し端子４と、第２引き出し端子５とを備える。空芯コイル２の巻き数は必要なインダクタンスに応じて適宜設定される。空芯コイル２はエッジワイズコイルを構成する。   The air-core coil 2 is formed by spirally winding a conductive wire with an insulating coating. The air-core coil 2 includes a winding part 2a, a first lead terminal 4 drawn from the winding part 2a, and a second lead terminal 5. The number of turns of the air-core coil 2 is appropriately set according to the required inductance. The air core coil 2 constitutes an edgewise coil.

圧粉コア３は、例えば、Ｆｅ基非晶質合金（Ｆｅ基金属ガラス合金）の粉末が結着材により固化成形されたものである。   For example, the powder core 3 is obtained by solidifying and molding a powder of an Fe-based amorphous alloy (Fe-based metal glass alloy) with a binder.

Ｆｅ基非晶質合金（Ｆｅ基金属ガラス合金）は、例えば、組成式が、Ｆｅ100-a-b-c-x-y-z-tＮｉaＳｎbＣｒcＰxＣyＢzＳｉtで示され、０ａｔ％≦ａ≦１０ａｔ％、０ａｔ％≦ｂ≦３ａｔ％、０ａｔ％≦ｃ≦６ａｔ％、６．８ａｔ％≦ｘ≦１０．８ａｔ％、２．２ａｔ％≦ｙ≦９．８ａｔ％、０ａｔ％≦ｚ≦４．２ａｔ％、０ａｔ％≦ｔ≦３．９ａｔ％である。 Fe-based amorphous alloy (Fe-based metallic glass alloy) is, for example, the composition formula is represented by Fe 100-abcxyzt Ni a Sn b Cr c P x C y B z Si t, 0at% ≦ a ≦ 10at% 0 at% ≦ b ≦ 3 at%, 0 at% ≦ c ≦ 6 at%, 6.8 at% ≦ x ≦ 10.8 at%, 2.2 at% ≦ y ≦ 9.8 at%, 0 at% ≦ z ≦ 4.2 at% 0 at% ≦ t ≦ 3.9 at%.

これにより、例えば、ガラス遷移温度（Ｔｇ）を約７００Ｋ以下にでき、飽和磁化Ｉｓを約１．２５Ｔ以上にでき、飽和質量磁化σｓを約１７０×１０-6Ｗｂｍ／ｋｇ以上にできる。 Thereby, for example, the glass transition temperature (Tg) can be about 700 K or less, the saturation magnetization Is can be about 1.25 T or more, and the saturation mass magnetization σs can be about 170 × 10 −6 Wbm / kg or more.

本実施形態では、上記の組成式から成るＦｅ基非晶質合金を例えば、アトマイズ法により粉末状に、あるいは液体急冷法により帯状（リボン状）に製造できる。   In the present embodiment, an Fe-based amorphous alloy having the above composition formula can be manufactured, for example, in a powder form by an atomizing method or in a strip shape (ribbon shape) by a liquid quenching method.

Ｆｅ基非晶質合金粉末は、略球状あるいは楕円体状等からなる。前記Ｆｅ基非晶質合金粉末は、コア中に多数個存在し、各Ｆｅ基非晶質合金粉末間が結着材（バインダー樹脂）にて絶縁された状態となっている。   The Fe-based amorphous alloy powder has a substantially spherical shape or an ellipsoidal shape. A large number of the Fe-based amorphous alloy powders are present in the core, and the Fe-based amorphous alloy powders are insulated by a binder (binder resin).

また、前記結着材としては、エポキシ樹脂、シリコーン樹脂、シリコーンゴム、フェノール樹脂、尿素樹脂、メラミン樹脂、ＰＶＡ（ポリビニルアルコール）、アクリル樹脂等の液状又は粉末状の樹脂あるいはゴムや、水ガラス（Ｎａ2Ｏ−ＳｉＯ2）、酸化物ガラス粉末（Ｎａ2Ｏ−Ｂ2Ｏ3−ＳｉＯ2、ＰｂＯ−Ｂ2Ｏ3−ＳｉＯ2、ＰｂＯ−ＢａＯ−ＳｉＯ2、Ｎａ2Ｏ−Ｂ2Ｏ3−ＺｎＯ、ＣａＯ−ＢａＯ−ＳｉＯ2、Ａｌ2Ｏ3−Ｂ2Ｏ3−ＳｉＯ2、Ｂ2Ｏ3−ＳｉＯ2）、ゾルゲル法により生成するガラス状物質（ＳｉＯ2、Ａｌ2Ｏ3、ＺｒＯ2、ＴｉＯ2等を主成分とするもの）等を挙げることができる。 Examples of the binder include epoxy resins, silicone resins, silicone rubbers, phenol resins, urea resins, melamine resins, PVA (polyvinyl alcohol), acrylic resins, and other liquid or powder resins, rubbers, water glass ( Na 2 O—SiO 2 ), oxide glass powder (Na 2 O—B 2 O 3 —SiO 2 , PbO—B 2 O 3 —SiO 2 , PbO—BaO—SiO 2 , Na 2 O—B 2 O 3 —ZnO, CaO—BaO—SiO 2 , Al 2 O 3 —B 2 O 3 —SiO 2 , B 2 O 3 —SiO 2 ), glassy substances (SiO 2 , Al 2 O 3 , ZrO produced by the sol-gel method) 2 and TiO 2 as main components).

また潤滑剤として、ステアリン酸亜鉛、ステアリン酸アルミニウム等を添加してもよい。結着材の混合比は５質量％以下、潤滑剤の添加量は０．１質量％〜１質量％程度である。   Further, zinc stearate, aluminum stearate or the like may be added as a lubricant. The mixing ratio of the binder is 5% by mass or less, and the addition amount of the lubricant is about 0.1% by mass to 1% by mass.

図１ないし図４に示すように、第１引き出し端子４及び第２引き出し端子５は、圧粉コア３の側面３ａから外部に突出する第１端子部６及び第２端子部７を備える。この実施形態では側面３ａは、Ｘ−Ｚ平面に平行な面で形成されている。   As shown in FIGS. 1 to 4, the first lead terminal 4 and the second lead terminal 5 include a first terminal portion 6 and a second terminal portion 7 that protrude outward from the side surface 3 a of the powder core 3. In this embodiment, the side surface 3a is formed as a plane parallel to the XZ plane.

更に第１引き出し端子４には、巻回部２ａと、第１端子部６との間に第１引き出し部８が形成されている。また第２引き出し端子５には、巻回部２ａと第２端子部７との間に第２引き出し部９が形成されている。   Further, the first lead terminal 4 is formed with a first lead portion 8 between the winding portion 2 a and the first terminal portion 6. The second lead terminal 5 is formed with a second lead portion 9 between the winding portion 2 a and the second terminal portion 7.

図１、図３、図４に示すように、第１引き出し部８及び第２引き出し部９は巻回部２ａとともに圧粉コア３内に埋設されている。   As shown in FIGS. 1, 3, and 4, the first lead portion 8 and the second lead portion 9 are embedded in the dust core 3 together with the winding portion 2a.

図１、図３に示すように、第１引き出し部８における巻回部２ａからの第１引き出し位置Ｘは、巻回部２ａの上面側（Ｚ１側）に位置し、第２引き出し部９における巻回部２ａからの第２引き出し位置Ｙは、巻回部２ａの下面側（Ｚ２側）に位置している。   As shown in FIGS. 1 and 3, the first drawing position X from the winding part 2 a in the first drawing part 8 is located on the upper surface side (Z1 side) of the winding part 2 a, and in the second drawing part 9. The second drawing position Y from the winding part 2a is located on the lower surface side (Z2 side) of the winding part 2a.

また図１、図３に示すように、圧粉コア３内に埋設された第１引き出し部８は、第１引き出し位置Ｘから圧粉コア３の側面３ａ方向（Ｙ２）に向けて引き出された上層部８ａと、上層部８ａから下方（Ｚ２）且つ圧粉コア３の側面３ａ方向（Ｙ２）に向けて傾きながら引き出された傾斜部８ｂと、傾斜部８ｂから第１端子部６に繋がる下層部８ｃとを有して構成されている。ここで第１引き出し位置Ｘをどの位置に定めるかにもよるが、第１引き出し位置Ｘを平面視にて巻回部２ａ上に位置させた場合、まず第１引き出し位置Ｘから水平方向（Ｙ１−Ｙ２）に引き出す上層部８ａを設け、この上層部８ａから傾く傾斜部８ｂを設けることが好適である。また傾斜部８ｂに繋がる下層部８ｃを設けずに、傾斜部８ｂから直ぐに外部に突出する第１端子部６が繋がる構造としてもよいが、わずかな区間だけ水平方向（Ｙ１−Ｙ２）に延びる下層部８ｃを設けたほうが、コア強度の向上を図ることができる等して好適である。以下では、第１引き出し部８にＹ１−Ｙ２方向に水平に延びる上層部８ａ及び下層部８ｃがあるものとして説明する。   As shown in FIGS. 1 and 3, the first drawer 8 embedded in the dust core 3 is drawn from the first drawer position X toward the side surface 3 a (Y2) of the dust core 3. Upper layer portion 8a, inclined portion 8b drawn from the upper layer portion 8a downward (Z2) and toward the side surface 3a direction (Y2) of the dust core 3, and a lower layer connected from the inclined portion 8b to the first terminal portion 6 Part 8c. Here, depending on which position the first pull-out position X is determined, when the first pull-out position X is positioned on the winding portion 2a in plan view, first, the horizontal direction (Y1 It is preferable to provide an upper layer portion 8a to be pulled out to -Y2) and to provide an inclined portion 8b inclined from the upper layer portion 8a. Alternatively, the lower terminal portion 8c connected to the inclined portion 8b may be provided, and the first terminal portion 6 that protrudes to the outside immediately from the inclined portion 8b may be connected. However, the lower layer extends in the horizontal direction (Y1-Y2) for only a small section. It is preferable to provide the portion 8c because the core strength can be improved. In the following description, it is assumed that the first lead portion 8 has an upper layer portion 8a and a lower layer portion 8c extending horizontally in the Y1-Y2 direction.

図３に示すように、第１引き出し部８の下層部８ｃの下面８ｃ１（及び傾斜部８ｂの最下位置８ｂ１）は、巻回部２ａの下面２ａ１と同一高さあるいは下面２ａ１よりも下方（Ｚ２）に位置している。ここで、「巻回部２ａ」は、図１に示す第１引き出し位置Ｘから第１引き出し端子４及び第２引き出し位置Ｙから第２引き出し端子５を除いた残りの空芯コイル２部分を指す。そして、「巻回部２ａの下面２ａ１」とは、第１引き出し端子４及び第２引き出し端子５を除いた残りの空芯コイル２の最下面を指す。また、「巻回部２ａの下面２ａ１と同一高さ」には、製造誤差、公差が含まれる。   As shown in FIG. 3, the lower surface 8c1 (and the lowest position 8b1 of the inclined portion 8b) of the lower layer portion 8c of the first lead portion 8 is the same height as the lower surface 2a1 of the winding portion 2a or below the lower surface 2a1 ( Z2). Here, the “winding portion 2a” refers to the remaining air-core coil 2 portion excluding the first lead terminal 4 from the first lead position X and the second lead terminal 5 from the second lead position Y shown in FIG. . The “lower surface 2 a 1 of the winding portion 2 a” refers to the lowermost surface of the remaining air-core coil 2 excluding the first lead terminal 4 and the second lead terminal 5. Further, “the same height as the lower surface 2a1 of the winding part 2a” includes manufacturing errors and tolerances.

一方、第２引き出し部９は、Ｙ１−Ｙ２方向に水平（平行）に引き出されている。図１，図３，図４に示すように、第１引き出し部８の下層部８ｃの下面８ｃ１（及び傾斜部８ｂの最下位置８ｂ１）及び第２引き出し部９の下面９ａは、圧粉コア３の下面３ｂよりも上方（Ｚ１）に位置している。   On the other hand, the 2nd drawer | drawing-out part 9 is pulled out horizontally (parallel) in the Y1-Y2 direction. As shown in FIGS. 1, 3, and 4, the lower surface 8 c 1 (and the lowest position 8 b 1 of the inclined portion 8 b) of the lower layer portion 8 c of the first drawer portion 8 and the lower surface 9 a of the second drawer portion 9 are formed of a dust core. 3 is located above (Z1) the lower surface 3b.

また図１ないし図４に示すように、第１引き出し部８の下層部８ｃ及び第２引き出し部９は、圧粉コア３の側面３ａに対して直交方向（Ｙ１−Ｙ２）に延出している。   Further, as shown in FIGS. 1 to 4, the lower layer portion 8 c and the second drawer portion 9 of the first drawer portion 8 extend in a direction orthogonal to the side surface 3 a of the dust core 3 (Y1-Y2). .

これにより図１、図３、図４に示すように、第１端子部６及び第２端子部７は、圧粉コア３の下面３ｂよりも上方（Ｚ１）に位置する圧粉コア３の側面３ａから直交方向（Ｙ１−Ｙ２）にて外部に突出している。   Thereby, as shown in FIGS. 1, 3, and 4, the first terminal portion 6 and the second terminal portion 7 are side surfaces of the dust core 3 positioned above (Z1) the lower surface 3 b of the dust core 3. It protrudes to the outside in the orthogonal direction (Y1-Y2) from 3a.

図１ないし図４に示す実施形態では、第１引き出し部８の下層部８ｃと第２引き出し部９とが同一高さに位置しており、よって、第１端子部６及び第２端子部７も、圧粉コア３の側面３ａに対し同一高さ位置から外部に突出している。ここで「同一高さ」には、製造誤差、公差が含まれる。   In the embodiment shown in FIGS. 1 to 4, the lower layer portion 8 c of the first lead portion 8 and the second lead portion 9 are located at the same height, and thus the first terminal portion 6 and the second terminal portion 7. Moreover, it protrudes outside from the same height position with respect to the side surface 3a of the powder core 3. Here, “same height” includes manufacturing error and tolerance.

また図１、図３、図４に示すように、第１端子部６及び第２端子部７の各先端６ａ，７ａは、下方（Ｚ２）にやや折り曲げられており、各端子部６，７の各先端６ａ，７ａは、同一高さであり且つ、圧粉コア３の下面３ｂと同一高さに位置するか、あるいは圧粉コア３の下面３ｂよりも下方（Ｚ２）に位置している。各端子部６，７は図示しない電子部品に対する設置面（実装面）を構成しているが、例えば端子部６，７の下面６ａ１，７ａ１（図３、図４参照）に、端子部より半田濡れ性により優れた層を形成する構成とすることもできる。   As shown in FIGS. 1, 3, and 4, the tips 6 a and 7 a of the first terminal portion 6 and the second terminal portion 7 are slightly bent downward (Z2), and the terminal portions 6 and 7 are respectively bent. The respective tips 6a and 7a are of the same height and are located at the same height as the lower surface 3b of the dust core 3 or below (Z2) the lower surface 3b of the dust core 3. . The terminal portions 6 and 7 constitute an installation surface (mounting surface) for an electronic component (not shown). For example, solder is applied to the lower surfaces 6a1 and 7a1 (see FIGS. 3 and 4) of the terminal portions 6 and 7 from the terminal portions. It can also be set as the structure which forms the layer excellent in wettability.

図１ないし図４に示す実施形態では、第１引き出し端子４及び第２引き出し端子５が、巻回部２ａから同方向（Ｙ２）に引き出されている。そして、図２、図３、図４に示すように、各引き出し端子４，５の引き出し方向とは逆側（Ｙ１）の圧粉コア３の側面にダミー端子１０が設けられている。   In the embodiment shown in FIGS. 1 to 4, the first lead terminal 4 and the second lead terminal 5 are drawn from the winding portion 2a in the same direction (Y2). As shown in FIGS. 2, 3, and 4, dummy terminals 10 are provided on the side surface of the dust core 3 on the opposite side (Y <b> 1) to the drawing direction of the drawing terminals 4 and 5.

ダミー端子１０は空芯コイル２と電気的に絶縁されている。図３、図４に示すように、ダミー端子１０の下面１０ａは、各端子部６，７の先端６ａ，７ａの下面６ａ１，７ａ１と同一高さで形成されている。ダミー端子１０は、２つの端子部６，７だけでは不安定なコイル封入圧粉コア１の設置時の姿勢を補助するためのもので、ダミー端子１０の形成は任意である。ただし、各引き出し端子４，５を同方向に引き出す図１ないし図４に示す実施形態では、ダミー端子１０を設けることで効果的に、コイル封入圧粉コア１の姿勢安定化を向上させることができ好適である。   The dummy terminal 10 is electrically insulated from the air-core coil 2. As shown in FIGS. 3 and 4, the lower surface 10 a of the dummy terminal 10 is formed at the same height as the lower surfaces 6 a 1 and 7 a 1 of the tips 6 a and 7 a of the terminal portions 6 and 7. The dummy terminal 10 is for assisting the posture at the time of installation of the coil-embedded dust core 1 which is unstable only by the two terminal portions 6 and 7, and the dummy terminal 10 can be formed arbitrarily. However, in the embodiment shown in FIGS. 1 to 4 in which the lead terminals 4 and 5 are pulled out in the same direction, the provision of the dummy terminal 10 can effectively improve the posture stabilization of the coil-embedded dust core 1. This is preferable.

本実施形態におけるコイル封入圧粉コア１（圧粉コア３）の幅寸法（Ｘ１−Ｘ２方向の寸法）、長さ寸法（Ｙ１−Ｙ２方向の寸法）及び高さ寸法（Ｚ１−Ｚ２方向の寸法）を数ｍｍ単位（例えばコア厚を２、３ｍｍ程度、幅寸法、長さ寸法を８、９ｍｍ程度）で形成することができる。また空芯コイル２を構成する導線幅は数百μｍ〜数ｍｍ程度、導線厚を数百μｍ程度で形成できる。また、図２に示す圧粉コア３の側面と空芯コイル２の側面間の幅寸法Ｔ１を狭い場所で数百μｍ程度で形成でき、広いところでも数ｍｍ程度である。   The width dimension (dimension in the X1-X2 direction), the length dimension (dimension in the Y1-Y2 direction), and the height dimension (dimension in the Z1-Z2 direction) of the coil-embedded dust core 1 (powder core 3) in this embodiment. ) In units of several mm (for example, the core thickness is about 2, 3 mm, the width dimension, the length dimension is about 8, 9 mm). Further, the conductor wire constituting the air-core coil 2 can be formed with a width of about several hundred μm to several mm and a conductor thickness of about several hundred μm. Moreover, the width dimension T1 between the side surface of the dust core 3 and the side surface of the air-core coil 2 shown in FIG.

本実施形態では、まず空芯コイル２を形成し、空芯コイル２の第１引き出し端子４及び第２引き出し端子５を所定位置にて所定方向に折り曲げ加工した後、圧粉コア３をプレス成形して空芯コイル２を圧粉コア３内に埋設する。   In this embodiment, the air core coil 2 is first formed, the first lead terminal 4 and the second lead terminal 5 of the air core coil 2 are bent in a predetermined direction at a predetermined position, and then the dust core 3 is press-molded. Then, the air-core coil 2 is embedded in the dust core 3.

以上のように本実施形態では、巻回部２ａの上面側（Ｚ１）から引き出される第１引き出し端子４と、下面側（Ｚ２）から引き出される第２引き出し端子５とを有し、各引き出し端子４，５は、圧粉コア３の側面３ａから外部に突出する各端子部６，７と、巻回部２ａと各端子部との間に位置して圧粉コア３内に埋設される各引き出し部８，９とを有している。   As described above, the present embodiment includes the first lead terminal 4 drawn from the upper surface side (Z1) of the winding portion 2a and the second lead terminal 5 drawn from the lower surface side (Z2), and each lead terminal. 4 and 5 are respectively embedded between the terminal portions 6 and 7 projecting outward from the side surface 3a of the dust core 3 and between the winding portion 2a and each terminal portion and embedded in the dust core 3. Drawers 8 and 9 are provided.

巻回部２ａの上面側（Ｚ１）から引き出される第１引き出し部８は、圧粉コア３内にて傾斜する傾斜部８ｂにより斜めに折り曲げられており、更に傾斜部８ｂから第１端子部６へ繋がる下層部８ｃを備える。このように第１引き出し部８を図６（比較例）のように直角でなく斜めに折り曲げることで、コイル封入コア１の小型化に伴って、空芯コイル２の小型化とともに所定のインダクタンスに調整するべく、導線厚はある程度の厚みを確保しつつ導線幅を狭くして導電厚に対する導電幅のアスペクト比が小さくなっても、コイル加工を簡単にすることができる。なお、傾斜部８ｂのＸ−Ｙ平面に対する傾斜角度は７０〜８０度程度とすることが好ましい。   The 1st drawer | drawing-out part 8 pulled out from the upper surface side (Z1) of the winding part 2a is bend | folded diagonally by the inclination part 8b inclined in the compacting core 3, and also the 1st terminal part 6 from the inclination part 8b. The lower layer part 8c connected to is provided. As described above, the first lead portion 8 is bent at an angle instead of a right angle as shown in FIG. 6 (comparative example), so that the coil-encapsulated core 1 is reduced in size and the air core coil 2 is reduced in size to a predetermined inductance. Coil processing can be simplified even when the conductor width is narrowed while the conductor width is narrowed to reduce the aspect ratio of the conductive width to the conductive thickness. The inclination angle of the inclined portion 8b with respect to the XY plane is preferably about 70 to 80 degrees.

また傾斜部８ｂは圧粉コア３内に埋設されており、第１引き出し部８の下層部８ｃ及び第２引き出し部９は圧粉コア３の側面３ａから直交方向（Ｙ１−Ｙ２）に延出して第１端子部６及び第２端子部７に繋がっている。よって第１端子部６及び第２端子部７は圧粉コア３の側面３ａに対し直交する方向（Ｙ１−Ｙ２）から外部に飛び出している。このように圧粉コア３の側面３ａに直交する方向（Ｙ１−Ｙ２）から各端子部６，７を外部に引き出すことで、特許文献４のように、傾斜部８ｂを、外部に飛び出させる構造に比べて、圧粉コア３の強度を高めることができる。また、各端子部６，７に力が加わった際に、各端子部６，７が引き出された付近の圧粉コア３に強い応力が加わるのを抑制できる。よって本実施形態では端子部６，７が突出した付近の圧粉コア３が割れやすい従来の不具合を抑制することができる。   The inclined portion 8b is embedded in the dust core 3, and the lower layer portion 8c and the second drawer portion 9 of the first lead portion 8 extend from the side surface 3a of the dust core 3 in the orthogonal direction (Y1-Y2). Are connected to the first terminal portion 6 and the second terminal portion 7. Therefore, the 1st terminal part 6 and the 2nd terminal part 7 have protruded outside from the direction (Y1-Y2) orthogonal to the side surface 3a of the compacting core 3. FIG. In this way, by pulling out the terminal portions 6 and 7 from the direction (Y1-Y2) orthogonal to the side surface 3a of the dust core 3, the inclined portion 8b protrudes to the outside as in Patent Document 4. As compared with the above, the strength of the powder core 3 can be increased. Further, when a force is applied to the terminal portions 6 and 7, it is possible to suppress a strong stress from being applied to the powder core 3 in the vicinity where the terminal portions 6 and 7 are pulled out. Therefore, in this embodiment, the conventional malfunction which the dust core 3 of the vicinity where the terminal parts 6 and 7 protruded easily breaks can be suppressed.

また、本実施形態では、第１引き出し部８の下層部８ｃの下面８ｃ１は、巻回部２ａの下面２ａ１と同一高さあるいは前記下面２ａ１よりも下方（Ｚ２）に位置している（図３参照）。これにより、第１引き出し部８の傾斜部８ｂを長く形成できる。   In the present embodiment, the lower surface 8c1 of the lower layer portion 8c of the first lead portion 8 is positioned at the same height as the lower surface 2a1 of the winding portion 2a or below (Z2) the lower surface 2a1 (FIG. 3). reference). Thereby, the inclined part 8b of the 1st drawer | drawing-out part 8 can be formed long.

これに対して図６の比較例では、コイルの巻回部２２から第１引き出し部２０が水平（Ｙ１−Ｙ２）に引き出され、圧粉コア２１の側面２１ａから外部に飛び出した第１引き出し部２０の突出部分２０ａが直角に下方（Ｚ２）に向けて折り曲げられている。なお突出部分２０ａの先端２０ｂの形状は図３と同じとした。上記したように図６の構成では、第１引き出し部２０を直角曲げしているためコイルの小型化に伴いコイル加工が困難となる。加えて、第１引き出し部２０を直角に折り曲げると、本実施形態のように傾斜部８ｂを設ける形態に比べて、第１引き出し部２０の長さ寸法が長くなってしまい、直流抵抗が上昇してしまう。   On the other hand, in the comparative example of FIG. 6, the 1st drawer | drawing-out part 20 was drawn out from the coil | winding part 22 horizontally (Y1-Y2), and protruded outside from the side surface 21a of the dust core 21. 20 protruding portions 20a are bent at a right angle downward (Z2). The shape of the tip 20b of the protruding portion 20a is the same as that in FIG. As described above, in the configuration of FIG. 6, since the first lead portion 20 is bent at a right angle, coil processing becomes difficult as the coil size is reduced. In addition, if the first lead portion 20 is bent at a right angle, the length of the first lead portion 20 becomes longer than that in the case where the inclined portion 8b is provided as in the present embodiment, and the DC resistance increases. End up.

これに対して本実施形態では上記したように、第１引き出し部８の下層部８ｃの下面８ｃ１を、巻回部２ａの下面２ａ１と同一高さあるいは前記下面２ａ１よりも下方（Ｚ２）に位置させ（図３参照）、これにより、第１引き出し部８の傾斜部８ｂをできるだけ長く形成しているから、第１引き出し部全体の引き出し長さを比較すると本実施形態のほうが図６のように直角曲げするよりも短くでき、直流抵抗を低下させることができる。   On the other hand, in the present embodiment, as described above, the lower surface 8c1 of the lower layer portion 8c of the first lead portion 8 is positioned at the same height as the lower surface 2a1 of the winding portion 2a or below (Z2) below the lower surface 2a1. (See FIG. 3), thereby, the inclined portion 8b of the first drawer portion 8 is formed as long as possible. Therefore, when comparing the drawer lengths of the entire first drawer portion, the present embodiment is as shown in FIG. It can be shorter than bending at right angles, and the DC resistance can be reduced.

また本実施形態では、第１引き出し部８の下層部８ｃの下面８ｃ１及び第２引き出し部９の下面９ａを、圧粉コア３の下面３ｂよりも上方（Ｚ１）に位置させているため（図３、図４参照）、第１引き出し部８の下層部８ｃ及び第２引き出し部９が圧粉コア３の下面３ｂから露出することなく、圧粉コア３内に適切に埋設でき、圧粉コア３の強度を高めることができる。   Moreover, in this embodiment, since the lower surface 8c1 of the lower layer part 8c of the 1st drawer | drawing-out part 8 and the lower surface 9a of the 2nd drawer | drawing-out part 9 are located above the lower surface 3b of the compacting core 3 (Z1) (FIG. 3, see FIG. 4), the lower layer portion 8c and the second drawer portion 9 of the first lead portion 8 can be appropriately embedded in the dust core 3 without being exposed from the lower surface 3b of the dust core 3. The strength of 3 can be increased.

以上により本実施形態によれば、コイル封入圧粉コア１の小型化において、コイル加工を簡単にできるとともに、圧粉コア３の強度の向上及び直流抵抗の低減等を図ることが可能になる。   As described above, according to the present embodiment, the coil processing can be simplified in the downsizing of the coil-embedded dust core 1, and the strength of the dust core 3 can be improved and the direct current resistance can be reduced.

また図１、図３、図４に示すように、第１引き出し部８の下層部８ｃと第２引き出し部９を同一高さで形成することで、各端子部６，７も、圧粉コア３の側面３ａにて同一高さから外部に突出させることができ、且つ同じ突き出し量にできる（図１、図３、図４参照）。よって圧粉コア３の側面３ａから外部に突出した第１端子部６及び第２端子部７を、下方に折り曲げる際、同じように折り曲げ加工すればよく、各端子部６，７の先端６ａ，７ａが同一高さ（ただし、圧粉コア３の下面３ｂと同一高さあるいは下面３ｂよりも下方に位置している）に揃うように加工しやすい。また本実施形態では、第１端子部６及び第２端子部７を、共に圧粉コア３の側面３ａの下方位置から外部に突出させることが出来るため、各端子部６，７の先端６ａ，７ａを下方に折り曲げる際、折り曲げ量を小さくでき加工を容易にできる。   Also, as shown in FIGS. 1, 3, and 4, by forming the lower layer portion 8c of the first lead portion 8 and the second lead portion 9 at the same height, each of the terminal portions 6, 7 is also a dust core. 3 can be protruded to the outside from the same height at the side surface 3a, and the same protruding amount can be obtained (see FIGS. 1, 3, and 4). Therefore, the first terminal portion 6 and the second terminal portion 7 that protrude outward from the side surface 3a of the dust core 3 may be bent in the same manner when bent downward. It is easy to work so that 7a is aligned at the same height (however, the same height as the lower surface 3b of the dust core 3 or located below the lower surface 3b). Moreover, in this embodiment, since both the 1st terminal part 6 and the 2nd terminal part 7 can be protruded outside from the downward position of the side surface 3a of the compacting core 3, the front-end | tip 6a of each terminal part 6,7, When bending 7a downward, the amount of bending can be made small and processing can be facilitated.

図４に示すように、第２引き出し部９は、Ｙ１−Ｙ２方向に水平に引き出されているが、途中で下方（Ｚ２）に折り曲げてもよい。ただしかかる場合でも、圧粉コア３の側面３ａ付近に位置する第２引き出し部９は圧粉コア３の側面３ａに対して直交する方向に延出している。更に第２引き出し部９の下面９ａ側全面に、圧粉コア３が設けられている（第２引き出し部９が圧粉コア３の下面３ｂから露出していない）。このとき、第１引き出し部８の下層部８ｃは、第２引き出し部９のうち下方に折り曲げられて最も下方に位置する部分と同一高さに調整されることが好適である。   As shown in FIG. 4, the second lead portion 9 is drawn horizontally in the Y1-Y2 direction, but may be bent downward (Z2) in the middle. However, even in such a case, the second lead portion 9 located in the vicinity of the side surface 3a of the dust core 3 extends in a direction orthogonal to the side surface 3a of the dust core 3. Furthermore, the dust core 3 is provided on the entire lower surface 9a side of the second drawer portion 9 (the second drawer portion 9 is not exposed from the lower surface 3b of the dust core 3). At this time, it is preferable that the lower layer portion 8c of the first lead portion 8 is adjusted to the same height as the portion of the second lead portion 9 that is bent downward and located at the lowest position.

図１ないし図４に示す実施形態では、第１引き出し端子４及び第２引き出し端子５は、巻回部２ａから同方向（Ｙ２）に引き出されており、巻回部２ａの中心Ｏ１（図２参照）から見て、各引き出し端子４，５が引き出される側に比べて、各引き出し端子４，５が引き出される側以外の領域での巻回部２ａの側面と圧粉コア３の側面３ａ間の幅寸法Ｔ１を薄く形成することができる。本実施形態では、各引き出し端子４，５を同方向に引き出すことで、図２に示すように、空芯コイル２全体を圧粉コア３内のＹ１側に片寄らせることができ、よって巻回部２ａの側面と圧粉コア３の側面３ａ間が幅寸法Ｔ１で形成された薄肉の圧粉コア３領域を広げることができ、コイル封入圧粉コア１の小型化をより効果的に促進することができる。また各引き出し端子４，５が引き出される側以外の領域では、圧粉コア３の側面を、空芯コイル２の巻回部２ａの側面と同じ湾曲状に形成することができ、これにより、より効果的に、コイル封入圧粉コア１の小型化を促進できる。   In the embodiment shown in FIGS. 1 to 4, the first lead terminal 4 and the second lead terminal 5 are drawn from the winding portion 2a in the same direction (Y2), and the center O1 (FIG. 2) of the winding portion 2a. As seen from the reference), compared to the side from which each of the lead terminals 4 and 5 is drawn, between the side surface of the winding portion 2a and the side surface 3a of the dust core 3 in the region other than the side from which the lead terminals 4 and 5 are drawn The width dimension T1 can be made thin. In the present embodiment, by pulling out the lead terminals 4 and 5 in the same direction, the entire air-core coil 2 can be shifted to the Y1 side in the dust core 3 as shown in FIG. The region between the side surface of the portion 2a and the side surface 3a of the dust core 3 can be expanded in the thin dust core 3 region formed with the width dimension T1, and the miniaturization of the coil-embedded dust core 1 is more effectively promoted. be able to. Further, in the region other than the side from which each of the lead terminals 4 and 5 is drawn, the side surface of the dust core 3 can be formed in the same curved shape as the side surface of the winding portion 2a of the air core coil 2, thereby Effectively, the miniaturization of the coil-embedded dust core 1 can be promoted.

ただし図５に示す第２実施形態に示すように、巻回部２ａから第１引き出し端子４と第２引き出し端子５とを１８０度反対方向に引き出すことも可能である。図５に示す実施形態では第１引き出し端子４と第２引き出し端子５との引き出し位置Ｗ、Ｖが巻回部２ａの中心Ｏ２から見て同じＹ２側に位置し、第１引き出し端子４と第２引き出し端子５とが高さ方向で一部重なる形態となっており、これにより、図２と同様にコイル封入圧粉コア１の小型化を効果的に促進することができる。   However, as shown in the second embodiment shown in FIG. 5, it is also possible to pull out the first lead terminal 4 and the second lead terminal 5 from the winding portion 2a in opposite directions by 180 degrees. In the embodiment shown in FIG. 5, the lead-out positions W and V of the first lead-out terminal 4 and the second lead-out terminal 5 are located on the same Y2 side when viewed from the center O2 of the winding portion 2a, and the first lead-out terminal 4 and the second lead-out terminal 4 The two lead terminals 5 partially overlap in the height direction, and as a result, the miniaturization of the coil-embedded dust core 1 can be effectively promoted as in FIG.

以上に示す本実施形態のコイル封入圧粉コア１は、小型で且つ熱伝導の高い面実装パワーインダクタや、その他の電子部品を構成することができる。   The coil-embedded dust core 1 of the present embodiment as described above can constitute a small-sized and highly heat-conductive surface-mount power inductor or other electronic components.

１ コイル封入圧粉コア
２ 空芯コイル
２ａ 巻回部
３ 圧粉コア
３ａ 側面
３ｂ 下面
４ 第１引き出し端子
５ 第２引き出し端子
６ 第１端子部
７ 第２端子部
８ 第１引き出し部
８ａ 上層部
８ｂ 傾斜部
８ｃ 下層部
９ 第２引き出し部
１０ ダミー端子 DESCRIPTION OF SYMBOLS 1 Coil enclosure dust core 2 Air-core coil 2a Winding part 3 Powder core 3a Side surface 3b Lower surface 4 1st extraction terminal 5 2nd extraction terminal 6 1st terminal part 7 2nd terminal part 8 1st extraction part 8a Upper layer part 8b Inclined portion 8c Lower layer portion 9 Second lead portion 10 Dummy terminal

Claims (6)

圧粉コアと、コイルと、を有し、
前記コイルは、前記圧粉コア内に埋設される巻回部と、前記巻回部から引き出される第１引き出し端子と第２引き出し端子とを備え、
前記第１引き出し端子及び前記第２引き出し端子は、夫々前記圧粉コアの側面から外部に露出する第１端子部及び第２端子部と、前記第１端子部と前記巻回部との間、及び前記第２端子部と前記巻回部との間に位置して前記圧粉コア内に埋設された第１引き出し部及び第２引き出し部とを備えており、
前記第１引き出し部における前記巻回部からの第１引き出し位置は、前記巻回部の上面側に位置し、前記第２引き出し部における前記巻回部からの第２引き出し位置は、前記巻回部の下面側に位置しており、
前記圧粉コア内に埋設された前記第１引き出し部は、前記第１引き出し位置から引き出されて下方且つ前記圧粉コアの側面方向に向けて傾く傾斜部を有しており、
前記傾斜部の最下位置は、前記巻回部の下面と同一高さあるいは前記下面よりも下方に位置するとともに、前記傾斜部の最下位置及び前記第２引き出し部の下面は、前記圧粉コアの下面よりも上方に位置しており、
前記第１端子部及び前記第２端子部は、前記圧粉コアの下面よりも上方に位置する前記圧粉コアの側面から直交方向にて外部に突出していることを特徴とするコイル封入圧粉コア。 A dust core and a coil;
The coil includes a winding part embedded in the dust core, a first lead terminal and a second lead terminal drawn from the winding part,
The first lead terminal and the second lead terminal are respectively exposed between the first terminal portion and the second terminal portion exposed from the side surface of the dust core, and between the first terminal portion and the winding portion, And a first drawer part and a second drawer part that are located between the second terminal part and the winding part and are embedded in the dust core,
The first drawer position from the winding part in the first drawer part is located on the upper surface side of the winding part, and the second drawer position from the winding part in the second drawer part is the winding position. Located on the lower surface side of the part,
The first drawer portion embedded in the dust core has an inclined portion that is pulled out from the first drawer position and tilts downward and toward the side surface of the dust core;
The lowest position of the inclined portion is located at the same height as the lower surface of the winding portion or below the lower surface, and the lowest position of the inclined portion and the lower surface of the second lead-out portion are Located above the lower surface of the core,
The said 1st terminal part and the said 2nd terminal part are protruded outside in the orthogonal direction from the side surface of the said powder core located above the lower surface of the said powder core, The coil enclosed powder compact characterized by the above-mentioned core. 前記第１端子部及び前記第２端子部は、前記圧粉コアの側面に対して同一高さ位置から外部に突出している請求項１記載のコイル封入圧粉コア。   The coil-embedded dust core according to claim 1, wherein the first terminal portion and the second terminal portion protrude outward from the same height position with respect to a side surface of the dust core. 前記圧粉コア内に埋設された前記第１引き出し部は、前記第１引き出し位置から前記圧粉コアの側面方向に向けて引き出された上層部と、前記上層部から傾く傾斜部と、前記傾斜部から前記第１端子部に繋がる下層部とを有しており、
前記第１引き出し部の下層部及び前記第２引き出し部は、前記圧粉コアの側面に対して直交した方向に延出して、夫々、前記第１端子部及び前記第２端子部に繋がっている請求項１又は２に記載のコイル封入コア。 The first lead portion embedded in the dust core includes an upper layer portion that is drawn from the first lead position toward a side surface of the dust core, an inclined portion that is inclined from the upper layer portion, and the inclination And a lower layer part connected to the first terminal part from the part,
The lower layer portion of the first lead portion and the second lead portion extend in a direction perpendicular to the side surface of the dust core, and are connected to the first terminal portion and the second terminal portion, respectively. The coil-encapsulated core according to claim 1 or 2. 前記第１引き出し部の下層部と、前記第２引き出し部とは同一高さで形成されて、前記第１端子部と前記第２端子部とが、前記圧粉コアの前記側面に対して同一高さ位置から外部に突出している請求項３記載のコイル封入圧粉コア。   The lower layer portion of the first lead portion and the second lead portion are formed at the same height, and the first terminal portion and the second terminal portion are the same with respect to the side surface of the dust core. The coil-embedded dust core according to claim 3, which protrudes outward from a height position. 前記圧粉コアの側面から外部に突出した前記第１端子部及び前記第２端子部の先端は下方に折り曲げられており、各端子部の先端は、同一高さであって、且つ前記圧粉コアの下面と同一高さあるいは前記下面よりも下方に位置している請求項１ないし４のいずれか１項に記載のコイル封入圧粉コア。   The tips of the first terminal portion and the second terminal portion that protrude outward from the side surface of the dust core are bent downward, the tips of each terminal portion have the same height, and the dust powder The coil-embedded dust core according to any one of claims 1 to 4, which is located at the same height as the lower surface of the core or below the lower surface. 前記第１引き出し端子及び前記第２引き出し端子は、前記巻回部から同方向に引き出されており、前記巻回部の中心から見て、各引き出し端子が引き出される側での前記巻回部の側面と前記圧粉コアの側面間の幅寸法に比べて、各引き出し端子が引き出される側以外の領域での前記巻回部の側面と前記圧粉コアの側面間の幅寸法が小さく形成されている請求項１ないし５のいずれか１項に記載のコイル封入圧粉コア。   The first lead terminal and the second lead terminal are drawn in the same direction from the winding part, and viewed from the center of the winding part, the winding part on the side from which each lead terminal is drawn Compared to the width dimension between the side surface and the side surface of the dust core, the width dimension between the side surface of the winding part and the side surface of the dust core in the region other than the side from which each lead terminal is pulled out is formed small. The coil-embedded dust core according to any one of claims 1 to 5.
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