JP2018074127A - Coil structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a coil structure with a small magnetic core.SOLUTION: A coil structure comprises: an annular magnetic core; and a coil that is configured by a spiral conductor and that has an inner conductor part arranged inside the magnetic core and an outer conductor part arranged outside of the magnetic core. A total width of the inner conductor part is smaller than that of the outer conductor part.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a coil structure.

  An automobile is equipped with an electrical junction box (also called a power distributor) that distributes power from a power source (battery) to a load such as a headlamp or a wiper. As a member constituting the internal circuit of the electrical junction box, for example, there is a circuit structure shown in Patent Document 1. The circuit structure is mounted on a control circuit board on which a conductor pattern (circuit pattern) is formed, an input terminal bus bar and an output terminal bus bar bonded to the control circuit board, and the control circuit board and both bus bars. Electronic components such as semiconductor switching elements.

  Among such circuit components, there is one in which a separately prepared coil component (coil structure) is usually surface-mounted on a bus bar of a circuit board as another electronic component of the semiconductor switching element. Examples of the coil component include a choke coil including a coil formed by winding a winding in a spiral shape and a magnetic core disposed inside and outside the coil. This coil component is generally arranged so that the axial direction of the coil is orthogonal to the plane of the bus bar (circuit board).

JP 2003-164040 A

  The coil structure generally has a circuit configuration because the turns of the coil are stacked in an upward direction perpendicular to the plane of the bus bar, and a portion of the magnetic core disposed outside the coil is disposed on the upper end surface side of the coil. It is a large (high) member in the body. For this reason, the height of the circuit structure increases, and the volume of the entire circuit structure increases. In order to reduce the height of the circuit structure, it is desired to reduce the size of the coil structure, in particular, the size of the magnetic core.

  Accordingly, an object is to provide a coil structure having a small magnetic core size.

The coil structure according to the present disclosure is:
An annular magnetic core;
A coil having a spiral conductor, an inner conductor portion disposed inside the magnetic core, and an outer conductor portion disposed outside the magnetic core;
The total width of the inner conductor portion is smaller than the total width of the outer conductor portion.

  The coil structure has a small magnetic core size.

1 is a perspective view illustrating an outline of a coil structure according to Embodiment 1. FIG. FIG. 2 is a top view schematically showing a coil structure according to the first embodiment. It is sectional drawing which shows the state cut | disconnected by the (III)-(III) cutting line of the coil structure shown in FIG. It is a cross-sectional view which shows the outline of the coil structure which concerns on the modification 1-1. It is a perspective view which shows the outline of the coil structure which concerns on modification 1-2. It is sectional drawing which shows the state cut | disconnected by the (VI)-(VI) cutting line of the coil structure shown in FIG. 6 is a perspective view showing an outline of a coil structure according to Embodiment 2. FIG. It is sectional drawing which shows the state cut | disconnected by the (VIII)-(VIII) cutting line of the coil structure shown in FIG.

<< Description of Embodiments of the Present Invention >>
First, embodiments of the present invention will be listed and described.

(1) A coil structure according to an aspect of the present invention is
An annular magnetic core;
A coil having a spiral conductor, an inner conductor portion disposed inside the magnetic core, and an outer conductor portion disposed outside the magnetic core;
The total width of the inner conductor portion is smaller than the total width of the outer conductor portion.

  According to said structure, it is easy to make the size of a magnetic core small. This is because the coil is spiral and each turn is positioned on the same plane, so that the height of the magnetic core can be made lower than that of a spiral coil in which the turns are stacked in the axial direction. In addition, since the total width of the inner conductor portion is smaller than the total width of the outer conductor portion, the coil having the same total width of the inner conductor portion and the total width of the outer conductor portion (hereinafter, the same total width coil) and the entire coil This is because the total width of the inner conductor portion is smaller and the width of the magnetic core can be smaller than that of the coil having the same total width. The total width means a value when the number of inner conductor portions and outer conductor portions is the same. Therefore, it is possible to construct a circuit structure having a low height and a small overall volume.

  Moreover, according to said structure, it is easy to improve heat dissipation. This is because when the resistance value of the entire coil is the same as that of the same coil having the same total width, the total width of the outer conductor portion is larger than that of the same coil having the same total width, so that the heat radiation area can be easily increased. In addition, since the coil satisfies “(total width of the inner conductor portion) <(total width of the outer conductor portion)”, the inner conductor portion generates heat more easily than the outer conductor portion. This is because the heat of the inner conductor portion that is more likely to generate heat is more likely to diffuse to the outer conductor portion that is less likely to generate heat and can take up a large heat radiation area. Therefore, the maximum temperature of the coil is easily lowered as compared with the coil having the same total width.

  (2) As one form of the said coil structure, it is mentioned that the largest width | variety of the said inner side conductor part is smaller than the width | variety of the said smallest outer side conductor part.

  According to said structure, it is easy to make the size of a magnetic core still smaller. This is because the widths of all the inner conductor portions are smaller than the widths of all the outer conductor portions, so that the total width of the inner conductor portions can be easily reduced.

  Moreover, according to said structure, it is easy to improve heat dissipation further. This is because the total width of the inner conductor portion is much smaller than that of the coil having the same total width, that is, the total width of the outer conductor portion is much larger, so that the heat radiation area can be further increased. In addition, because the difference between the total widths of the inner and outer conductor portions is increased, the heat of the inner conductor portion is easily diffused by the outer conductor portion.

  (3) As one form of the said coil structure, it is mentioned that the said coil is comprised by a part of plate-shaped bus bar arrange | positioned at the lower surface of a circuit board.

  According to said structure, the productivity of a circuit structure body can be improved. Since the coil is formed of a part of the bus bar, the coil can be manufactured simultaneously with the bus bar, and it is not necessary to prepare the bus bar and the coil individually. Typically, the bus bar can be manufactured by punching a single flat conductor into a desired wiring pattern. In that case, a coil can be manufactured by punching a part of a flat conductor into a desired spiral shape. And a circuit structure can be manufactured simultaneously with preparation of a coil structure only by attaching a magnetic core to a coil of a bus bar. That is, it is not necessary to mount the coil structure and the coil on the bus bar after preparing and combining the coil and the magnetic core.

  (4) As one form of the said coil structure, it is mentioned that the said coil is comprised by a part of foil-like circuit pattern formed in the upper surface of a circuit board.

  According to said structure, it is easy to make the size of a magnetic core still smaller. This is because the foil-like circuit pattern can be easily reduced in width and thickness as compared with the plate-like bus bar.

  (5) As one form of the said coil structure, it has the thermal radiation member arrange | positioned on the one surface side of the said coil, and radiates the heat of the said coil, The said thermal radiation member is equipped with the accommodation recessed part which accommodates a part of magnetic core. Can be mentioned.

  According to said structure, the heat of a coil and a magnetic core can be thermally radiated effectively by providing a heat radiating member. Further, since the heat radiating member includes the housing recess, it is possible to construct a circuit structure having a low height while suppressing an increase in the height of the magnetic core.

<< Details of Embodiment of the Present Invention >>
Details of embodiments of the present invention will be described below with reference to the drawings. The same reference numerals in the figure indicate the same names.

Embodiment 1
[Coil structure]
With reference to FIGS. 1-3, the coil structure 1A which concerns on Embodiment 1 is demonstrated. The coil structure 1 </ b> A includes an annular magnetic core 2 and coils 3 disposed inside and outside the magnetic core 2. This coil structure 1 </ b> A is typically provided in the circuit configuration body 100. For example, as shown in FIG. 1, the circuit structure 100 is arranged on a circuit board 110 having an upper surface on which a foil-like circuit pattern (not shown) constituting a signal circuit is formed, and on the lower surface of the circuit board 110. A plate-shaped bus bar 130 constituting the power circuit and an electronic component mounted on at least one of the circuit pattern and the bus bar 130 are provided. One electronic component is a coil structure 1A according to an embodiment. One of the features of the coil structure 1A is that the coil 3 is formed by forming a part of the bus bar 130 in a spiral shape, and the inner conductor 31 and the magnetic core 2 disposed inside the magnetic core 2 of the coil 3. This is that the size (width) of the outer conductor portion 32 arranged on the outer side of the capacitor satisfies a specific magnitude relationship. Here, a heat radiating member 5 (150) for radiating heat of the coil 3 (bus bar 130) is disposed on the lower surface of the coil 3 (bus bar 130). Details will be described below. For convenience of explanation, FIGS. 1 to 3 show the vicinity of the coil structure 1 </ b> A according to the first embodiment in the circuit configuration body 100 and omit other parts. 2 and 3, the circuit board is omitted, and in FIG. 2, the coil 3 is hatched. In the following description, the heat dissipating member 5 side (the lower side in FIG. 1 and FIG. 3 and the inner side in FIG. 2) of the coil 3 (bus bar 130) of the circuit structure 100 is defined as “lower” and the opposite side as “up” Yes.

[Magnetic core]
The magnetic core 2 is configured by connecting a plurality of divided core portions in an annular shape, and forms a closed magnetic circuit by exciting the coil 3 (FIGS. 1 and 3). The connection / separation form of the magnetic core 2 can be UI type, UU type, LL type, or the like. The connection / separation surface may be along the vertical direction, or may be along a direction orthogonal to the vertical direction. The position of the connection / separation surface is preferably a position that is not arranged on the same plane as the coil 3, that is, a position shifted from the plane of the coil 3. If it does so, the leakage magnetic flux from a connection and isolation | separation surface does not penetrate | invade into the coil 3 easily. Therefore, it is easy to suppress an increase in loss (Joule loss), and it is easy to suppress a decrease in magnetic characteristics. The connecting / separating surfaces may be connected to each other via a gap material made of a material having a lower relative magnetic permeability than both core portions, or may be directly connected to each other without using a gap material. .

  Here, the magnetic core 2 is divided into upper and lower parts, and an upper core part 21 having a U-shaped cross section covering the upper side of the coil 3 and a lower core part having an I-shaped cross section disposed below the coil 3. And U-I type (FIGS. 1 and 3). The positions of the connecting / separating surfaces of the upper and lower core portions 21 and 22 are positions where a step is generated in the vertical direction with respect to the coil 3 (inner conductor portion 31) (here, positioned below the coil 3). The connection / separation surfaces of the upper and lower core portions 21 and 22 are stored in a storage recess 51 of the heat radiating member 5 described later, and are positioned below the upper surface of the heat radiating member 5. The connection / separation surfaces of the upper and lower core portions 21 and 22 are directly connected without a gap material therebetween.

  The magnetic core 2 can be used in various forms made of known constituent materials. As the magnetic core 2, a molded body using magnetic powder or a laminated body in which a plurality of magnetic thin plates (for example, electromagnetic steel sheets) having an insulating coating are laminated can be used. The compact includes, for example, a compact compact using a powder of a soft magnetic material (soft magnetic metal or soft magnetic nonmetal), a sintered compact obtained by sintering the powder after press molding, and the powder and a resin. A composite material molded body obtained by subjecting the mixture to injection molding or cast molding can be used. Examples of the soft magnetic metal include an iron group metal, an iron base alloy containing Fe as a main component, and an amorphous metal. The iron group metal is Fe, Ni, Co. Typical examples of iron-based alloys include Fe-Si alloys, Fe-Ni alloys, and Fe-Si-Al alloys. Examples of the soft magnetic nonmetal include metal oxides, for example, oxides containing Fe such as ferrite.

  When the gap material is provided, the gap material is made of, for example, ceramics such as alumina, nonmagnetic materials such as resin (for example, PPS resin), composite materials including soft magnetic powder and resin, and elastic materials such as various rubbers. Materials.

[coil]
The coil 3 is composed of a spiral conductor (FIGS. 1 and 2). Here, the coil 3 is configured by a part of a plate-like bus bar 130 disposed on the lower surface of the circuit board 110 in the circuit structure 100. The coil 3 is a planar coil in which each turn is located on the same plane as the other part 131 (for example, an output (input) terminal described later) of the bus bar 130. The number of turns of the coil 3 can be appropriately selected according to a desired inductance. 1-3, the coil 3 of 3 turns is illustrated for convenience of explanation. The intervals between the turns are substantially equal. The outer shape of the coil 3 (spiral) is rectangular, but it may be circular. The conductor material may be the same copper or copper alloy as the bus bar 130 material.

  The coil 3 includes an inner conductor portion 31 disposed inside the magnetic core 2 and an outer conductor portion 32 disposed outside the magnetic core 2 (FIGS. 1 to 3). The “inner conductor portion arranged inside the magnetic core” means not only the portion arranged inside the magnetic core 2 but also the central portion of the inner conductor portion 31 arranged inside the magnetic core 2, for example. In addition, the case where the vicinity of the end portion of the inner conductor portion 31 is located outside the magnetic core 2 is also included in the “inner conductor portion disposed inside the magnetic core”. That is, the axial length of the inner conductor portion 31 may be longer than the length of the magnetic core 2, and the end portion of the inner conductor portion 31 and its vicinity may protrude from the end face of the magnetic core 2 and be exposed. Good. Both end portions of the coil 3 have an inner peripheral end portion 33 arranged on the innermost periphery of the spiral outside the magnetic core 2 and an outer peripheral end portion 34 drawn out to the outermost periphery of the spiral outside the magnetic core 2.

  The inner conductor portion 31 is a linear narrow portion that is disposed inside and outside the magnetic core 2 (indicated by a two-dot chain line in FIG. 2) and is parallel to the axial direction (left-right direction in FIG. 2) of the magnetic core 2. 2 and an end portion which is arranged outside the magnetic core 2 and is continuous with both end portions of the center portion (FIG. 2). The outer conductor part 32 has a linear parallel part parallel to the axial direction (the central part) of the magnetic core 2 and a linear orthogonal part orthogonal to the parallel part. Among the orthogonal portions, one orthogonal portion (the right side in FIG. 2) of the outermost periphery of the coil 3 is connected to the end portion of the inner conductor portion 31 and the outer peripheral end portion 34 of the coil 3. The other orthogonal portion connects the parallel portion of the outer conductor portion 32 and the end portion of the inner conductor portion 31. The parallel part on the innermost periphery of the coil 3 is connected to the orthogonal part and the inner peripheral end 33 of the coil 3.

  The cross-sectional shape of both the conductor parts 31 and 32 is a rectangular shape (FIG. 3). The thickness of both the conductor parts 31 and 32 is uniform in the longitudinal direction. The thickness is a length along the vertical direction. The thickness of both the conductor parts 31 and 32 is larger than the thickness of the foil-like circuit pattern in the circuit board 110 (for example, 20 micrometers or more and 150 micrometers or less), and is the same as the thickness of the other part 131 of the bus bar 130. As for the thickness of both the conductor parts 31 and 32, 0.3 mm or more and 2.0 mm or less are mentioned, for example. The width Wi of the inner conductor portion 31 and the width Wo of the outer conductor portion 32 are different from each other as will be described in detail (FIG. 2). Each width Wi, Wo is a length along a direction perpendicular to both the longitudinal direction and the vertical direction of the central portion and the parallel portion (orthogonal portion) of each conductor portion 31, 32. When the outer shape of the coil 3 is circular, the width of each of the conductor portions 31 and 32 is a length along the normal direction of the curved portion.

  The total width of the inner conductor portion 31 is smaller than the total width of the outer conductor portion 32. Thereby, it is easy to reduce the size of the magnetic core 2. This is because the coil 3 is spiral and each turn is located on the same plane, so that the height of the magnetic core 2 can be made lower than that of a spiral coil in which the turns are stacked in the axial direction. In addition, when the resistance value of the coil having the same total width of the inner conductor portion 31 and the same width of the outer conductor portion 32 is the same as that of the coil having the same total width, the inner conductor portion This is because the total width of 31 is small and the width of the magnetic core 2 can be reduced. The total width means a value when the number of the inner conductor portions 31 and the outer conductor portions 32 is the same. Moreover, it is easy to improve heat dissipation. This is because when the resistance value of the entire coil is the same as that of the same coil having the same total width, the total width of the outer conductor portion 32 is larger than that of the same coil having the same total width, so that the heat radiation area can be easily increased. Moreover, the coil 3 is more likely to generate heat than the outer conductor portion 32 by satisfying “(total width of the inner conductor portion 31) <(total width of the outer conductor portion 32)”. This is because the heat of the inner conductor portion 31 that is more likely to generate heat than the coil having the same total width is likely to diffuse to the outer conductor portion 32 that is less likely to generate heat and has a larger heat dissipation area. Therefore, the maximum temperature of the coil 3 can be easily lowered as compared with the coil having the same total width.

  The width Wi of all the inner conductor portions 31 may not be smaller than the width Wo of all the outer conductor portions 32, but the width Wi of all the inner conductor portions 31 is smaller than the width Wo of all the outer conductor portions 32. It is preferable. That is, the width Wi of the largest inner conductor portion 31 is preferably smaller than the width Wo of the smallest outer conductor portion 32. Then, since the total width of the inner conductor portion 31 can be further reduced, it is easy to further reduce the size of the magnetic core 2. In addition, it is easier to improve heat dissipation. This is because the total width of the inner conductor portion 31 is smaller than that of the coil having the same total width, that is, the total width of the outer conductor portion 32 is much larger, so that the heat radiation area can be further increased. In addition, because the difference between the total widths of the inner and outer conductor portions is increased, the heat of the inner conductor portion 31 is easily diffused by the outer conductor portion 32.

  The width Wi of each inner conductor portion 31 is uniform here, but may be non-uniform. The width Wo of each outer conductor portion 32 is uniform here, but may be nonuniform when the width Wi of each inner conductor portion 31 is nonuniform.

  The inner peripheral end 33 is electrically connected to an output (input) terminal of the bus bar 130 by a conductive member such as a jumper chip 180. The arrangement position of the inner peripheral end 33 can be appropriately selected according to the position of the output (input) terminal, and is preferably located on the side closer to the output (input) terminal. Then, it is easy to shorten the length of the jumper chip 180. The outer peripheral end 34 constitutes an input (output) terminal of the bus bar 130. The outer peripheral end 34 is drawn out in the same direction as the output (input) terminal here, but can of course be drawn out in a different direction.

  The coil 3 can be produced in accordance with the production of the bus bar 130. The bus bar 130 can be typically manufactured by a punching process in which a single flat conductor is punched into a desired wiring pattern. At that time, the coil 3 can be produced by punching a part of the flat conductor into a desired spiral shape.

[Intervening member]
The coil structure 1 </ b> A can be configured to include an interposition member 4 interposed between the magnetic core 2 and the inner conductor portion 31 of the coil 3 (FIG. 3). The interposition member 4 enhances electrical insulation between the magnetic core 2 and the inner conductor portion 31. In addition, the heat of the inner conductor portion 31 is transmitted to the magnetic core 2. The interposition member 4 also has a function of supporting the inner conductor portion 31 from the lower surface side in the magnetic core 2.

  The interposition member 4 is configured by combining upper and lower divided pieces 41 and 42 that are divided into upper and lower parts, for example. The lower divided piece 42 is interposed between the lower core portion 22 and the inner conductor portion 31, and the upper divided piece 41 is interposed between the upper core portion 21 and the inner conductor portion 31. One of the two split pieces 41 and 42 preferably has an intervening convex portion 43 that protrudes to the other side so as to be interposed between the inner conductor portions 31. If it does so, the electrical insulation of the inner side conductor parts 31 which the interposition convex part 43 adjoins can be improved. In addition, it is preferable that one of the split pieces 41 and 42 has an outer convex portion 44 that protrudes to the other side so as to be disposed outside the inner conductor portions 31 at both ends. If it does so, while being able to improve the electrical insulation between the inner conductor part 31 and magnetic core 2 of both ends, each inner conductor part 31 can be accommodated and positioned in the recessed part 45 between adjacent convex parts. . In FIG. 3, for convenience of explanation, the gap is exaggerated between the recess 45 and the inner conductor portion 31. Here, the lower divided piece 42 has an intervening convex portion 43 and an outer convex portion 44.

  One of the two divided pieces 41, 42 may have an intervening convex portion 43, and the other may have an outer convex portion 44, or both of the divided pieces 41, 42 may have an intervening convex portion 43 and an outer convex portion 44. And may be provided. Here, the interposition member 4 includes both the upper and lower divided pieces 41 and 42, but may include only the lower divided piece 42 without the upper divided piece 41.

  Examples of the material of the interposition member 4 include thermoplastic resins such as polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), polyamide (PA) resin, and polybutylene terephthalate (PBT) resin. . This resin preferably contains an inorganic filler. Specific examples of the filler include an alumina filler. If it does so, it will be easy to transmit the heat of the inner side conductor part 31 to the magnetic core 2 via the interposition member 4. FIG.

[Heat dissipation member]
The heat radiating member 5 radiates the heat of the coil 3 (FIGS. 1 to 3). The heat radiating member 5 is disposed below the coil 3. The heat radiating member 5 is constituted by a part of the heat radiating member 150 arranged below the bus bar 130 of the circuit structure 100. The size of the heat radiating member 5 may be a size that allows contact with the entire lower surface of the coil 3 (bus bar 130). The heat dissipating member 5 may be formed of a flat plate member, or a flat plate member and a fin formed of a plurality of protrusions protruding downward from the lower surface of the flat plate member may be integrally formed. . When fins are provided, it is easy to increase heat dissipation by increasing the surface area of the heat dissipation member 5. The upper surface of the heat radiating member 5 is flat here.

  The heat radiating member 5 has a housing recess 51 for housing a part of the magnetic core 2. The housing recess 51 is formed from the upper surface to the lower surface side of the heat dissipation member 5. The size of the storage recess 51 is slightly larger than the magnetic core 2. As the depth of the storage recess 51 increases, the height of the magnetic core 2 can be reduced. Therefore, the heat of the magnetic core 2 can be effectively radiated without increasing the height of the magnetic core 2. Here, the depth of the storage recess 51 is deeper than the height of the lower core portion 22, and the depth at which the connecting / separating surfaces of the upper and lower core portions 21, 22 can be stored, that is, the lower side The depth is such that all of the core part 22 and a part of the upper core part 21 can be accommodated. The storage recess 51 can be formed by cutting the upper surface of the heat dissipation member 5 or the like. In addition, the storage recess may be formed by punching from the upper surface side to the lower surface side. In that case, the protrusion which protrudes below rather than a peripheral region is formed in the location which comprises the lower surface of a storage recessed part.

  Examples of the constituent material of the heat dissipating member 5 include a metal material having excellent thermal conductivity. Examples of the metal material include aluminum and an aluminum alloy.

[Insulation layer]
An insulating layer 6 is interposed between the coil 3 and the heat radiating member 5 to enhance electrical insulation therebetween (FIGS. 1 to 3). The insulating layer 6 is constituted by a part of the insulating layer 160 disposed between the bus bar 130 and the heat dissipation member 150 of the circuit structure 100. The insulating layer 6 transmits the heat of the coil 3 (bus bar 130) to the heat radiating member 5. The insulating layer 6 is formed with a notch so as to surround the periphery (three sides) of the storage recess 51 so as not to cover the upper portion of the storage recess 51 of the heat dissipation member 5. The gap is filled without any gaps (Fig. 2). The insulating layer 6 may be configured by applying its constituent material, or may be configured by a sheet.

  The constituent material of the insulating layer 6 includes an insulating resin. In particular, the constituent material of the insulating layer 6 is preferably an insulating resin excellent in thermal conductivity. Specific examples of the resin include an epoxy resin and a silicone resin. This resin preferably contains an inorganic filler as in the case of the interposition member 4. Then, the heat of the coil 3 can be easily transmitted to the heat radiating member 5 through the insulating layer 6. The insulating layer 6 may be made of the insulating resin adhesive.

[Manufacture of coil structure]
The coil structure 1A is manufactured by combining a preparatory process for preparing the magnetic core 2 and the spiral coil 3 and the magnetic core 2 and the coil 3 so that the coil 3 is arranged inside and outside the magnetic core 2. It can be performed by a method for manufacturing a coil structure including an assembly process for manufacturing the body 1A. Preparation of the coil 3 in a preparation process is performed by preparing the bus bar 130 provided with the coil 3. Specifically, as described above, when the bus bar 130 is manufactured by punching a single flat conductor into a desired wiring pattern, a portion of the flat conductor is punched into a desired spiral shape to thereby produce the coil 3. Is made. In the assembly process, the upper and lower core portions are assembled at a predetermined position of the coil 3 so as to surround the outer periphery thereof. Assembling the magnetic core 2 to the coil 3 includes a laminated coil 3 in which the circuit board 110, the bus bar 130 and the heat dissipation member 150 are laminated, a laminated coil 3 in which the circuit board 110 and the bus bar 130 are laminated, or a bus bar 130. And the heat dissipation member 150 may be performed on the coil 3 of the laminated body, or may be performed on the coil 3 of the bus bar 130 before the laminated body is manufactured.

[Usage]
The coil structure 1A can be suitably used as a constituent member of a circuit structure provided in an electric junction box for automobiles. In addition, the coil structure 1A can be suitably used as a constituent member of a substrate for a high-current power circuit such as a DC voltage converter, an AC / DC converter, or a DC / AC inverter. Examples of these constituent members include a choke coil, a transformer, and a noise filter.

  As described at the beginning of the first embodiment, the circuit structure 100 includes a circuit board 110 having an upper surface on which a foil-like circuit pattern constituting a signal circuit is formed, and a power circuit disposed on the lower surface of the circuit board 110. , And an electronic component mounted on at least one of the circuit pattern and the bus bar 130 (FIG. 1). The circuit board 110 has a circuit pattern (not shown) formed on the upper surface thereof. In the circuit board 110, the magnetic core 2, the inner peripheral end 33, the jumper chip 180, and a rectangular opening 112 (FIG. 1) for exposing a part of the output terminal (the other part 131 of the bus bar 130) are formed. Has been. As for the thickness of the circuit board 110, 1 mm or more and 3 mm or less are mentioned, for example. The circuit pattern is formed of copper foil. The circuit board 110 can be a printed circuit board. The bus bar 130 is configured by a plate-like member such as copper or a copper alloy as described above, and the thickness is 0.3 mm or more and 2.0 mm or less, which is the same as the thickness of the coil 3 described above. The bus bar 130 includes the coil 3 described above. The electronic component includes, for example, a switching element such as a relay or a field effect transistor (FET) in addition to the coil structure 1A. The circuit board 110 and the bus bar 130 (coil 3) can be bonded by an adhesive sheet (not shown) interposed therebetween. A heat radiating member 150 that dissipates heat from the bus bar 130 is disposed on the lower surface of the bus bar 130. An insulating layer 160 is interposed between the bus bar 130 and the heat radiating member 150 to enhance electrical insulation between them.

[Function and effect]
According to the coil structure 1A according to the first embodiment, the following effects can be obtained.

  (1) Since it is easy to reduce the height size of the magnetic core 2, it is possible to construct the circuit structure 100 having a low height and a small overall volume. This is because the coil 3 is a planar coil in which each turn is located on the same plane, so that the height of the magnetic core 2 can be reduced. In addition, since the total width of the inner conductor portion 31 is small, the width of the magnetic core can be reduced.

  (2) It is easy to improve heat dissipation. This is because the total width of the outer conductor portions 32 arranged on the heat radiating member 5 is large, so that the heat radiating area can be easily increased. In addition, since the total width of the outer conductor portion 32 is larger than the total width of the inner conductor portion 31, the heat of the inner conductor portion 31 that is more likely to generate heat is less likely to generate heat and the heat dissipation area can be increased. It is because it is easy to diffuse.

  (3) The productivity of the circuit structure 100 can be increased. Since the coil 3 is constituted by a part of the bus bar 130, the coil 3 can be manufactured simultaneously with the production of the bus bar 130 by punching one flat conductor into a desired wiring pattern, and the coil 3 and the bus bar 130 are individually prepared. There is no need to do. And the circuit structure 100 can be manufactured simultaneously with manufacture of the coil structure 1A only by assembling the magnetic core 2 to the coil 3 of the bus bar 130. That is, it is not necessary to mount the magnetic core 2 and the coil 3 constituting the coil structure 1A on the bus bar 130 after preparing and combining them.

<< Modification 1-1 >>
With reference to FIG. 4, the coil structure which concerns on the modification 1-1 is demonstrated. The coil structure according to Modification 1-1 is that the interposition member 4 interposed between the magnetic core 2 and the coil 3 includes a conductor piece 46 that contacts the inner conductor portion 31. Mainly different from the structure 1A. Hereinafter, the description will focus on the differences, and the description of the same configuration and the same effect will be omitted. This is the same in the modified example 1-2 and the second embodiment described later. FIG. 4 is a cross-sectional view showing a state where the coil structure is cut at the same position as the cross-sectional view shown in FIG. 3, and the circuit board is omitted as in FIG.

[Intervening member]
The interposition member 4 includes an upper divided piece 41 and a lower divided piece 42 similar to those in the first embodiment. The lower divided piece 42 includes a conductor piece 46 that is housed in the recess 45 and contacts the inner conductor portion 31. Thereby, the cross-sectional area of the conductor arrange | positioned inside the magnetic core 2 can be enlarged, making the size of the magnetic core 2 small. Therefore, since the thickness is large even if the width of the conductor is small, a sufficient cross-sectional area for energization can be secured, and the amount of heat generated by the inner conductor portion 31 and the conductor piece 46 disposed in the magnetic core 2 can be further reduced. The depth of the recess 45 can accommodate the inner conductor portion 31 and the conductor piece 46, that is, the projecting length of the intervening convex portion 43 and the outer convex portion 44 that form the concave portion 45 is the inner conductor portion 31 and the conductor piece 46. The length is equivalent to the total height. The formation region of the conductor piece 46 is preferably a region extending over the entire length in the axial direction of the magnetic core 2 in the lower divided piece 42. The conductor piece 46 may be made of the same material as that of the inner conductor portion 31. The conductor piece 46 may be fixed to the recess 45 of the lower divided piece 42 with an adhesive or the like. The conductor piece 46 and the inner conductor portion 31 are preferably joined while ensuring conductivity by soldering or the like.

<< Modification 1-2 >>
A coil structure 1A according to Modification 1-2 will be described with reference to FIGS. The coil structure 1A according to the modified example 1-2 is mainly different from the coil structure 1A according to the first embodiment in that the coil 3 has a step portion formed in a step shape. 5 and 6, the circuit board is omitted.

[coil]
The coil 3 has a conductor recess 35 formed so that the inner conductor portion 31 (the central portion and the both end portions) and a part of the orthogonal portion of the outer conductor portion 32 are recessed on the lower surface side. That is, the coil 3 (each turn) includes a portion located on the same plane as the other portion 131 of the bus bar 130 and a conductor concave portion 35 located so as to be shifted in the vertical direction with respect to the other portion 131 of the bus bar 130. The boundary between the portion of the coil 3 on the same plane as the other portion 131 of the bus bar 130 and the conductor recess 35 is between the parallel portion of the innermost circumference of the coil 3 and the inner conductor portion 31 of the innermost circumference of the coil 3. There is an interval. Here, the position is located between the parallel portion of the innermost periphery of the coil 3 and the housing recess 51 of the heat radiating member 5. Although the depth (length along the vertical direction) of the conductor recess 35 depends on the thickness of the heat radiating member 5, the depth of the magnetic core 2 in the circuit structure 100 can be reduced as the depth increases. Therefore, the circuit structure 100 having a low height and a small overall volume can be constructed. The conductor recess 35 can be formed by performing a press process after the above-described flat plate conductor is punched.

[Heat dissipation member]
The heat radiating member 5 has a heat radiating recess 52 along the conductor recess 35 in addition to the housing recess 51. The depth of the storage recess 51 is increased by the depth of the conductor recess 35. Therefore, the height of the magnetic core 2 in the circuit structure 100 can be reduced. Depending on the thickness of the heat dissipating member 5 and the height of the magnetic core 2, the upper surface of the magnetic core 2 can be at the same position as or lower than the upper surface of the jumper chip 180. The depth of the heat radiating recess 52 is equal to the depth of the conductor recess 35 in this example. Between the heat radiation recess 52 and the conductor recess 35, an insulating recess 61 of the insulating layer 6 described later is interposed. Therefore, no space is formed between the heat radiation recess 52 and the conductor recess 35, and the heat of the coil 3 can be transmitted to the heat radiation member 5 through the insulating layer 6, so that the heat radiation performance does not deteriorate.

[Insulation layer]
The insulating layer 6 has an insulating recess 61 interposed between the conductor recess 35 of the coil 3 and the heat dissipation recess 52 of the heat dissipation member 5. The depth of the insulating recess 61 is equal to the depth of the conductor recess 35. The insulating recess 61 fills the gap between the conductor recess 35 and the heat dissipation recess 52 without any gap.

<< Embodiment 2 >>
[Coil structure]
A coil structure 1B according to Embodiment 2 will be described with reference to FIGS. The coil structure 1B according to the second embodiment is mainly different from the coil structure 1A according to the first embodiment in that the coil 3 is configured by a part of the circuit pattern 111 provided on the circuit board 110 in the circuit structure 100. . The coil 3 (circuit board 110) is disposed on the heat dissipation member 5 without a bus bar. In addition, the coil 3 (circuit board 110) may be arrange | positioned on the thermal radiation member 5 via the bus bar.

  The coil 3 includes a spiral circuit pattern 111 formed on the upper surface of the circuit board 110. The circuit pattern 111 is made of copper foil. The coil 3 is a planar coil in which each turn is located on the same plane as the other part 111 a of the circuit pattern 111 of the circuit board 110. The thickness of the coil 3 is 20 μm or more and 150 μm or less, for example, similar to the thickness of the circuit pattern of the first embodiment.

  The circuit board 110 is formed with a through hole 113 through which a part of the magnetic core 2 is inserted (FIG. 8). Here, the number of the through holes 113 is one, and one leg portion of the upper core portion 21 having a U-shaped cross section is inserted. A portion of the circuit board 110 where the inner conductor portion 31 is provided is disposed inside the magnetic core 2 together with the inner conductor portion 31. Note that the number of through holes 113 may be a number (two) that matches the number of legs of the magnetic core 2, and both legs of the magnetic core 2 may be inserted.

  Here, the coil structure 1 </ b> B does not include an interposition member interposed between the magnetic core 2 and the coil 3. Since the circuit board 110 has a certain degree of rigidity, the inner conductor portion 31 can be arranged on the inner side of the magnetic core 2 without contacting the inner peripheral surface without providing an intervening member. This is because it is easy to ensure insulation between them. Of course, you may provide the interposed member. In that case, the interposed member may include only the upper divided piece on the exposed side of the circuit pattern 111 or may include both upper and lower divided pieces.

[Function and effect]
According to the coil structure 1 </ b> B according to the second embodiment, the foil-like circuit pattern 111 is configured by the upper core portion 21 and the lower core portion 22 because the foil-like circuit pattern 111 can be easily reduced in width and thickness as compared with the plate-like bus bar 130. Can reduce the internal space. Therefore, it is easy to further reduce the size of the magnetic core 2, and it is possible to construct the circuit structure 100 having a low height and a small overall volume.

  The present invention is not limited to these exemplifications, but is defined by the scope of the claims, and is intended to include all modifications within the scope and meaning equivalent to the scope of the claims. For example, the interposition member can be configured by a part of the insulating layer. In that case, a through hole is formed instead of a notch in the insulating layer to form a portion arranged in the magnetic core. At this time, the height of the lower core portion may be a height at which the upper surface and the insulating layer are in contact with each other.

DESCRIPTION OF SYMBOLS 1A, 1B Coil structure 2 Magnetic core 21 Upper core part 22 Lower core part 3 Coil 31 Inner conductor part 32 Outer conductor part 33 Inner peripheral edge part 34 Outer peripheral edge part 35 Conductive recessed part 4 Interposition member 41 Upper divided piece 42 Lower side Dividing piece 43 Intervening convex part 44 Outer convex part 45 Concave part 46 Conductor piece 5 Heat radiation member 51 Storage concave part 52 Thermal radiation concave part 6 Insulating layer 61 Insulating concave part 100 Circuit component 110 Circuit board 111 Circuit pattern 111a Other part 112 Opening part 113 Through hole 130 Bus bar 131 Other parts 150 Heat radiation member 160 Insulating layer 180 Jumper chip

Claims (5)

An annular magnetic core;
A coil having a spiral conductor, an inner conductor portion disposed inside the magnetic core, and an outer conductor portion disposed outside the magnetic core;
A coil structure in which a total width of the inner conductor portion is smaller than a total width of the outer conductor portion.   The coil structure according to claim 1, wherein a width of the largest inner conductor portion is smaller than a width of the smallest outer conductor portion.   The said coil is a coil structure of Claim 1 or Claim 2 comprised by a part of plate-shaped bus bar arrange | positioned at the lower surface of a circuit board.   The coil structure according to claim 1 or 2, wherein the coil includes a part of a foil-like circuit pattern formed on an upper surface of a circuit board. A heat dissipating member disposed on one side of the coil to dissipate heat of the coil;
The coil structure according to any one of claims 1 to 4, wherein the heat radiating member includes a housing recess that houses a part of the magnetic core.

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