JP2020188150A - Inductor and manufacturing method thereof - Google Patents

Abstract

To provide an inductor and a manufacturing method thereof which can suppress an increase in the size of parts and an increase in the resistance value of a conductor pattern.SOLUTION: An inductor includes a first conductor pattern layer 20 having first and second conductor patterns 22 and 23 having linear portions 22a and 23a extending in one direction, and a second conductor pattern layer 30 having third and fourth conductor patterns 32 and 33 having linear portions 32a and 33a extending in one direction. Further, in the normal direction with respect to one surface of a magnetic core 10, the linear portion 22a formed on the first conductor pattern layer 20 and the linear portion 32a formed on the second conductor pattern layer 30 are alternately arranged on the same line. Then, these alternately arranged ones are electrically connected via a first terminal 41.SELECTED DRAWING: Figure 5A

Description

The present invention relates to an inductor and a method for manufacturing the inductor.

Conventionally, Patent Document 1 has proposed a sheet-shaped inductor having a magnetic core and a coil. This inductor penetrates a magnetic core in which a molded sheet of a mixture containing a flat metal powder having a two-dimensionally oriented soft magnetism and a binder is laminated, a surface conductor provided on the front and back surfaces of the magnetic core, and the magnetic core. It is configured to have a via conductor that connects the conductors. By using an inductor with such a configuration, it is possible to improve the magnetic characteristics and reliability, reduce the electrical resistance, and simplify the manufacturing method.

Japanese Unexamined Patent Publication No. 2013-243330

The inductor of Patent Document 1 described above is configured by directly forming a surface conductor on the front and back surfaces of the magnetic core, or by adhering a laminated resin substrate having a surface conductor formed on one side to the front and back surfaces of the magnetic core.

However, with such a method, the conductor can be formed only on two planes, and it is difficult to secure a large number of turns. That is, when trying to obtain a desired inductance, if the number of turns is small, it is necessary to increase the cross-sectional area of the magnetic core, that is, the area of the surface through which the magnetic flux penetrates. Therefore, if the number of turns is small, the body size of the component becomes large.

Further, in the inductor of Patent Document 1, in order to form a coil, one of the conductor patterns on the two planes is made into a conductor pattern in which a current flows perpendicular to the magnetic flux, and the other is tilted with respect to the magnetic flux. It is necessary to make a conductor pattern in which current flows in the direction. The tilted conductor pattern has a longer wiring length than the conductor pattern in which a current flows perpendicular to the magnetic flux. This causes a problem that the resistance value of the conductor pattern becomes large when applied to a magnetic part having a large number of coils and magnetic legs, in addition to causing an increase in the size of the part.

In view of the above points, it is an object of the present invention to provide an inductor capable of suppressing an increase in the size of a component and an increase in a resistance value of a conductor pattern, and a method for manufacturing the inductor.

In order to achieve the above object, the inductor according to claim 1 is composed of a flat magnetic member (11) having one surface and another surface, and has a plurality of openings (11) penetrating from one surface to the other surface. By forming 12) side by side in one direction, the magnetic core (10) is composed of a plurality of magnetic legs (13) extending in the direction perpendicular to one direction, and the magnetic core is arranged on one side of the magnetic core to provide first insulation. Other than the first conductor pattern layer (20) in which the layer (21) and the conductor pattern (22, 23) having the linear portions (22a, 23a) extending in one direction are formed, and the magnetic core. A second conductor pattern layer in which a second insulating layer (31) arranged on the surface side and a conductor pattern (32, 33) having a linear portion (32a, 33a) extending in one direction are formed. (30) and a connection terminal (40) for electrically connecting the conductor pattern formed in the first conductor pattern layer and the conductor pattern formed in the second conductor pattern layer through the opening. In the normal direction with respect to the one surface, the linear portion of the conductor pattern formed on the first conductor pattern layer and the linear portion of the conductor pattern formed on the second conductor pattern layer are alternately arranged on the same line. The alternately arranged ones are electrically connected via the connection terminal.

In such a configuration, the linear portion of the conductor pattern on the first conductor pattern layer side and the linear portion of the conductor pattern of the second conductor pattern layer are connected through the connection terminal. Then, the connection form of being connected to the linear portion of the conductor pattern of the first conductor pattern layer again through the connection terminal is repeated. Therefore, a current is passed through a structure in which the magnetic legs are woven by the linear portion of the conductor pattern of the first conductor pattern layer, the linear portion of the conductor pattern of the second conductor pattern layer, and the connection terminals. .. Therefore, a magnetic flux according to the right-handed screw rule is generated in the magnetic core, and power conversion becomes possible.

In such a configuration, only the conductor pattern perpendicular to the magnetic flux is required, and it is not necessary to tilt the conductor pattern. Therefore, the wiring length can be shortened, the increase in the size of the component can be suppressed, and the increase in the resistance value of the conductor pattern can be suppressed.

In the method for manufacturing an inductor according to claim 6, a plurality of openings (12) formed of a flat plate-shaped magnetic member (11) having one surface and another surface and penetrated from one surface to the other surface are one. A magnetic core (10) having a plurality of magnetic legs (13) extending in a direction perpendicular to one direction by being formed side by side in a direction is prepared, and the magnetic core is arranged on one surface side of the magnetic core. A first conductor pattern layer in which an insulating layer (21) and a conductor pattern (22, 23) having a linear portion (22a, 23a) extending in one direction and a connecting portion (22b, 23b) are formed. (20) is prepared, and the second insulating layer (31), which is arranged on the other surface side of the magnetic core, the linear portions (32a, 33a) extending in one direction, and the connecting portion (32b,) The second conductor pattern layer (30) in which the conductor pattern (32, 33) having 33b) is formed is prepared, and the conductor pattern and the second conductor pattern formed in the first conductor pattern layer through the opening are prepared. A connection terminal (40) composed of a columnar member that electrically connects the conductor pattern formed in the layer is prepared.

Then, the first conductor pattern layer and the second conductor pattern layer are arranged on one surface and the other surface of the magnetic core, and through the opening, at least one of the connecting portion of the first conductor pattern layer and the connecting portion of the second conductor pattern layer. After inserting the connection terminal into the formed through hole, the connection portion where the through hole is formed and the connection terminal are connected by using solder (61 to 64), so that the first surface is normal to one surface. The linear portion of the conductor pattern formed on the first conductor pattern layer and the linear portion of the conductor pattern formed on the second conductor pattern layer are alternately arranged on the same line, and the alternately arranged ones are arranged. Connect electrically at the connection terminal.

The inductor according to claim 1 can be manufactured by such a manufacturing method.

The method for manufacturing an inductor according to claim 9 has a first insulating layer (21) having one surface and another surface, and a linear portion (22a) extending in one direction on one surface side of the first insulating layer. A first conductor pattern layer comprising a first conductor pattern (22) and a second conductor pattern (23) having a linear portion (23a) extending in one direction on the other surface side of the first insulating layer. By forming (20) and forming a magnetic film on the second conductor pattern and then patterning, a plurality of openings (12) are formed side by side in one direction with respect to the one direction. By forming a magnetic core (10) in which a plurality of magnetic legs (13) extending in the vertical direction are formed, and by forming a conductor layer on the magnetic core and then patterning it, it extends in the above-mentioned one direction. A third conductor pattern (32) having the formed linear portion (32a) is formed, a second insulating layer (31) is formed on the third conductor pattern, and a conductor is further formed on the second insulating layer. By forming a layer and then patterning it, a fourth conductor pattern (33) having a linear portion (33a) extending in one direction is formed, and a second conductor pattern layer (30) is formed. And do.

After that, a first hole (81) from the first conductor pattern to the third conductor pattern is formed by drilling, and a second hole (82) from the fourth conductor pattern to the second conductor pattern is formed. And, the first terminal (41) for electrically connecting the first conductor pattern and the third conductor pattern is formed in the first hole, and the fourth conductor pattern and the second conductor pattern are electrically connected in the second hole. To form the second terminal (42) to be used.

According to such a manufacturing method, the inductor according to claim 3 can be manufactured.

The reference reference numerals in parentheses attached to each component or the like indicate an example of the correspondence between the component or the like and the specific component or the like described in the embodiment described later.

It is a perspective view of the inductor which concerns on 1st Embodiment. It is a top view of the magnetic core. It is a top view which showed the layout of the 1st conductor pattern in the 1st conductor pattern layer. It is a top view which showed the layout through the 2nd conductor pattern in the 1st conductor pattern layer. It is a top view which showed the layout of the 3rd conductor pattern in the 2nd conductor pattern layer. It is a top view which showed the layout through the 4th conductor pattern in the 2nd conductor pattern layer. It is a figure which showed one surface of the 1st conductor pattern layer on the upper surface side where the 1st conductor pattern was formed, and is the top view which showed the layout by showing the 2nd conductor pattern by the broken line. It is the figure which showed one surface of the 2nd conductor pattern layer on the upper surface side where the 3rd conductor pattern was formed, and is the top view which showed the layout by showing the 4th conductor pattern by a broken line. It is a top view which showed the layout of the 1st conductor pattern shown by a solid line, and the 3rd conductor pattern shown by a broken line by superimposing the 1st conductor pattern layer and the 2nd conductor pattern layer. It is a top view which showed the layout of the 2nd conductor pattern shown by a solid line and the 4th conductor pattern shown by a broken line by superimposing the 1st conductor pattern layer and the 2nd conductor pattern layer. It is sectional drawing of VA-VA in FIG. It is a cross-sectional view of VB-VB in FIG. FIG. 5 is a sectional view taken along line VC-VC in FIG. It is a cross-sectional view of VD-VD in FIG. It is a figure which shows typically the flow of the electric current and the magnetic flux in the 1st conductor pattern and the 3rd conductor pattern when the inductor of 1st Embodiment is seen from the upper surface. It is a figure which shows typically the flow of the electric current and the magnetic flux in the 2nd conductor pattern and the 4th conductor pattern when the inductor of 1st Embodiment is seen from the upper surface. FIG. 5 is a cross-sectional view of the inductor according to the second embodiment, which is a cross-sectional view of a portion corresponding to the VA-VA cross section in FIG. FIG. 5 is a cross-sectional view of the inductor according to the second embodiment, which is a cross-sectional view of a portion corresponding to the VC-VC cross section in FIG. It is a figure which shows typically the flow of the electric current and the magnetic flux in the 1st conductor pattern and the 3rd conductor pattern when the inductor of 3rd Embodiment is seen from the upper surface. It is a figure which shows typically the flow of the electric current and the magnetic flux in the 2nd conductor pattern and the 4th conductor pattern when the inductor of 3rd Embodiment is seen from the upper surface. It is sectional drawing of IXA-IXA in FIG. 8A. It is sectional drawing of IXB-IXB in FIG. 8B. It is a figure which shows typically the flow of the electric current and the magnetic flux in the 1st conductor pattern and the 3rd conductor pattern when the inductor of 4th Embodiment is seen from the upper surface. It is a figure which shows typically the flow of the electric current and the magnetic flux in the 2nd conductor pattern and the 4th conductor pattern when the inductor of 4th Embodiment is seen from the upper surface. 10A and 10B are cross-sectional views taken along the line XIA-XIA. 10A and 10B are cross-sectional views taken along the line XIB-XIB. It is sectional drawing which showed the state in the manufacturing process of the inductor described in 5th Embodiment. It is sectional drawing which showed the state in the manufacturing process of the inductor following FIG. 12A. It is sectional drawing which showed the state of the connection process in the manufacturing process of the inductor described in 6th Embodiment. It is sectional drawing which showed the state of the connection process in the manufacturing process of the inductor following FIG. 13A. It is sectional drawing which showed the manufacturing process of the inductor described in 7th Embodiment. It is sectional drawing which showed the manufacturing process of the inductor following FIG. 4A. It is sectional drawing which showed the manufacturing process of the inductor following FIG. 4B. It is sectional drawing which showed the manufacturing process of the inductor following FIG. 4C. It is sectional drawing which showed the manufacturing process of the inductor following FIG. 4D. It is sectional drawing which showed the manufacturing process of the inductor following FIG. 4E. It is sectional drawing which showed the manufacturing process of the inductor following FIG. 4F. It is sectional drawing which showed the manufacturing process of the inductor following FIG. 4G. It is sectional drawing which showed the manufacturing process of the inductor following FIG. 4H. It is sectional drawing which showed the manufacturing process of the inductor following FIG. 4I.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. In each of the following embodiments, parts that are the same or equal to each other will be described with the same reference numerals.

(First Embodiment)
The inductor according to the first embodiment will be described. The inductor described here is used, for example, as an inductor provided in a power converter in an electric vehicle or the like in a vehicle.

The inductor 100 shown in FIG. 1 has electricity between the flat magnetic core 10 and the conductor pattern layers 20 and 30 and both conductor pattern layers 20 and 30 arranged on one side and the opposite side of the magnetic core 10. It has a connection terminal 40 for making a target connection. The magnetic core 10 and the both conductor pattern layers 20 and 30 have a rectangular shape with the upper surface shape having one direction as the longitudinal direction. In the following, the longitudinal direction of the magnetic core 10 and the like is the x direction, the lateral direction is the y direction, and the thickness direction of the magnetic core 10, that is, the normal direction with respect to one surface of the magnetic core 10 and one surfaces of the conductor pattern layers 20 and 30 is the z direction. It is explained as.

As shown in FIG. 2, the magnetic core 10 is composed of a flat plate-shaped magnetic member 11 having one surface and the other surface. The magnetic member 11 is formed with a plurality of openings 12 penetrating from one surface to the other, and the plurality of openings 12 are arranged side by side in the x direction so that the plurality of magnetic legs 13 extending in the y direction are formed. It is said to be a formed structure. Here, nine magnetic legs 13 are formed by forming the eight openings 12. Of the magnetic legs 13, those located inside are thicker than those located at both ends. Although the number of magnetic legs 13 is set to 9 here, this number is arbitrary and may be 2 or more.

The conductor pattern layer 20 corresponds to the first conductor pattern layer, and as shown in FIGS. 1, 3A and 3B, one surface opposite to the magnetic core 10 is the upper surface, and one surface on the magnetic core 10 side is the lower surface. , A conductor pattern is formed on at least one of them. The conductor pattern layer 20 is assumed to have a conductor pattern formed on an insulating layer 21 such as a resin corresponding to the first insulating layer. In the case of the present embodiment, the first conductor pattern 22 is formed on the upper surface side of the insulating layer 21, and the second conductor pattern 23 is formed on the lower surface side.

As shown in FIG. 3A, the first conductor pattern 22 has a configuration having a plurality of linear portions 22a having the x direction as the longitudinal direction. A plurality of linear portions 22a are arranged on each of the plurality of lines extending in the x direction. In adjacent lines, linear portions 22a are provided alternately. In other words, if the plurality of linear portions 22a are arranged in a staggered pattern and the portion of the insulating layer 21 where the linear portion 22a is not arranged is a non-arranged portion 21a, the linear portions 22a are arranged on each line. And the non-arranged portion 21a are alternately repeated. Then, in the adjacent lines, the order of the linear portion 22a and the non-arranged portion 21a is reversed.

Further, on both sides of each linear portion 22a in the x direction, connecting portions 22b for electrical connection with other conductor patterns are provided. Except for the two linear portions 22a of each line arranged at both ends in the x direction, one is connected to each side of each linear portion 22a in the longitudinal direction so as to project from each linear portion 22a in the x direction. A portion 22b is provided. Then, the connecting portions 22b provided at both ends of each linear portion 22a are arranged so as to be closer to one side of the linear portion 22a in the lateral direction and above the paper surface in FIG. 3A.

Further, in the case where one end of the linear portion 22a of each line in the x direction, that is, the one arranged at the right end of the paper surface in FIG. 3A, the connecting portion 22b of the end located inward of the conductor pattern layer 20 is linear. It is provided so as to project from the portion 22a in the x direction. The connecting portion 22b at the end of the linear portion 22a located on the outer side of the conductor pattern layer 20 is arranged in the linear portion 22a.

Further, in the case where the other end of the linear portion 22a of each line in the x direction, that is, the one arranged at the left end of the paper surface in FIG. 3A, the connecting portion 22b at the end located inward of the conductor pattern layer 20 is a straight line. It is provided so as to project from the shape portion 22a in the x direction. The connecting portion 22b of the end portion of the linear portion 22a located on the outer side of the conductor pattern layer 20 is provided at the tip of the protruding portion 22c protruding from the linear portion 22a in one direction in the y direction. Therefore, at the position of the other end in the x direction, the first conductor pattern 22 is L-shaped by the linear portion 22a and the drawer portion 22c.

Further, the first conductor pattern 22 is provided with a first pad 22d at a position on the upper left of the paper surface of FIG. 3A. An electrical connection with the outside can be achieved through the first pad 22d.

As shown in FIG. 3B, the second conductor pattern 23 also has a configuration having a plurality of linear portions 23a having the x direction as the longitudinal direction. A plurality of linear portions 23a are arranged on each of a plurality of lines extending in the x direction. In adjacent lines, linear portions 23a are provided alternately. In other words, if the plurality of linear portions 23a are arranged in a staggered pattern and the portion of the insulating layer 21 in which the linear portion 23a is not arranged is a non-arranged portion 21n, the linear portion 23a is on each line. And the non-arranged portion 21b are alternately repeated. Then, in the adjacent lines, the order of the linear portion 23a and the non-arranged portion 21b is reversed.

Further, on both sides of each linear portion 23a in the x direction, connecting portions 23b for electrical connection with other conductor patterns are provided. The connecting portion 23b is a through-hole via that penetrates the insulating layer 21 and is provided up to one side on which the first conductor pattern 22 is arranged, but it does not have to be a through-hole via. Except for the two linear portions 23a of each line arranged at both ends in the x direction, one is connected to each side of each linear portion 23a in the longitudinal direction so as to project from each linear portion 23a in the x direction. A portion 23b is provided. Then, the connecting portions 23b provided at both ends of each linear portion 23a are moved to the other side of the linear portion 23a in the lateral direction, that is, in the direction opposite to the first conductor pattern 22, that is, in FIG. 3B, downward on the paper surface. Have been placed.

Further, in the case where one end of the linear portion 23a of each line in the x direction, that is, the one arranged at the right end of the paper surface in FIG. 3B, the connecting portion 23b of the end located inward of the conductor pattern layer 20 is linear. It is provided so as to project from the portion 23a in the x direction. The connecting portion 23b of the end portion of the linear portion 23a located on the outer side of the conductor pattern layer 20 is provided at the tip of the protruding portion 23c protruding from the linear portion 23a in one direction in the y direction. Therefore, at the position of one end in the x direction, the second conductor pattern 23 is L-shaped by the linear portion 23a and the drawer portion 23c. As shown in FIG. 4A, at the position of the right end of the paper surface, the linear portion 23a is longer than the linear portion 22a, and the drawer portion 23c is arranged so as not to overlap the linear portion 22a.

Further, the other end of the linear portion 23a of each line in the x direction, that is arranged at the left end of the paper surface in FIG. 3B, has one connecting portion 23b on both sides in the longitudinal direction of the linear portion 23a. It is provided so as to project from the shaped portion 23a in the x direction. The connecting portion 23b at the end of the linear portion 23a located on the outer side of the conductor pattern layer 20 has a long overhang length from the linear portion 23a, and as shown in FIG. 4A, the left end of the paper surface. At the position, it protrudes from the linear portion 22a.

As described above, the second conductor pattern 23 has the same configuration as the first conductor pattern 22, but has a layout in which the first conductor pattern 22 is substantially inverted. That is, the linear portion 22a of the first conductor pattern 22 and the non-arranged portion 21b on the lower surface side on which the second conductor pattern 23 is arranged face each other. On the contrary, the linear portion 23a of the second conductor pattern 23 and the non-arranged portion 21a on the upper surface side where the first conductor pattern 22 is arranged face each other. In FIG. 4A, the connecting portion 22b is moved to the upper side of the paper surface and the connecting part 23b is moved to the lower side of the paper surface, so that the connecting portion 22b and the connecting portion 23b are arranged at different positions in the y direction.

The conductor pattern layer 30 corresponds to the second conductor pattern layer, and has a conductor pattern formed on at least one of them, with one surface on the magnetic core 10 side as the upper surface and one surface on the opposite side of the magnetic core 10 as the lower surface. .. The conductor pattern layer 30 is said to have a conductor pattern formed on an insulating layer 31 such as a resin corresponding to the second insulating layer. In the case of the present embodiment, the third conductor pattern 32 is formed on the upper surface side of the insulating layer 31, and the fourth conductor pattern 33 is formed on the lower surface side.

As shown in FIG. 3C, the third conductor pattern 32 also has a configuration having a plurality of linear portions 32a having the x direction as the longitudinal direction. A plurality of linear portions 32a are arranged on each of the plurality of lines in the x direction. In adjacent lines, linear portions 32a are provided alternately. In other words, if the plurality of linear portions 32a are arranged in a staggered pattern and the portion of the insulating layer 31 where the linear portion 32a is not arranged is a non-arranged portion 31a, the linear portions 32a are arranged on each line. And the non-arranged portion 31a are alternately repeated. Then, in the adjacent lines, the order of the linear portion 32a and the non-arranged portion 31a is reversed.

Further, on both sides of each linear portion 32a in the x direction, connecting portions 32b for making an electrical connection with another conductor pattern are provided. The connecting portion 32b is a through-hole via that penetrates the insulating layer 31 and is provided up to one side on which the fourth conductor pattern 33 is arranged, but it does not have to be a through-hole via. Of the linear portions 32a of each line, except for the two arranged at both ends in the x direction, one is connected to each side of each linear portion 32a in the longitudinal direction so as to project from each linear portion 32a in the x direction. A portion 32b is provided. Then, the connecting portions 32b provided at both ends of each linear portion 32a are arranged so as to be closer to one side of the linear portion 32a in the lateral direction, in the case of FIG. 3C, above the paper surface.

Further, in the case where one end of the linear portion 32a of each line in the x direction, that is, the one arranged at the right end of the paper surface in FIG. 3C, the connecting portion 32b of the end located inward of the conductor pattern layer 30 is linear. It is provided so as to project from the portion 32a in the x direction. The connecting portion 32b of the end portion of the linear portion 32a located on the outer side of the conductor pattern layer 20 is provided at the tip of the protruding portion 32c protruding from the linear portion 32a in one direction in the y direction. Therefore, at the position of one end in the x direction, the third conductor pattern 32 is L-shaped by the linear portion 32a and the drawer portion 32c. As shown in FIG. 4B, at the position at the right end of the paper surface, the linear portion 32a is longer than the linear portion 33a described later, and the drawer portion 32c is arranged so as not to overlap the linear portion 33a. There is.

Further, in the other end of the linear portion 32a of each line in the x direction, that is arranged at the left end of the paper surface in FIG. 3C, the connecting portion 32b at the end located inward of the conductor pattern layer 30 is a straight line. It is provided so as to project from the shaped portion 32a in the x direction. The connecting portion 32b at the end of the linear portion 32a located on the outer side of the conductor pattern layer 30 is arranged in the linear portion 32a.

As described above, the third conductor pattern 32 has the same configuration as the first conductor pattern 22, but has a layout in which the first conductor pattern 22 is substantially inverted as shown in FIG. 4C. That is, the non-arranged portion 31a on the upper surface side where the third conductor pattern 32 is arranged and the linear portion 22a of the first conductor pattern 22 face each other. On the contrary, the non-arranged portion 21a on the upper surface side where the first conductor pattern 22 is arranged and the linear portion 32a of the third conductor pattern 32 face each other. Regarding the connecting portion 22b and the connecting portion 32b, the connecting portion 22b is moved above the paper surface in FIG. 3A, and the connecting part 32b is also moved above the paper surface in FIG. 3C so that they match in the y direction and overlap each other in the z direction. .. Further, as shown in FIG. 4C, when viewed from the z direction, both the linear portion 22a and the linear portion 32a are arranged on a plurality of lines, and at the left end in the drawing, each linear portion 32a is an adjacent line. It overlaps with the drawer portion 22c provided in the linear portion 22a of the above. Similarly, at the right end in the drawing, each linear portion 22a overlaps with a drawer portion 32c provided in the linear portion 32a of the adjacent line.

As shown in FIG. 3D, the fourth conductor pattern 33 has a configuration having a plurality of linear portions 33a having the x direction as the longitudinal direction. A plurality of linear portions 33a are arranged on each of the plurality of lines in the x direction. In adjacent lines, linear portions 33a are provided alternately. In other words, if the plurality of linear portions 33a are arranged in a staggered pattern and the portion of the insulating layer 31 where the linear portion 33a is not arranged is a non-arranged portion 31b, the linear portions 33a are arranged on each line. And the non-arranged portion 31b are alternately repeated. Then, in the adjacent lines, the order of the linear portion 33a and the non-arranged portion 31b is reversed.

Further, on both sides of each linear portion 33a in the x direction, connecting portions 33b for electrical connection with other conductor patterns are provided. Except for two of the linear portions 33a of each line arranged at both ends in the x direction, one is connected to each side of each linear portion 33a in the longitudinal direction so as to project from each linear portion 33a in the x direction. A portion 33b is provided. Then, the connecting portions 33b provided at both ends of each linear portion 33a are arranged so as to be closer to one side of the linear portion 33a in the lateral direction, which is lower than the paper surface in FIG. 3D.

Further, one of the linear portions 33a of each line arranged in the x direction, that is, the one arranged at the right end of the paper surface in FIG. 3D, has one connecting portion 33b on both sides in the longitudinal direction of the linear portion 32a. It is provided so as to project from the portion 33a in the x direction. The connecting portion 33b at the end of the straight portion 33a located on the outer side of the conductor pattern layer 20 has a long overhang length from the linear portion 33a, and as shown in FIG. 4D, the right end of the paper surface. At the position, it protrudes from the linear portion 33a. However, in the line below the page of FIG. 3D, the linear portion 33a extends to the same position as the connecting portion 33b in the other lines. Therefore, at the lower right position on the paper surface of FIGS. 3A and 3D, the outer connecting portion 22b provided on the linear portion 22a and the outer connecting portion 33b provided on the linear portion 33a are in the z direction. Overlap in.

Further, in the case where the other end of the linear portion 33a of each line in the x direction, that is, the one arranged at the left end of the paper surface in FIG. 3D, the connecting portion 33b at the end located inward of the conductor pattern layer 20 is a straight line. It is provided so as to project from the shape portion 33a in the x direction. The connecting portion 33b of the end portion of the linear portion 33a located on the outer side of the conductor pattern layer 20 is provided at the tip of the protruding portion 33c protruding from the linear portion 33a in one direction in the y direction. Therefore, at the position of the other end in the x direction, the fourth conductor pattern 33 is L-shaped by the linear portion 33a and the drawer portion 33c.

Further, the fourth conductor pattern 33 is provided with a second pad 33d at a position on the upper left of the paper surface in FIG. 3D. An electrical connection with the outside can be achieved through the second pad 33d.

As described above, the fourth conductor pattern 33 has the same configuration as the third conductor pattern 32, but has a layout in which the third conductor pattern 32 is substantially inverted. That is, the linear portion 33a of the fourth conductor pattern 33 and the non-arranged portion 31b on the upper surface side on which the third conductor pattern 32 is arranged face each other. On the contrary, the linear portion 32a of the third conductor pattern 32 and the non-arranged portion 31a on the lower surface side on which the fourth conductor pattern 33 is arranged face each other. In FIG. 4B, the connecting portion 32b is moved to the upper side of the paper surface and the connecting part 32b is moved to the lower side of the paper surface, so that the connecting portion 33b and the connecting portion 32b are arranged at different positions in the y direction.

The fourth conductor pattern 33 has the same configuration as the second conductor pattern 23, but has a layout in which the second conductor pattern 23 is substantially inverted as shown in FIG. 4D. That is, the non-arranged portion 31b on the lower surface side on which the fourth conductor pattern 33 is arranged and the linear portion 23a of the second conductor pattern 23 face each other. On the contrary, the non-arranged portion 21b on the lower surface side on which the second conductor pattern 23 is arranged and the linear portion 33a of the fourth conductor pattern 33 face each other. As shown in FIG. 4D, the connecting portion 23b and the connecting portion 33b are aligned in the y direction and overlap each other in the z direction by moving the connecting portion 23b and the connecting portion 32b together below the paper surface. Further, as shown in FIG. 4D, when viewed from the z direction, both the linear portion 23a and the linear portion 33a are arranged on a plurality of lines, and at the right end in the drawing, each linear portion 33a is an adjacent line. It overlaps with the drawer portion 23c provided in the linear portion 23a of the above. Similarly, at the left end in the drawing, each linear portion 23a overlaps with a drawer portion 33c provided in the linear portion 33a of the adjacent line.

The connection terminal 40 is a terminal that makes an electrical connection between the conductor pattern layer 20 and the conductor pattern layer 30 and extends in the z direction. The connection terminal 40 has first terminals 41 to third terminals 43. The positions where the first terminals 41 to the third terminals 43 are arranged are the positions outside the opening 12 of the magnetic core 10 and the magnetic core 10. Then, the first terminals 41 to the third terminals 43 electrically connect the conductor pattern layer 20 and the conductor pattern layer 30 through the opening 12 and the outside of the magnetic core 10.

The first terminal 41 electrically connects the first conductor pattern 22 and the third conductor pattern 32. Specifically, as shown in FIGS. 4C, 5A and 5B, the connecting portions 22b and the connecting portions 32b, which are arranged so as to overlap in the z direction, are connected. As a result, the linear portion 22a of the first conductor pattern 22 and the linear portion 32a of the third conductor pattern 32 are connected through the first terminal 41, and then are connected to the linear portion 22a of the first conductor pattern 22 again. The connection form is repeated. In other words, the linear portion 22a and the linear portion 32a are alternately connected by the first terminal 41, and the magnetic legs 13 are woven by these. 5A and 5B are views showing the VA-VA cross section and the VB-VB cross section in FIG. 1, respectively, but the scales have been changed to make the figures easier to see.

Further, at one end in the x direction, at the left end in FIG. 4C, the lead-out portion 22c of the first conductor pattern 22 is pulled out to the adjacent line, so that the third conductor pattern 32 of the adjacent line is drawn through the first terminal 41. It is connected to the connecting portion 32b of. Further, at the other end in the x direction, at the right end in FIG. 4C, the lead-out portion 32c of the third conductor pattern 32 is pulled out to the adjacent line, so that the first conductor pattern of the adjacent line is drawn through the first terminal 41. It is connected to the connecting portion 22b of 22. Then, in the upper left of the paper surface of FIG. 4C, the linear portion 32a is connected to the first pad 22d through the first terminal 41.

Therefore, when viewed from above the paper surface of FIG. 4C, the first conductor pattern 22 and the third conductor pattern 32 are meanderingly connected to the left and right sides of the paper surface via the first terminal 41, and are connected from the upper left first pad 22d to the lower right. It is connected to the position of.

The second terminal 42 electrically connects the second conductor pattern 23 and the fourth conductor pattern 33. Specifically, as shown in FIGS. 4D, 5C and 5D, the connecting portion 23b and the connecting portion 33b which are overlapped and arranged in the z direction are connected. As a result, the linear portion 23a of the second conductor pattern 23 and the linear portion 33a of the fourth conductor pattern 33 are connected through the second terminal 42, and then are connected to the linear portion 23a of the second conductor pattern 23 again. The connection form is repeated. In other words, the linear portion 23a and the linear portion 33a are alternately connected by the second terminal 42, and the magnetic legs 13 are woven by these. Note that FIGS. 5C and 5D are views showing the VC-VC cross section and the VD-VD cross section in FIG. 1, respectively, but the scales have been changed to make the figures easier to see.

Further, at one end in the x direction, at the right end in FIG. 4D, the lead-out portion 23c of the second conductor pattern 23 is pulled out to the adjacent line, so that the fourth conductor pattern 33 of the adjacent line is drawn through the second terminal 42. It is connected to the connecting portion 33b of. Further, at the other end in the x direction, at the left end in FIG. 4D, the lead-out portion 33c of the fourth conductor pattern 33 is pulled out to the adjacent line, so that the second conductor pattern of the adjacent line is drawn through the second terminal 42. It is connected to the connecting portion 23b of 23. Then, in the upper left of the paper surface of FIG. 4D, the linear portion 23a is connected to the second pad 33d through the second terminal 42.

Therefore, when viewed from above the paper surface of FIG. 4D, the second conductor pattern 23 and the fourth conductor pattern 33 are connected to the left and right sides of the paper surface in a meandering manner via the second terminal 42, and are connected from the lower right position to the upper left second. It is connected to the pad 33d.

The third terminal 43 electrically connects the first conductor pattern 22 and the fourth conductor pattern 33 at the lower right of the paper surface of FIG. The connection point between the first conductor pattern 22 and the fourth conductor pattern 33 is a turning point. That is, in FIG. 4C, the first conductor pattern 22 and the third conductor pattern 32 are connected to the left and right in a meandering manner from the first pad 22d on the upper right to reach the turning position on the lower right, and the first conductor pattern is reached at the turning point. 22 and the fourth conductor pattern 33 are connected. Further, from there, the fourth conductor pattern 33 and the second conductor pattern 23 are connected in a meandering manner to the left and right to reach the second pad 33d on the upper left.

As described above, the inductor 100 according to the present embodiment is formed by forming a coil by the first to fourth conductor patterns 22, 23, 32, 33 and the connection terminal 40, and winding the coil around the magnetic core 10. Is configured. Subsequently, the operation and effect of the inductor 100 of the present embodiment will be described. Here, the inductor 100 of the present embodiment will be described with reference to FIGS. 6A and 6B which are simplified.

As described above, after the linear portion 22a of the first conductor pattern 22 and the linear portion 32a of the third conductor pattern 32 are connected through the first terminal 41, the linear portion 22a of the first conductor pattern 22 is again connected. The connection form of being connected to is repeated. Therefore, with the first pad 22d as the starting point, the magnetic legs 13 are woven by the first conductor pattern 22, the third conductor pattern 32, and the first terminal 41 as shown in FIGS. 5A and 5B. An electric current will be passed. As a result, when a current flows from the first pad 22d, as shown in FIG. 6A, a current flows from the front side of the paper surface to the other side of the paper surface in the opening 12 on the left side in the drawing, and the opening on the right side in the drawing. In No. 12, a current flows in the opposite direction. This is the same between all adjacent lines.

Therefore, in the opening 12 on the left side in FIG. 6A, a clockwise magnetic flux according to the right-handed screw rule is generated in the magnetic core 10 centering on the current from the front side of the paper surface to the other side of the paper surface. Further, in the opening 12 on the right side in FIG. 6A, a counterclockwise magnetic flux according to the right-handed screw rule is generated in the magnetic core 10 centering on the current from the other side of the paper surface to the front side of the paper surface. As a result, magnetic fluxes in the same direction are generated in the magnetic legs 13 located at the center in FIG. 6A, so that strong magnetic fluxes can be generated.

Similarly, the linear portion 23a of the second conductor pattern 23 and the linear portion 33a of the fourth conductor pattern 33 are connected through the second terminal 42, and then are connected to the linear portion 23a of the second conductor pattern 23 again. The connection form of being done is repeated. Therefore, as shown in FIGS. 5C and 5D, the magnetic leg 13 has a structure in which the magnetic leg 13 is woven by the second conductor pattern 23, the fourth conductor pattern 33, and the second terminal 42, and the current ends at the second pad 33d. Will be washed away. As a result, when a current flows from the second pad 33d, as shown in FIG. 6B, a current flows from the front side of the paper surface to the other side of the paper surface in the opening 12 on the left side in the figure, and the opening on the right side in the figure. In No. 12, a current flows in the opposite direction. This is the same between all adjacent lines.

Therefore, in the opening 12 on the left side in FIG. 6B, a clockwise magnetic flux according to the right-handed screw rule is generated in the magnetic core 10 centering on the current from the front side of the paper surface to the other side of the paper surface. Further, in the opening 12 on the right side in FIG. 6B, a counterclockwise magnetic flux according to the right-handed screw rule is generated in the magnetic core 10 centering on the current from the other side of the paper surface to the front side of the paper surface. As a result, a strong magnetic flux can be generated by generating magnetic fluxes in the same direction in the magnetic leg 13 located at the center in FIG. 6B.

In this way, the set of the first conductor pattern 22, the third conductor pattern 32, and the first terminal 41 and the set of the second conductor pattern 23, the fourth conductor pattern 33, and the second terminal 42 each generate magnetic flux in the same direction. It is generated. Therefore, the inductor 100 can be used to configure a power converter capable of performing efficient power exchange.

Then, in the inductor 100 having such a configuration, all the linear portions 22a, 23a, 32a, 33a of the first to fourth conductor patterns 22, 23, 32, 33 are arranged in the direction perpendicular to the magnetic flux. Therefore, it is not necessary to incline the conductor pattern with respect to the magnetic flux, and it is possible to reduce the dead space in the opening 12 where the connection terminal 40 is not arranged. Therefore, the wiring length can be shortened, the increase in the size of the component can be suppressed, and the increase in the resistance value of the conductor pattern can be suppressed.

Further, in the present embodiment, not only the set in which the first conductor pattern 22 and the third conductor pattern 33 are connected by the first terminal 41, but also the second conductor pattern 23 and the fourth conductor pattern 33 are connected by the second terminal 42. It also has a connected set. That is, the conductor pattern layers 20 and 30 are double-sided substrates having conductor patterns on both the front and back surfaces. It is not essential to have both of these sets, and even if only one of them is provided, the increase in the size of the component body and the increase in the resistance value of the conductor pattern due to the fact that the linear portions 22a, 23a, 32a, and 33a are not tilted are suppressed. Can be suppressed. However, by providing two sets, the line widths of the first to fourth conductor patterns 22, 23, 32, and 33 when the substrate area is the same as compared with the case where the conductor pattern is provided on only one side of the single-sided substrate. Can be expanded. Therefore, the first to fourth conductor patterns 22, 23, 32, and 33 can be made to have lower resistance, so that the above effect can be further obtained.

Further, if the number of turns of the coil per magnetic leg 13 is an even number, the winding start and winding end of the coil can be symmetrically positioned with the magnetic core 10 in between. Therefore, a set in which the first conductor pattern 22 and the third conductor pattern 33 are connected by the first terminal 41 and a set in which the second conductor pattern 23 and the fourth conductor pattern 33 are connected by the second terminal 42 are combined. It may be arranged symmetrically and can be easily implemented.

When the coil is wound so as to knit the magnetic leg 13 as in the present embodiment, the magnetic leg 13 is not wound all around once, but it is the opening 12 that contributes to the generation of the magnetic flux. It is a part of the connection terminal 40 through which a current flows so as to pass through. Therefore, the number of turns of the coil per one magnetic leg 13 referred to here means the number of connection terminals 40 penetrating the inside of the opening 12.

(Second Embodiment)
The second embodiment will be described. In this embodiment, the coil is changed to a multi-layer structure with respect to the first embodiment, and the other parts are the same as those in the first embodiment. Therefore, only the parts different from the first embodiment will be described.

As shown in FIGS. 7A and 7B, in the present embodiment, two conductor pattern layers 20 are laminated and arranged on one surface side of the magnetic core 10, and two conductor pattern layers 30 are laminated on the other surface side. It is arranged. The first conductor pattern 22 and the second conductor pattern 23 formed on the two conductor pattern layers 20 are the same as those in the first embodiment, and are the same patterns as each other. Further, the third conductor pattern 32 and the fourth conductor pattern 33 formed on the two conductor pattern layers 30 are also the same as those in the first embodiment, and are the same patterns as each other.

7A and 7B are cross-sectional views taken out from only a part of the inductor 100 of the present embodiment. FIG. 7A is a diagram corresponding to the VA-VA cross section in FIG. 1, but the scale has been changed to make the diagram easier to see. Further, FIG. 7B is a diagram corresponding to the VC-VC cross section in FIG. 1, but the scale is changed to make the diagram easier to see.

In this way, it is also possible to provide the same number of conductor pattern layers 20 and 30 with the magnetic core 10 interposed therebetween. In such a configuration, the first conductor patterns 22, the second conductor patterns 23, the third conductor patterns 32, and the fourth conductor patterns 33 can be connected in parallel via the connection terminal 40. .. This makes it possible to reduce the resistance values of the conductor pattern layers 20 and 30.

(Third Embodiment)
The third embodiment will be described. This embodiment is different from the first and second embodiments in the pattern structure of the conductor pattern layers 20 and 30, and the other parts are the same as those of the first and second embodiments. Only the part different from the second embodiment will be described.

As shown in FIGS. 8A and 8B, the basic structure of the conductor pattern layers 20 and 30 of the present embodiment is the same as that of the first embodiment. However, as shown in FIGS. 9A and 9B, among the first to fourth conductor patterns 22, 23, 32, and 33, those formed on the same conductor pattern layers 20, 30 when projected in the z direction, It has a structure that does not overlap in the lateral direction. More specifically, when projected in the z direction, a gap S1 is provided between the first conductor pattern 22 and the third conductor pattern 32 in the y direction, and the second conductor pattern 23 and the fourth conductor pattern 33 in the y direction are provided. A gap S2 is also provided between the two.

The dimensions of the gaps S1 and S2 are arbitrary, but here they are set to the same value so that the widths of the first to fourth conductor patterns 22, 23, 32, and 33 in the lateral direction are equal.

By providing the gaps S1 and S2 in this way, when projected in the z direction, the first conductor pattern 22 and the second conductor pattern 23 overlap, and the third conductor pattern 32 and the fourth conductor pattern 33 overlap. It is possible to suppress the generation of stray capacitance due to the overlap between them. This makes it possible to suppress a decrease in efficiency of the inductor 100 due to stray capacitance.

Here, the case where the conductor pattern layers 20 and 30 are provided one by one as in the first embodiment is taken as an example, but the structure is such that a plurality of conductor pattern layers 20 and 30 are provided as in the second embodiment. You can also. Even in that case, when projected in the z direction, among the first to fourth conductor patterns 22, 23, 32, 33, those formed on the same conductor pattern layers 20 and 30 overlap each other in the lateral direction. It should be a structure that does not exist.

(Fourth Embodiment)
A fourth embodiment will be described. This embodiment is different from the first and second embodiments in the pattern structure of the conductor pattern layers 20 and 30, and the other parts are the same as those of the first and second embodiments. Only the part different from the second embodiment will be described.

As shown in FIGS. 10A, 10B, 11A and 11B, in the present embodiment, the first conductor pattern 22 and the second conductor pattern 23 formed on the conductor pattern layer 20 are arranged so as to overlap each other in the z direction. It is done. Further, in the z direction, the third conductor pattern 32 and the fourth conductor pattern 33 formed on the conductor pattern layer 30 are arranged so as to overlap each other.

Then, the first to fourth conductor patterns 22, 23, 32, 33 are connected to each other via the connection terminal 40 on the same line, and the lengths of the linear portions 22a, 23a, 32a, 33a are changed. Has been done.

Specifically, with respect to the first conductor pattern 22 and the third conductor pattern 32 connected via the first terminal 41, the linear portion 22a is longer than the linear portion 32a. Further, regarding the second conductor pattern 23 and the fourth conductor pattern 33 connected via the second terminal 42, the linear portion 23a is shorter than the linear portion 33a. That is, of the conductor pattern layers 20 and 30, the second conductor pattern 23 and the third conductor pattern 32 located inside the inductor 100 are short, and the first conductor pattern 22 and the fourth conductor pattern 33 located outside the inductor 100 are short. It has been lengthened.

Further, as shown in FIG. 10A, starting from the one located at the upper left of the first conductor pattern 22, the current flows in a meandering manner through the first terminal 41 and the third conductor pattern 32 in order, and is located at the lower left. The third conductor pattern 32 is the end point. Then, the third conductor pattern 32 located at the lower left in FIG. 10A and the second conductor pattern 23 located at the upper left in FIG. 10B are connected. As a result, as shown in FIG. 10B, a current flows in a meandering manner starting from the one located at the upper left of the second conductor pattern 23, passing through the second terminal 42 and the fourth conductor pattern 33 in order, and is located at the lower left. The fourth conductor pattern 33 is the end point.

With this configuration, the first conductor pattern 22 located outside the inductor 100 and the third conductor pattern 32 located inside are connected, and the second conductor pattern 23 located inside the inductor 100 and located outside the inductor 100. It is connected to the 4th conductor pattern. As a result, as shown in FIGS. 10A and 10B, adjacent connection terminals 40 arranged in the same opening 12 are arranged at different positions in the x direction, and can be prevented from being aligned in the y direction. That is, the connection terminals 40 arranged in the same opening 12 can be arranged in a plurality of rows. Even in this way, it is possible to increase the number of turns per magnetic leg 13 as in the first embodiment. Therefore, in this case, even if the connecting portions 22b, 23b, 32b, 33b are not provided so as to project from the linear portions 22a, 23a, 32a, 33a as in the first embodiment, the linear portions 22a, It may be provided in 23a, 32a, 33a.

(Fifth Embodiment)
A fifth embodiment will be described. In this embodiment, a specific connection method using the connection terminal 40 in the first to fourth embodiments will be described with reference to FIGS. 12A and 12B. It should be noted that FIGS. 12A and 12B are cross-sectional views showing a state at the time of connection in a cross section parallel to the y direction passing through the connection terminal 40, but the number of terminals is reduced in order to make the figure easier to see. is there.

The connection terminal 40 and the first to fourth conductor patterns 22, 23, 32, 33 may be connected by any method, and one of the methods will be described here.

First, as shown in FIG. 12A, a jig 50 capable of installing a structure in which the conductor pattern layers 20 and 30 are arranged on both sides of the magnetic core 10 is prepared. The jig 50 has an accommodating portion 51 composed of a stepped recess. The accommodating portion 51 is composed of a bottom recess 51a located at the bottom and an upper recess 51b located above the bottom recess 51a. The bottom recess 51a has a width shorter than that of the magnetic core 10 and the conductor pattern layers 20 and 30. Further, the upper recess 51b has the same width as the magnetic core 10 and the conductor pattern layers 20 and 30.

When the magnetic core 10 and the conductor pattern layers 20 and 30 are arranged in the accommodating portion 51 with respect to such a jig 50, they are installed at the stepped portion between the bottom recess 51a and the top recess 51b. Further, the inner wall surface of the upper recess 51b is in contact with the outer peripheral surfaces of the magnetic core 10 and the conductor pattern layers 20 and 30, and the magnetic core 10 and the conductor pattern layers 20 and 30 are positioned. As a result, the through holes provided in the connecting portions 22b and 32b and the through holes provided in the connecting portions 23b and 33b are aligned in the z direction, respectively.

Then, the connection terminal 40 made of a columnar member is inserted into each through hole from above, and the connection terminal 40 is fitted until it comes into contact with the bottom recess 51a. As a result, each connection terminal 40 is surely inserted into the conductor pattern layer 30 from the conductor pattern layer 20 through the opening 12. After that, the connection terminal 40 and the connection portions 22b and 23b are connected using solders 61 and 62. Although the second conductor pattern 23 is arranged on the magnetic core 10 side, the connecting portion 23b is provided as a through-hole via that penetrates the insulating layer 21 and is provided up to one side on which the first conductor pattern 22 is formed. Therefore, soldering is possible on the one side.

Subsequently, as shown in FIG. 12B, the magnetic core 10 and the conductor pattern layers 20 and 30 soldered to the connection terminal 40 are taken out from the jig 50, turned over, and installed again in the accommodating portion 51. Then, this time, the connection terminal 40 and the connection portions 32b and 33b are connected by using the solders 63 and 64. Although the third conductor pattern 32 is arranged on the magnetic core 10 side, the connecting portion 32b is provided as a through-hole via that penetrates the insulating layer 31 and is provided up to one side on which the fourth conductor pattern 33 is formed. Therefore, soldering is possible on the one side.

In this way, through holes are formed in the connection portions 22b, 23b, 32b, 33b, the connection terminal 40 is inserted into the through holes, and then the connection portions 22b, 23b, 32b, 33b and the like are connected by soldering or the like. It can be connected to the connection terminal 40.

(Sixth Embodiment)
The sixth embodiment will be described. Also in this embodiment, a specific connection method using the connection terminal 40 in the first to fourth embodiments will be described with reference to FIGS. 13A and 13B. 13A and 13B are cross-sectional views showing a state of connection in a cross section parallel to the y direction passing through the connection terminal 40, but the number of terminals is reduced in order to make the figure easier to see. is there.

As shown in FIG. 13A, a jig 50 similar to that of the fifth embodiment is prepared, and the magnetic core 10 and the conductor pattern layers 20 and 30 are arranged in the accommodating portion 51. In the case of the present embodiment, the connection portion 23b of the second conductor pattern 23 arranged on the magnetic core 10 side is provided with the second terminal 42, and the connection portion 32b of the third conductor pattern 32 is provided with the first terminal 41 in advance. It is joined. Therefore, when the conductor pattern layer 30 and the magnetic core 10 are arranged in the accommodating portion 51 and then arranged in the conductor pattern layer 20, the first terminal 41 is in the through hole of the connecting portion 22b, and the second terminal 42 is in the connecting portion 33b. Each is fitted into the through hole of.

In this state, first, the first terminal 41 and the connecting portion 22b are connected using the solder 61. Then, as shown in FIG. 13B, the soldered magnetic core 10 and the conductor pattern layers 20 and 30 are taken out from the jig 50, turned over, and installed again in the accommodating portion 51. Then, this time, the second terminal 42 and the connecting portion 33b are connected by using the solder 64.

Even with such a structure, the connection portions 22b, 23b, 32b, 33b and the connection terminal 40 can be connected by soldering or the like, as in the fifth embodiment.

(7th Embodiment)
A seventh embodiment will be described. In this embodiment, a configuration equivalent to that of the first to fourth embodiments is configured by a laminating process. Since the inductor 100 is manufactured by the lamination process, the magnetic core 10 and the conductor pattern layers 20 and 30 are integrally manufactured, but the basic structure is the same as that of the first to fourth embodiments. .. Here, a method of manufacturing the inductor 100 by the lamination process will be described with reference to FIGS. 14A to 14J.

First, as shown in FIG. 14A, the conductor pattern layer 20 is prepared. Regarding the conductor pattern layer 20, a resin layer or the like is prepared as the insulating layer 21, conductor layers are formed on both sides thereof, and then the conductor layers are patterned to form the first conductor pattern 22 and the second conductor pattern 23. As the conductor layer, for example, metal plating such as carbon nanotubes and copper can be used.

Next, as shown in FIG. 14B, an insulating film 70 composed of a resin layer or the like is formed so as to cover the second conductor pattern 23. Then, as shown in FIG. 14C, a magnetic film made of a magnetic material is formed on the insulating film 70, and then the magnetic core 10 is patterned to form the opening 12.

Subsequently, as shown in FIG. 14D, an insulating film 71 composed of a resin layer or the like is formed so as to cover the magnetic core 10 including the inside of the opening 12. Then, as shown in FIG. 14E, a conductor layer made of carbon nanotubes, metal plating, or the like is formed on the insulating film 71, and then the conductor layer is patterned to form the third conductor pattern 32. After that, as shown in FIG. 14F, an insulating layer 31 composed of a resin layer or the like is formed so as to cover the third conductor pattern 32. Further, as shown in FIG. 14G, a conductor layer made of carbon nanotubes, metal plating, or the like is formed on the insulating layer 31, and then the conductor layer is patterned to form the fourth conductor pattern 33.

Further, as shown in FIG. 14H, by performing laser machining or the like from each of the first conductor pattern 22 side and the fourth conductor pattern 33 side, a hole is drilled in the portion formed by the first terminal 41 and the second terminal 42. I do. Specifically, the first hole 81 from the first conductor pattern 22 to the third conductor pattern 32 and the second hole 82 from the fourth conductor pattern 33 to the second conductor pattern 23 are formed. Then, as shown in FIG. 14I, through-hole vias 41a and 42a are formed on the inner walls of the first hole 81 and the second hole 82, and as shown in FIG. 14J, copper paste or the like is formed in the through-hole vias 41a and 42a. The conductor materials 41b and 42b are embedded. As a result, the first terminal 41 and the second terminal 42 are configured.

As described above, the inductor 100 in which the magnetic core 10 and the conductor pattern layers 20 and 30 are laminated can be manufactured by the lamination process. As described above, the inductor 100 having the structure of the first to fourth embodiments can be manufactured even by using the lamination process.

(Other embodiments)
Although the present disclosure has been described in accordance with the above-described embodiment, the present disclosure is not limited to the embodiment, and includes various modifications and modifications within an equal range. In addition, various combinations and forms, as well as other combinations and forms that include only one element, more, or less, are also within the scope of the present disclosure.

For example, in each of the above embodiments, it goes without saying that the elements constituting the embodiment are not necessarily essential except when it is clearly stated that they are essential and when they are clearly considered to be essential in principle. No. Further, in each of the above embodiments, when numerical values such as the number, numerical values, amounts, and ranges of the constituent elements of the embodiment are mentioned, when it is clearly stated that they are particularly essential, and in principle, the number is clearly limited to a specific number. It is not limited to the specific number except when it is done. In addition, in each of the above embodiments, when referring to the shape, positional relationship, etc. of a component or the like, the shape, unless otherwise specified or limited in principle to a specific shape, positional relationship, etc. It is not limited to the positional relationship.

As an example, in the first embodiment, the layout is such that the linear portions 22a, 23a, 32a, 33a of the first to fourth conductor patterns 22, 23, 32, 33 are all arranged on the same line. However, this is the layout having the most area efficiency in the form including the first to fourth conductor patterns 22, 23, 32, 33, and may be different layouts. For example, the line of the linear portion 22a and the linear portion 32a connected to each other via the first terminal 41 and the line of the linear portion 23a and the linear portion 33a connected to each other via the second terminal 42 are y. The layout may be arranged alternately in the direction.

Further, a second coil that connects the coil composed of the first conductor pattern 22, the third conductor pattern 32, and the first terminal 41 and the coil composed of the second conductor pattern 23, the fourth conductor pattern 33, and the second terminal 42 are connected. The position of the three terminals 43 is also arbitrary.

Further, although the shape of the opening 12 is rectangular in FIG. 2, it may be oval or the like. That is, the magnetic legs 13 may extend in the direction perpendicular to the arrangement direction of at least the plurality of openings 12.

10 ... Magnetic core, 11 ... Magnetic member, 12 ... Opening, 13 ... Magnetic legs, 20, 30 ... Conductor pattern layer, 21, 31 ... Insulation layer, 22, 23, 32, 33 ... First to fourth conductor patterns , 22a, 23a, 32a, 33a ... Linear part, 22b, 23b, 32b, 33b ... Connection part, 22c, 23c, 32c, 33c ... Drawer part, 22d, 33d ... First, second pad, 40 ... Connection terminal 41-43 ... 1st to 3rd terminals, 50 ... jig, 61-64 ... solder, 100 ... inductor

Claims (9)

The plate-shaped magnetic member (11) having one surface and the other surface is formed, and a plurality of openings (12) penetrating from the one surface to the other surface are formed side by side in one direction. A magnetic core (10) composed of a plurality of magnetic legs (13) extending in a direction perpendicular to one direction, and
A first, which is arranged on one surface side of the magnetic core and has a first insulating layer (21) and a conductor pattern (22, 23) having linear portions (22a, 23a) extending in one direction. Conductor pattern layer (20) and
A second insulating layer (31) arranged on the other surface side of the magnetic core and a conductor pattern (32, 33) having a linear portion (32a, 33a) extending in one direction are formed. Two-conductor pattern layer (30) and
Through the opening, it has a connection terminal (40) for electrically connecting the conductor pattern formed in the first conductor pattern layer and the conductor pattern formed in the second conductor pattern layer.
In the normal direction with respect to the one surface, the linear portion of the conductor pattern formed on the first conductor pattern layer and the linear portion of the conductor pattern formed on the second conductor pattern layer are on the same line. Inductors that are alternately arranged in the same direction, and the alternately arranged inductors are electrically connected via the connection terminals. A plurality of the first conductor pattern layers are provided on the one surface side of the magnetic core.
A plurality of the second conductor pattern layers are provided on the other surface side of the magnetic core in the same number as the first conductor pattern layers.
The linear portion of the conductor pattern provided in the plurality of first conductor pattern layers and the linear portion of the conductor pattern provided in the plurality of second conductor pattern layers are both via the connection terminal. By being electrically connected, the conductor patterns provided in the plurality of first conductor pattern layers are connected in parallel, and the conductor patterns provided in the plurality of second conductor pattern layers are connected in parallel. The inductor according to claim 1. The first conductor pattern layer is, as the conductor pattern formed on the first conductor pattern layer, a first conductor pattern (22) formed on one surface of the first insulating layer opposite to the magnetic core. , With a second conductor pattern (23) formed on one surface on the magnetic core side.
The second conductor pattern layer includes a third conductor pattern (32) formed on one surface of the second insulating layer on the magnetic core side as the conductor pattern formed on the second conductor pattern layer. It has a fourth conductor pattern (33) formed on one side opposite to the magnetic core.
The linear portion of the first conductor pattern and the linear portion of the third conductor pattern are electrically connected via a first terminal (41) constituting the connection terminal.
1 or claim 1, wherein the linear portion of the second conductor pattern and the linear portion of the fourth conductor pattern are electrically connected via a second terminal (42) constituting the connection terminal. 2. The inductor according to 2. There are a plurality of lines in which the linear portion of the conductor pattern formed on the first conductor pattern layer and the linear portion of the conductor pattern formed on the second conductor pattern layer are connected.
The linear portion in the first conductor pattern and the linear portion in the second conductor pattern formed on the same first conductor pattern layer and arranged on adjacent lines among the plurality of lines are magnetic. When projected in the normal direction with respect to one surface of the core, it is arranged with a gap (S1).
The linear portion in the third conductor pattern and the linear portion in the fourth conductor pattern formed on the same second conductor pattern layer and arranged on adjacent lines among the plurality of lines are magnetic. The inductor according to claim 3, wherein the inductor is arranged with a gap (S2) when projected in the normal direction with respect to one surface of the core. In the one direction, the linear portion of the first conductor pattern is made longer than the linear portion of the third conductor pattern.
In the one direction, the linear portion of the fourth conductor pattern is made longer than the linear portion of the second conductor pattern.
The inductor according to claim 3, wherein the first terminal and the second terminal are arranged at different positions in the one direction in the same opening. The plate-shaped magnetic member (11) having one surface and the other surface is formed, and a plurality of openings (12) penetrating from the one surface to the other surface are formed side by side in one direction. To prepare a magnetic core (10) composed of a plurality of magnetic legs (13) extending in a direction perpendicular to one direction, and
A conductor pattern (22,) arranged on one side of the magnetic core and having a first insulating layer (21), linear portions (22a, 23a) extending in one direction, and connecting portions (22b, 23b). To prepare the first conductor pattern layer (20) on which 23) is formed,
A conductor pattern (32) arranged on the other surface side of the magnetic core and having a second insulating layer (31), linear portions (32a, 33a) extending in one direction, and connecting portions (32b, 33b). , 33) and the second conductor pattern layer (30) are prepared, and
A connection terminal (40) formed of a columnar member that electrically connects the conductor pattern formed in the first conductor pattern layer and the conductor pattern formed in the second conductor pattern layer through the opening. And to prepare
The first conductor pattern layer and the second conductor pattern layer are arranged on the one surface and the other surface of the magnetic core, and the connection portion of the first conductor pattern layer and the second conductor pattern layer are arranged through the opening. After inserting the connection terminal into the through hole formed in at least one of the connection portions, the connection portion in which the through hole is formed and the connection terminal are connected by using solder (61 to 64). Thereby, in the normal direction with respect to the one surface, the linear portion of the conductor pattern formed on the first conductor pattern layer and the linear portion of the conductor pattern formed on the second conductor pattern layer are formed. A method for manufacturing an inductor, which comprises alternately arranging them on the same line and electrically connecting the alternately arranged ones at the connection terminals. By preparing the first conductor pattern layer, it is necessary to prepare a layer having the through hole formed in the connecting portion.
By preparing the second conductor pattern layer, it is possible to prepare a layer having the through hole formed in the connecting portion.
By electrically connecting with the connection terminal, the connection terminal is inserted into the through hole of the first conductor pattern layer and the through hole of the second conductor pattern layer through the opening, and then the connection terminal is inserted. The method for manufacturing an inductor according to claim 6, wherein the connection portion and the connection terminal are connected by using the solder. By preparing the first conductor pattern layer, the conductor pattern is formed on one surface of the first insulating layer opposite to the magnetic core, and the through hole is formed in the connection portion. To prepare,
By preparing the second conductor pattern layer, the conductor pattern is formed on one surface of the second insulating layer on the magnetic core side, and the connection terminal is connected to the connection portion. That is
By electrically connecting with the connection terminal, the connection terminal is inserted into the through hole of the first conductor pattern layer through the opening, and then the connection portion and the connection terminal are soldered. The method for manufacturing an inductor according to claim 6, wherein the inductor is connected by using. A first insulating layer (21) having one surface and another surface, a first conductor pattern (22) having a linear portion (22a) extending in one direction on one surface side of the first insulating layer, and the first conductor pattern (22). 1. To form a first conductor pattern layer (20) including a second conductor pattern (23) having a linear portion (23a) extending in one direction on the other surface side of the insulating layer.
A magnetic film is formed on the second conductor pattern and then patterned to form a plurality of openings (12) side by side in one direction, whereby a plurality of magnetic legs extending in a direction perpendicular to the one direction. Forming the magnetic core (10) in which (13) is configured, and
By forming a conductor layer on the magnetic core and then patterning it, a third conductor pattern (32) having a linear portion (32a) extending in one direction is formed, and the third conductor pattern (32) is formed. A second insulating layer (31) is formed on the conductor pattern, a conductor layer is further formed on the second insulating layer, and then patterning is performed to form a linear portion (1) extending in one direction. Forming the fourth conductor pattern (33) having 33a) to form the second conductor pattern layer (30),
By drilling, a first hole (81) from the first conductor pattern to the third conductor pattern is formed, and a second hole (82) from the fourth conductor pattern to the second conductor pattern is formed. To do and
A first terminal (41) for electrically connecting the first conductor pattern and the third conductor pattern is formed in the first hole, and the fourth conductor pattern and the second conductor pattern are formed in the second hole. A method of manufacturing an inductor, comprising forming a second terminal (42) that is electrically connected.

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