JP2023123279A - inductor - Google Patents

Abstract

To provide an inductor capable of increasing reliability.SOLUTION: An inductor 100 includes: a magnetic core 10 having a bottom surface 11, a top surface 12 and side faces 13a-13d; a coil part 21 embedded in the core 10; a coil element connected to an end of the coil 21, and has a drawer part 22 drawn out from the side face 13c to an outside of the core 10; and a plate-like electrode member 30 that is placed on the side face 13c and electrically connected to the coil element via a lead-out part 22. The electrode member 30 has a side plate part 32 located along the side face 13c from which the lead-out part 22 is drawn out and multiple projecting plate parts 35 projecting from the side plate portion 32 in a direction away from side face 13c. The side plate portion 32 has a through opening 33 passing through the side plate portion 32 in a thickness direction. The lead-out part 22 passes through the through opening 33 and is in contact with the multiple projecting plate parts 35. The multiple projecting plate parts 35 are welded to the lead-out part 22.SELECTED DRAWING: Figure 1

Description

The present disclosure relates to inductors.

2. Description of the Related Art Inductors, which are passive elements that store electrical energy as magnetic energy, are used in, for example, DC-DC converter devices for the purpose of boosting/boosting power supply voltage and smoothing direct current. The inductor is mounted, for example, on the surface of a circuit board or the like. For example, Patent Literature 1 discloses an inductor including a main body containing a magnetic material, a coil element arranged inside the main body, and a terminal fitting connected to the coil element. In the inductor described in Patent Document 1, the tip of the coil element is exposed from the main body, and the terminal fitting is welded to the exposed tip of the coil element.

JP 2011-243685 A

In the conventional inductor, the reliability of the inductor may be low because the connection reliability between the electrode member, which is a terminal fitting, and the coil element is low. In view of the above, an object of the present disclosure is to improve the reliability of inductors.

An inductor according to an aspect of the present disclosure includes a magnetic core having a bottom surface, a top surface, and side surfaces connected to the bottom surface and the top surface, a coil portion embedded in the magnetic core, and an end portion of the coil portion. a coil element having a lead portion led out from the side surface to the outside of the magnetic core; and a plate-like electrode member disposed on the side surface and electrically connected to the coil element through the lead portion. wherein the electrode member has a side plate portion arranged along a side surface from which the lead portion is drawn, and a plurality of protruding plate portions protruding from the side plate portion in a direction away from the side surface; The side plate portion has a through opening penetrating in the thickness direction of the side plate portion, the drawer portion passes through the through opening and contacts the plurality of protruding plate portions, and the plurality of protruding plate portions are: It is welded to the lead-out portion.

According to the present disclosure, it is possible to improve the reliability of the inductor.

1 is a first perspective view of an inductor according to an embodiment; FIG. FIG. 4 is a second perspective view of the inductor according to the embodiment; FIG. 4 is a diagram showing a state before the lead-out portion and projecting plate portion of the inductor according to the embodiment are welded; It is the figure which looked at the drawer part and projecting plate part which are shown in FIG. 3 from the front and the side. FIG. 10 is a diagram showing an example of a manufacturing process of the projecting plate portion of the inductor according to the embodiment; FIG. 10 is a perspective view of a lead-out portion and a projecting plate portion of an inductor according to Modification 1 of the embodiment; FIG. 10 is a diagram showing a state before the lead-out portion and the projecting plate portion of the inductor according to Modification 1 of the embodiment are welded; FIG. 10 is a diagram showing an example of a manufacturing process of the projecting plate portion of the inductor according to Modification 1 of the embodiment; FIG. 10 is a perspective view of an inductor lead-out portion and a projecting plate portion according to Modification 2 of the embodiment; FIG. 10 is a diagram showing a state before the lead-out portion and the projecting plate portion of the inductor according to Modification 2 of the embodiment are welded; FIG. 11 is a perspective view of an inductor lead-out portion and a projecting plate portion according to Modification 3 of the embodiment; FIG. 10 is a diagram showing a state before the lead-out portion and the projecting plate portion of the inductor according to Modification 3 of the embodiment are welded; FIG. 11 is a perspective view of an inductor lead-out portion and a projecting plate portion according to Modification 4 of the embodiment; FIG. 10 is a diagram showing a state before the lead-out portion and projecting plate portion of the inductor according to Modification 4 of the embodiment are welded; FIG. 10 is a perspective view of an inductor lead-out portion and a projecting plate portion according to Modification 5 of the embodiment; FIG. 10 is a diagram showing a state before the lead-out portion and the projecting plate portion of the inductor according to Modification 5 of the embodiment are welded; FIG. 14 is a diagram showing an example of a manufacturing process of a projecting plate portion of an inductor according to Modification 5 of the embodiment; FIG. 11 is a perspective view of an inductor lead-out portion and a projecting plate portion according to Modification 6 of the embodiment; FIG. 14 is a diagram showing a state before the lead-out portion and the protruding plate portion of the inductor according to Modification Example 6 of the embodiment are welded; It is the figure which looked at the side-plate part of the inductor which concerns on the modified example 6 of embodiment from the side. It is a figure which shows an example of the manufacturing process of the side-plate part of the inductor which concerns on the modification 6 of embodiment. It is a figure which shows the other example of the side-plate part of the modification 6 of embodiment. It is a figure which shows the other example of the side-plate part of the modification 6 of embodiment.

(Background leading up to this disclosure)
In the structure in which the electrode member is welded to the tip of the coil element as in Patent Document 1 described above, the cross-sectional area of the connection portion that connects the coil element and the electrode member is small, and the reliability of the connection between the coil element and the electrode member is reduced. performance may be reduced. In addition, in the structure in which the electrode member is welded to the tip of the coil element, the cross-sectional area of the current path at the welded portion cannot be increased, and there is a problem that the DC resistance increases and the reliability of the inductor deteriorates. Further, if the cross-sectional area of the current path at the welded portion cannot be increased, the temperature rises when the inductor is energized, and the reliability of the inductor deteriorates.

The present disclosure has the configuration shown below in order to improve the reliability of the inductor. Hereinafter, embodiments will be described more specifically with reference to the drawings.

It should be noted that each of the embodiments described below is a specific example of the present disclosure. Numerical values, shapes, materials, components, arrangement positions of components, connection forms, steps, order of steps, and the like shown in the following embodiments are examples, and are not intended to limit the present disclosure. Further, among the constituent elements in the following embodiments, constituent elements not described in independent claims will be described as optional constituent elements.

Also, in this specification, terms indicating the relationship between elements such as parallel, and terms indicating the shape of elements such as rectangular parallelepipeds, and numerical ranges are not expressions that express only strict meanings, but substantially It is an expression that means to include a difference in an equivalent range, for example, a few percent difference.

In addition, each figure is a schematic diagram that has been appropriately emphasized, omitted, or adjusted in proportion to show the present disclosure, and is not necessarily strictly illustrated, and differs from the actual shape, positional relationship, and ratio. Sometimes. In each figure, substantially the same configurations are denoted by the same reference numerals, and redundant description may be omitted or simplified.

In addition, each drawing shows an X-axis, a Y-axis and a Z-axis which mean three directions orthogonal to each other, and these axes and axial directions along these axes are used for explanation as needed. Each axis is attached for explanation, and does not limit the direction and orientation in which the inductor is used.

In this specification, the terms "top surface" and "bottom surface" in the configuration of the inductor refer to the top surface (vertically upper surface) and the bottom surface (vertically lower surface) in absolute spatial recognition. Instead, it is used as a term defined by the relative positional relationship of the constituent elements of the inductor.

(Embodiment)
[Structure of inductor]
A configuration of an inductor according to an embodiment will be described. An inductor is a passive element that stores electrical energy flowing through a coil element as magnetic energy.

FIG. 1 is a first perspective view of an inductor 100 according to an embodiment. 2 is a second perspective view of inductor 100. FIG. 1 shows an overall view of inductor 100, and a lower view shows an enlarged perspective view of lead-out portion 22 and projecting plate portion 35 of inductor 100. As shown in FIG.

As shown in FIGS. 1 and 2, the inductor 100 includes a magnetic core 10, a coil element having a coil portion 21 and a plurality of lead portions 22, a plurality of electrode members 30 as external terminals, a lead portion 22 and electrodes. and a connecting portion for connecting the member 30 .

In the following description, the positive half of the X-axis of inductor 100 will be mainly described, but the negative half of inductor 100 has the same structure as the positive half of inductor 100. and similar explanations apply.

The outline of the inductor 100 is roughly determined by, for example, the shape of the magnetic core 10, which is a rectangular parallelepiped dust core. Note that the magnetic core 10 can be molded into an arbitrary shape by molding. In other words, the inductor 100 of any shape can be realized by adjusting the shape of the magnetic core 10 when it is molded. In the magnetic core 10 of the present embodiment, for example, the dimension in the X-axis direction is 17 mm or more, the dimension in the Y-axis direction is 17 mm or more, and the dimension in the Z-axis direction is 7 mm or more.

The magnetic core 10 is an outer shell portion of the inductor 100 and covers a part of the coil element (coil portion 21). The magnetic core 10 includes a magnetic material, and is, for example, a powder magnetic core made of metal magnetic powder, resin material, or the like. In addition, the magnetic core 10 should just be formed using a magnetic material. Ferrite may be used as the magnetic material, or another magnetic material may be used. A particulate material having a predetermined elemental composition such as Fe--Si--Al, Fe--Si, Fe--Si--Cr or Fe--Si--Cr--B is used as the metal magnetic powder. As the resin material, a material such as a silicone-based resin is selected that can maintain a certain shape by binding the particles of the metal magnetic powder while insulating the particles of the metal magnetic powder.

The magnetic core 10 has, for example, a rectangular parallelepiped shape. Magnetic core 10 has bottom surface 11 , top surface 12 facing back to bottom surface 11 , and four side surfaces 13 a, 13 b, 13 c, and 13 d connecting bottom surface 11 and top surface 12 . The side surfaces 13a and 13b are arranged in the X-axis direction and face each other. The side surface 13c and the side surface 13d are arranged in the Y-axis direction and face each other. The bottom surface 11, top surface 12, and side surfaces 13a, 13b, 13c, and 13d are each substantially flat planes. The set of bottom surface 11 and top surface 12, the set of side surface 13a and side surface 13b, and the set of side surface 13c and side surface 13d are sets of surfaces having a parallel positional relationship. The bottom surface 11, the top surface 12, and the side surfaces 13a, 13b, 13c, and 13d extend in crossing directions, more specifically, in orthogonal directions. Further, the side surfaces 13a and 13b and the side surfaces 13c and 13d extend in a crossing direction, more specifically, in a direction orthogonal to each other.

The coil element has a coil portion 21 made of a single wire embedded in the magnetic core 10 and a plurality of lead portions 22 corresponding to both ends of the wire and exposed to the outside of the magnetic core 10 . That is, the coil element according to the embodiment is composed of one coil portion 21 and two lead portions 22 . In addition, in FIG. 1, the embedded coil portion 21 is indicated by a broken line.

The coil element is composed of, for example, a conducting wire. The conducting wire is made of a metal material selected from, for example, metals such as aluminum, copper, silver, and gold, alloys containing one or more of these metals, and materials consisting of metals or alloys and other substances. It is composed of a metal wire and an insulating film covering the metal wire. Specifically, the conducting wire is, for example, a copper wire coated with an insulating film. The coil part 21 and the lead-out part 22 are names given to respective parts formed by processing one member made of the same material, for example.

The coil portion 21 is a portion covered with the magnetic core 10 . The coil portion 21 is composed of a wound conductive wire and functions as a coil. The number of turns of the coil portion 21 is not particularly limited, and is appropriately selected, for example, from 0.5 turns to 10 turns, in accordance with the performance required of the inductor 100 and the restrictions such as the size of the magnetic core 10 . The cross-section of the conducting wire that constitutes the coil portion 21 is, for example, a rectangular wire with sides of 3.5 mm×2.5 mm. The coil portion 21 is wound in the vertical direction by overlapping the planes including the long sides of the cross section of the conductive wire. The coil portion 21 is embedded in the magnetic core 10 so that the winding axis of the coil portion 21 extends along the direction (Z-axis direction) connecting the bottom surface 11 and the top surface 12 .

The coil portion 21 has an end portion (not shown) connected to the side surface 13c of the magnetic core 10 from the wound portion. One of the ends of the coil portion 21 is arranged on the positive side of the X-axis, which is to the right of the winding axis when viewed from the direction perpendicular to the side surface 13c. It is arranged on the negative side of the X-axis, which is to the left of the winding axis. In addition, the end of the coil portion 21 is located at a height closer to the bottom surface 11 than the center of the side surface 13c when viewed from the direction perpendicular to the side surface 13c, and the height from the bottom surface 11 is the same.

The drawn-out portion 22 is connected to the end portion of the coil portion 21 and drawn out from the side surface 13c of the magnetic core 10 to extend. Specifically, the lead-out portion 22 extends in a direction perpendicular to the side surface 13c from a height closer to the bottom surface 11 than the center of the side surface 13c. The drawer portion 22 is drawn out from one side surface 13c of the four side surfaces 13a to 13d.

FIG. 3 is a diagram showing a state before the lead-out portion 22 and the projecting plate portion 35 of the inductor 100 are welded. 4A and 4B are front and side views of the drawer portion 22 and the projecting plate portion 35 shown in FIG. In this example, viewing from the front means viewing from the Y-axis direction perpendicular to the side surface 13c, and viewing from the side means viewing from the X-axis direction perpendicular to the side surface 13a. FIG. 4(a) shows a front view of the drawer portion 22 and projecting plate portion 35, and FIG. 4(b) shows a cross-sectional view taken along the center line of FIG. 4(a). ing.

The drawer portion 22 shown in FIGS. 3 and 4 has a rectangular cross section. The drawer portion 22 includes a drawer top surface 22a parallel to the top surface 12, a drawer bottom surface 22b positioned closer to the bottom surface 11 than the drawer top surface 22a, and two drawer side surfaces 22c connecting the drawer top surface 22a and the drawer bottom surface 22b. have. The drawer top surface 22a and the drawer bottom surface 22b are parallel to each other. The insulating film is removed from the drawer top surface 22a, the drawer bottom surface 22b, and the drawer side surface 22c so as to be conductive with the electrode member 30. As shown in FIG. The lead portion 22 passes through a through opening 33 of a side plate portion 32 of the electrode member 30 to be described later, and is in contact with a plurality of projecting plate portions 35 .

As shown in FIG. 1, the electrode member 30 is arranged outside the magnetic core 10 (for example, on the bottom surface 11 side, the side surface 13c side, and the other side surface 13d side), and is electrically connected to the lead portion 22 through the connection portion. It is connected. The electrode member 30 is provided corresponding to each of the two lead portions 22 . The electrode member 30 contains a conductive material and is made of, for example, a metal plate. The metal material plate is a metal material selected from metals such as aluminum, copper, silver, and gold, alloys containing one or more of these metals, and materials composed of metals or alloys and other substances. Configured.

The electrode member 30 includes a bottom plate portion 31 arranged on the bottom surface 11 side of the magnetic core 10, a side plate portion 32 connected to the bottom plate portion 31, a side plate portion 32 arranged on the side surface 13c side of the magnetic core 10, and a plurality of projections projecting outward from the side plate portion 32. It has a plate portion 35 .

The electrode member 30 also has a locking portion 38 connected to the bottom plate portion 31 and arranged on the side of the other side surface 13 d of the magnetic core 10 . The bottom plate portion 31, the side plate portion 32, the locking portion 38, and the plurality of protruding plate portions 35 are names given to respective parts formed by processing one member made of the same material, for example. .

Bottom plate portion 31 is arranged on bottom surface 11 side of magnetic core 10 so as to extend along bottom surface 11 . The bottom plate portion 31 may be fixed to the magnetic core 10 via an adhesive. The bottom plate portion 31 is soldered to the circuit board when the inductor 100 is mounted on the circuit board. In addition, the bottom plate portion 31 may be provided with a portion projecting to the outside of the magnetic core 10 when viewed from the top surface 12 side (planar view in the Z-axis direction). The preheating of 1 makes it easy to warm the overhanging portion and improves the solderability, which is preferable.

The side plate portion 32 is arranged to correspond to one side surface 13c of the four side surfaces 13a to 13d of the magnetic core 10. As shown in FIG. The side plate portion 32 is connected to the bottom plate portion 31 , is arranged along the side surface 13 c of the magnetic core 10 , and extends from the bottom plate portion 31 toward the top surface 12 . Further, the side plate portion 32 has a through opening 33 penetrating in the thickness direction.

The through opening 33 has, for example, a square shape, and the aforementioned drawer portion 22 is inserted into the through opening 33 . Although the side plate portion 32 is in contact with the side surface 13c of the magnetic core 10 when viewed from the X-axis direction, the side plate portion 32 may be arranged with a gap from the side surface 13c. The side plate portion 32 may be fixed to the magnetic core 10 via an adhesive.

The protruding plate portion 35 is a portion that protrudes outward from the side plate portion 32 . The plurality of protruding plate portions 35 has a first protruding plate portion 36 and a second protruding plate portion 37 positioned closer to the bottom surface 11 than the first protruding plate portion 36 . In other words, the first projecting plate portion 36 is located closer to the top surface than the second projecting plate portion 37 is. The first protruding plate portion 36 and the second protruding plate portion 37 are parallel to the bottom surface 11 or the top surface 12 of the magnetic core 10 and face each other with the drawer portion 22 interposed therebetween. The width of the first protruding plate portion 36 is wider than the width of the second protruding plate portion 37 when viewed from the Y-axis direction perpendicular to the side plate portion 32 .

Each protruding plate portion 35 rises from a portion of the boundary region between the side plate portion 32 and the through opening 33 and protrudes away from the side surface 13c of the magnetic core 10 . For example, the first projecting plate portion 36 rises from the boundary region along the inner wall 33a of the through opening 33 on the top surface 12 side, and the second projecting plate portion 37 extends along the inner wall 33b of the through opening 33 on the bottom surface 11 side. rising from the perimeter area. Each projecting plate portion 35 is arranged perpendicular to the side plate portion 32 or along the direction in which the drawer portion 22 extends. For example, the protruding length of the protruding plate portion 35 protruding from the side plate portion 32 is 1.5 times or more the plate thickness of the protruding plate portion 35 . Each protruding plate portion 35 may protrude further than the tip portion 22e of the lead portion 22 before the protruding plate portion 35 and the lead portion 22 are welded.

Each of the first projecting plate portion 36 and the second projecting plate portion 37 is in contact with the drawer portion 22 . In other words, the drawer portion 22 is in contact with each of the first protruding plate portion 36 and the second protruding plate portion 37 . The first protruding plate portion 36 has a first contact surface 36a in contact with the drawer top surface 22a of the drawer portion 22, and the second protruding plate portion 37 has a second contact surface 36a in contact with the drawer bottom surface 22b of the drawer portion 22. It has a contact surface 37b. The first contact surface 36a and the second contact surface 37b face each other with the drawer portion 22 interposed therebetween.

The first contact surface 36 a and the second contact surface 37 b are formed by different surfaces of the electrode member 30 . For example, when the plate-shaped electrode member 30 has a first surface that is one of the main surfaces of the plate-shaped member and a second surface that is the other of the two main surfaces, and the first surface is in contact with the side surface 13c of the magnetic core 10, The first contact surface 36a is made up of part of the second surface, and the second contact surface 37b is made up of part of the first surface.

Each projecting plate portion 35 has a root portion 35f located on the side plate portion 32 side, and has a tip portion 35e located on the opposite side of the root portion 35f. A tip portion 35 e of the projecting plate portion 35 is in contact with or close to a tip portion 22 e of the drawer portion 22 . The distal end portion 35e of the projecting plate portion 35 before welding may be slightly separated from the distal end portion 22e of the drawer portion 22 .

In the present embodiment, at least a connecting portion is formed at a location where the leading end portion 22e of the drawer portion 22 and the leading end portion 35e of the protruding plate portion 35 are in contact or close to each other (see FIG. 1). The connecting portion is formed by welding the drawer portion 22 and each projecting plate portion 35 together. For example, the connecting portion is composed of a plurality of weld marks ws formed by laser seam welding. When viewed from the Y-axis direction, the plurality of weld marks ws are along the direction in which the upper side of the drawer portion 22, which is the drawer top surface 22a, and the lower side of the drawer portion 22, which is the drawer bottom surface 22b, extend. It is connected. All of the plurality of weld marks ws may be continuously connected, or some of the weld marks ws may be continuously connected. Also, adjacent welding marks ws may be continuously connected so as to overlap each other. The first protruding plate portion 36 is welded to the top surface 22a of the drawer, and the second protruding plate portion 37 is welded to the bottom surface 22b of the drawer. be.

As described above, in the present embodiment, the lead-out portion 22 of the coil element passes through the through opening 33 of the side plate portion 32 and is in contact with the plurality of projecting plate portions 35 . is welded to

According to this, it is possible to lengthen the length of the connecting portion formed by welding each protruding plate portion 35 and the lead-out portion 22 . As a result, the cross-sectional area of the connecting portion connecting the coil element and the electrode member 30 can be increased, and the reliability of the connection between the coil element and the electrode member 30 can be enhanced. In addition, since the cross-sectional area of the current path in the connecting portion can be increased, the direct current resistance can be reduced and the reliability of the inductor can be enhanced. Moreover, since the cross-sectional area of the current path in the connecting portion can be increased, it is possible to suppress temperature rise when the inductor is energized, and to enhance the reliability of the inductor.

Next, the locking portion 38 of the electrode member 30 will be described.

In the following description, the half of the inductor 100 on the negative side of the X axis will be mainly described. and similar explanations apply.

As shown in FIG. 2, the electrode member 30 has a locking portion 38 along the side surface 13d. More specifically, the locking portion 38 is connected to the bottom plate portion 31 and arranged along the side surface 13 d of the magnetic core 10 . The locking portion 38 extends from the bottom plate portion 31 toward the top surface 12, and extends from the tip portion of the convex portion 131d that is the outermost portion of the side surface 13d of the magnetic core 10 when viewed from the X-axis direction, and the innermost portion of the side surface 13d. is placed between the In addition, the locking portion 38 is arranged corresponding to one of the four side surfaces 13d. The locking portion 38 is formed with an opening 38a. The opening 38a is a square-shaped through-hole that penetrates the electrode member 30 in the thickness direction (here, the Y-axis direction). The opening 38a corresponds to a convex portion 131d formed on the side surface 13d, and the locking portion 38 is arranged so that the convex portion 131d penetrates the opening 38a. The locking portion 38 may be fixed to the magnetic core 10 via an adhesive. In such an engaging portion 38, the side surface of the convex portion 131d on the top surface 12 side and the inner surface of the opening 38a on the top surface 12 side (facing the bottom surface 11 side) are engaged with each other, so that the magnetic core 10 and the electrode member 30 are fixed. In other words, the electrode member 30 is locked to the convex portion 131d by the locking portion 38, welded at the connecting portion, and (in some cases, by bonding the bottom plate portion 31, the side plate portion 32, and the locking portion 38), It is fixed to the magnetic core 10 . Such a convex portion 131d is formed, for example, closer to the bottom surface 11 than the center of the magnetic core 10, as shown in the drawing. In this manner, the magnetic core 10 has the convex portion 131d and the electrode member 30 has the locking portion 38, so that the electrode member 30 and the magnetic core 10 can be firmly fixed.

[Manufacturing method of inductor]
Next, a method for manufacturing the inductor 100 described above will be described. Manufacture of the inductor according to the embodiment is performed as follows. Note that the method of manufacturing the inductor 100 is not limited to the following example.

In the method of manufacturing the inductor 100, first, a step of pressure-molding the magnetic core 10 together with the coil element is performed. The above process is executed by placing the coil element having the coil portion 21 in a molding die and molding the powder magnetic core under pressure. The pressure during pressure molding is, for example, 5 tons/cm ² , and the thermosetting temperature is, for example, 185°C. After pressure molding, the drawn-out portion 22 exposed without being covered with the magnetic core 10 protrudes perpendicularly to the side surface 13c of the magnetic core 10, for example. The lead-out portion 22 is irradiated with, for example, a laser beam to remove the insulating coating.

Next, a step of preparing the electrode member 30 having the bottom plate portion 31, the side plate portion 32, the projecting plate portion 35 and the locking portion 38 by punching and bending the metal material plate is performed. In this step, the first projecting plate portion 36 and the second projecting plate portion 37 of the side plate portion 32 are bent in advance in a direction away from the side surface 13 c of the magnetic core 10 .

5A and 5B are diagrams showing an example of a manufacturing process of the projecting plate portion 35 of the inductor 100. FIG.

First, as shown in FIG. 5A, a metal plate is punched. At this time, for example, an inverted U-shaped punching process is performed so that a region T2 that will become the second projecting plate portion 37 in a later process remains.

Next, as shown in (b) of FIG. 5 , the region T2 is bent to the side opposite to the surface where the side plate portion 32 abuts on the side surface 13c in a post-process, thereby forming a second portion erected from the side plate portion 32. is formed. Further, a through opening 33 is formed in the space left by the bending process. A bending line (folding line) L2 of the second projecting plate portion 37 substantially coincides with the inner wall 33b of the through opening 33 on the bottom surface 11 side.

Next, as shown in (c) of FIG. 5, the region T1 that will become the first projecting plate portion 36 in the future is bent in the same direction as the second projecting plate portion 37, thereby forming the first projecting plate. A portion 36 is formed. The first protruding plate portion 36 is formed using the region T<b>1 located closer to the top surface 12 than the side plate portion 32 . A bending line (folding line) L1 of the first protruding plate portion 36 substantially coincides with the inner wall 33a of the through opening 33 on the top surface 12 side. Note that the step shown in (c) of FIG. 5 may be performed before the step (b) of FIG. 5 .

Next, a step of arranging the electrode members 30 on the magnetic core 10 as shown in FIG. 1 is performed. First, the drawer portion 22 is inserted into the through opening 33 of the side plate portion 32 to arrange the side plate portion 32 along the side surface 13 c of the magnetic core 10 . Then, the bottom plate portion 31 is bent along the bottom surface 11 of the magnetic core 10 . Then, the engaging portion 38 is bent along the other side surface 13 d of the magnetic core 10 . At this time, the drawer portion 22 is inserted into the through opening 33 of the side plate portion 32, and the drawer portion 22 and the first projecting plate portion 36 and the second projecting plate portion 37 come into contact with each other. Also, the convex portion 131d is inserted into the opening 38a of the locking portion 38. As shown in FIG. Further, when any one or all of the bottom plate portion 31, the side plate portion 32, and the locking portion 38 of the electrode member 30 are adhered to the magnetic core 10, a thermosetting adhesive that is viscous when uncured is used in this step. It is applied to the portion where the electrode member 30 and the magnetic core 10 are in contact with each other. The adhesive is not cured in this step, but is cured in a later step.

Next, a step of welding each protruding plate portion 35 and the lead portion 22 by laser seam welding or the like is performed. Specifically, connecting portions are formed along the drawer top surface 22 a and the drawer bottom surface 22 b of the drawer portion 22 . The weld mark ws formed on the connecting portion is circular, and is formed, for example, by rotating the spot of the laser beam with a predetermined radius.

Next, the electrode member 30 is bent so that the locking portion 38 of the electrode member 30 is locked to the convex portion 131 d of the magnetic core 10 . In this process, as shown in FIG. 1, when the magnetic core 10 is pressure-molded, a bottom surface recess 11a is formed in advance at a position overlapping the bottom plate portion 31 of the bottom surface 11 so as to be recessed toward the inside of the magnetic core 10. Then, a step of bending the bottom plate portion 31 so as to enter the bottom recessed portion 11a may be performed. As a result, a bottom crimped portion 31a is formed on the bottom plate portion 31, and the electrode member 30 is narrowed. By narrowing the electrode member 30 in this way, the entire electrode member 30 is tightened to the magnetic core 10, and the locking portion 38 of the electrode member 30 is firmly locked to the protruding portion 131d of the magnetic core 10. and the magnetic core 10 can be firmly fixed. When the electrode member 30 and the magnetic core 10 are to be adhered to each other, a step of curing the adhesive by heat treatment is performed after this step. Thus, inductor 100 is manufactured.

[Modification 1 of Embodiment]
An inductor 100A according to Modification 1 of the embodiment will be described. In this example, an example in which the first protruding plate portion 36 has an opening (protruding plate opening 36h) connected to the through opening 33 will be described.

FIG. 6A is a perspective view of the lead-out portion 22 and the projecting plate portion 35 of the inductor 100A according to Modification 1 of the embodiment. FIG. 6B is a diagram showing a state before the lead-out portion 22 and the projecting plate portion 35 of the inductor 100A are welded.

An inductor 100A of Modification 1 includes a magnetic core 10, a coil element having a coil portion 21 and a lead portion 22, and an electrode member 30 as an external terminal (not shown), as in the first embodiment. The electrode member 30 has a bottom plate portion 31 , side plate portions 32 and a plurality of projecting plate portions 35 . The side plate portion 32 has a through opening 33 penetrating in the thickness direction. The drawer portion 22 passes through the through opening 33 and is in contact with the plurality of projecting plate portions 35 . A plurality of projecting plate portions 35 are welded to the drawer portion 22 .

The first protruding plate portion 36 of the inductor 100A of Modification 1 has a protruding plate opening 36h penetrating in the thickness direction. The protruding plate opening 36 h is located on the side plate portion 32 side when viewed from the center of the first protruding plate portion 36 and is connected to the through opening 33 . Due to the protruding plate opening 36h, when the inductor 100A is viewed from the top surface 12 side in the Z-axis direction, part of the top surface 22a of the extension portion 22 is exposed. The width of the projecting plate opening 36h when viewed in the Z-axis direction is the same as the width of the through opening 33. As shown in FIG. The opening length of the projecting plate opening 36h in the Y-axis direction is shorter than the length of the drawer portion 22. As shown in FIG.

FIG. 7 is a diagram showing an example of a manufacturing process of the projecting plate portion 35 of the inductor 100A.

First, as shown in FIG. 7(a), a metal plate is punched. At this time, a predetermined shape is punched so that a region T2 that will become the second protruding plate portion 37 in a later process remains.

Next, as shown in (b) of FIG. 7, the second protruding plate portion 37 erected from the side plate portion 32 is formed by bending the region T2. An opening 33i is formed in the space left by the bending process. This opening 33i is composed of a through opening 33 and a projecting plate opening 36h which will be described in the next step.

Next, as shown in FIG. 7C, the region T1a that will become the first protruding plate portion 36 in a post-process is bent in the same direction as the second protruding plate portion 37, thereby forming the first protruding plate. A portion 36 is formed. The inner wall of the opening 33i on the side of the top surface 12 is provided closer to the top surface 12 than the inner wall 33a shown in FIG. 5B. Therefore, the bending line L1a is provided at a position that intersects two side walls connecting the inner wall on the top surface side and the inner wall on the bottom surface side of the opening 33i. By bending the region T1a along the bending line L1a, the through opening 33 is formed in the side plate portion 32, and the projecting plate opening 36h is formed in the first projecting plate portion 36. As shown in FIG. By providing the folding line L1a at such a position, the length of the folding line when folding the metal material plate can be shortened. Thereby, the bending process of the first protruding plate portion 36 can be performed easily and accurately.

Also in the inductor 100A of Modified Example 1, the lead-out portion 22 of the coil element passes through the through opening 33 of the side plate portion 32 and contacts the plurality of projecting plate portions 35. is welded to Thereby, the same effects as in the first embodiment can be obtained.

[Modification 2 of Embodiment]
An inductor 100B according to Modification 2 of the embodiment will be described. In this example, a part of the first projecting plate portion 36 is bent along the side surface of the drawer portion 22 (drawer side surface 22c).

FIG. 8A is a perspective view of the lead-out portion 22 and the projecting plate portion 35 of the inductor 100B according to Modification 2 of the embodiment. FIG. 8B is a diagram showing a state before the lead-out portion 22 and the projecting plate portion 35 of the inductor 100B are welded.

Inductor 100B of modification 2 includes magnetic core 10, a coil element having coil portion 21 and lead portion 22, and electrode member 30 as an external terminal (not shown), as in the first embodiment. The electrode member 30 has a bottom plate portion 31 , side plate portions 32 and a plurality of projecting plate portions 35 . The side plate portion 32 has a through opening 33 penetrating in the thickness direction. The drawer portion 22 passes through the through opening 33 and is in contact with the plurality of projecting plate portions 35 . A plurality of projecting plate portions 35 are welded to the drawer portion 22 .

The first protruding plate portion 36 of Modification 2 includes a protruding plate main body 36m arranged along the drawer top surface 22a and a plurality of side surfaces arranged along the drawer side surface 22c of the drawer portion 22 from the protruding plate main body 36m. and a portion 36n. Each of the plurality of side portions 36n is provided on the tip portion 35e side of the first protruding plate portion 36. As shown in FIG. For example, the plurality of side portions 36n are formed by bending the projecting plate main body 36m as a base along the drawer side surface 22c. The projecting plate main body 36m is welded to the top surface 22a of the drawer, and the side portion 36n is welded to the side surface 22c of the drawer portion 22. As shown in FIG.

By providing the side portion 36n, the length of the connecting portion formed by welding the projecting plate portion 35 and the lead portion 22 can be further increased. As a result, the cross-sectional area of the connecting portion connecting the coil element and the electrode member 30 can be further increased, and the reliability of the connection between the coil element and the electrode member 30 can be enhanced. In addition, since the cross-sectional area of the current path in the connecting portion can be increased, the direct current resistance can be reduced and the reliability of the inductor can be enhanced. Moreover, since the cross-sectional area of the current path in the connecting portion can be increased, it is possible to suppress temperature rise when the inductor is energized, and to improve the reliability of the inductor.

[Modification 3 of Embodiment]
An inductor 100C according to Modification 3 of the embodiment will be described. In this example, an example in which the width of the tip portion 35e of the first projecting plate portion 36 when viewed in the Y-axis direction is narrower than the width of the root portion 35f will be described.

FIG. 9A is a perspective view of the lead-out portion 22 and the projecting plate portion 35 of the inductor 100C according to Modification 3 of the embodiment. FIG. 9B is a diagram showing a state before the lead-out portion 22 and the projecting plate portion 35 of the inductor 100C are welded.

An inductor 100C of Modification 3 includes a magnetic core 10, a coil element having a coil portion 21 and a lead portion 22, and an electrode member 30 as an external terminal (not shown), as in the first embodiment. The electrode member 30 has a bottom plate portion 31 , side plate portions 32 and a plurality of projecting plate portions 35 . The side plate portion 32 has a through opening 33 penetrating in the thickness direction. The drawer portion 22 passes through the through opening 33 and is in contact with the plurality of projecting plate portions 35 . A plurality of projecting plate portions 35 are welded to the drawer portion 22 .

In the first projecting plate portion 36 of Modification 3, the width of the tip portion 35e away from the side plate portion 32 is narrower than the width of the root portion 35f near the side plate portion 32. As shown in FIG. For example, the width of the tip portion 35e is 0.5 to 0.8 times the width of the root portion 35f. The width of the first protruding plate portion 36 gradually narrows from the root portion 35f toward the tip portion 35e. The width of the root portion 35 f of the first protruding plate portion 36 is wider than the width of the second protruding plate portion 37 . The width of the tip portion 35 e of the first projecting plate portion 36 is the same as the width of the tip portion 35 e of the second projecting plate portion 37 .

As described above, by narrowing the width of the tip portion 35e of the first protruding plate portion 36, when the first protruding plate portion 36 is welded to the drawer portion 22, the tip of the first protruding plate portion 36 The portion 35e can be easily melted. Therefore, welding can be performed without applying excessive heat to the first protruding plate portion 36, and heat transfer to the magnetic core 10 side can be suppressed. Thereby, it is possible to suppress the thermal deterioration of the inductor 100C.

[Modification 4 of Embodiment]
An inductor 100D according to Modification 4 of the embodiment will be described. In this example, the width of the distal end portion 35e of the projecting plate portion 35 when viewed in the Y-axis direction is narrower than the width of the distal end portion 22e of the drawer portion 22 will be described.

FIG. 10A is a perspective view of a lead-out portion 22 and a projecting plate portion 35 of an inductor 100D according to Modification 4 of the embodiment. FIG. 10B is a diagram showing a state before the lead-out portion 22 and the projecting plate portion 35 of the inductor 100D are welded.

An inductor 100D of Modification 4 includes a magnetic core 10, a coil element having a coil portion 21 and a lead portion 22, and an electrode member 30 as an external terminal (not shown), as in the first embodiment. The electrode member 30 has a bottom plate portion 31 , side plate portions 32 and a plurality of projecting plate portions 35 . The side plate portion 32 has a through opening 33 penetrating in the thickness direction. The drawer portion 22 passes through the through opening 33 and is in contact with the plurality of projecting plate portions 35 . A plurality of projecting plate portions 35 are welded to the drawer portion 22 .

In the two projecting plate portions 35 of Modification 4, the width of the tip portion 35e apart from the side plate portion 32 is narrower than the width of the tip portion 22e of the drawer portion 22. As shown in FIG. For example, the width of the tip portion 35e is 0.8 times or more and less than 1 time the width of the tip portion 22e. The width of each projecting plate portion 35 gradually narrows from the root portion 35f toward the tip portion 35e. In the second projecting plate portion 37, although the width of the root portion 35f of the second projecting plate portion 37 is narrower than the width of the root portion 35f of the first projecting plate portion 36, the distance from the root portion 35f to the tip portion is still large. The width gradually narrows toward 35e. The width of the tip portion 35 e of the first projecting plate portion 36 is the same as the width of the tip portion 35 e of the second projecting plate portion 37 .

As described above, by narrowing the width of the tip portion 35e of the projecting plate portion 35, the tip portion 35e of the projecting plate portion 35 is easily melted when welding the first projecting plate portion 36 to the drawer portion 22. be able to. Therefore, welding can be performed without applying excessive heat to the protruding plate portion 35, and heat transfer to the magnetic core 10 side can be suppressed. This can suppress the thermal deterioration of the inductor 100D.

[Modification 5 of Embodiment]
An inductor 100E according to Modification 5 of the embodiment will be described. In this example, the first contact surface 36a of the first projecting plate portion 36 and the second contact surface 37b of the second projecting plate portion 37 are formed on the same surface of the electrode member 30. explain.

FIG. 11A is a perspective view of the lead-out portion 22 and the projecting plate portion 35 of the inductor 100E according to Modification 5 of the embodiment. FIG. 11B is a diagram showing a state before the lead-out portion 22 of the inductor 100E and the projecting plate portion 35 are welded.

Inductor 100E of modification 5 includes magnetic core 10, a coil element having coil portion 21 and lead portion 22, and electrode member 30 as an external terminal (not shown), as in the first embodiment. The electrode member 30 has a bottom plate portion 31 , side plate portions 32 and a plurality of projecting plate portions 35 . The side plate portion 32 has a through opening 33 penetrating in the thickness direction. The drawer portion 22 passes through the through opening 33 and is in contact with the plurality of projecting plate portions 35 . A plurality of projecting plate portions 35 are welded to the drawer portion 22 .

In Modified Example 5, the first contact surface 36a of the first projecting plate portion 36 in contact with the top surface 22a of the drawer and the second contact surface 37b of the second projecting plate portion 37 in contact with the bottom surface 22b of the drawer are electrodes. It consists of the same face of the member 30 . For example, when the plate-shaped electrode member 30 has a first surface that is one of the main surfaces of the plate-shaped member and a second surface that is the other of the two main surfaces, and the first surface is in contact with the side surface 13c of the magnetic core 10, The first contact surface 36a is composed of a portion of the first surface, and the second contact surface 37b is composed of another portion of the first surface. That is, the first contact surface 36 a and the second contact surface 37 b are formed by the same first surface of the electrode member 30 .

12A and 12B are diagrams showing an example of a manufacturing process of the projecting plate portion of the inductor 100E.

First, as shown in FIG. 12(a), a metal plate is punched. At this time, for example, an H-shaped punching process is performed so that a region T1b that will become the first protruding plate portion 36 and a region T2 that will become the second protruding plate portion 37 in a later process remain.

Next, as shown in (b) of FIG. 12 , the above regions T1b and T2 are bent to the side opposite to the surface where the side plate portion 32 abuts on the side surface 13c in a post-process, thereby erecting from the side plate portion 32. A first protruding plate portion 36 and a second protruding plate portion 37 are formed. Further, a through opening 33 is formed in the space left by the bending process. The bending line L1b of the first projecting plate portion 36 substantially coincides with the inner wall 33a of the through opening 33 on the top surface 12 side, and the bending line L2 of the second projecting plate portion 37 is on the bottom surface 11 side of the through opening 33. It substantially matches the inner wall 33b.

By forming the first contact surface 36a and the second contact surface 37b on the same surface of the electrode member 30 as described above, the bending process of the first projecting plate portion 36 and the second projecting plate portion 37 can be simplified. can be performed with high accuracy. In addition, for example, the bending of the first protruding plate portion 36 and the second protruding plate portion 37 can be performed simultaneously using a punch or the like, thereby simplifying the manufacturing process.

[Modification 6 of Embodiment]
An inductor 100F according to Modification 6 of the embodiment will be described. In this example, an example in which the projecting plate portion 35 has the same configuration as that of Modified Example 5 and a part of the side plate portion 32 is raised away from the side surface 13c of the magnetic core 10 will be described.

FIG. 13A is a perspective view of the lead-out portion 22 and the projecting plate portion 35 of the inductor 100F according to Modification 6 of the embodiment. FIG. 13B is a diagram showing a state before the lead-out portion 22 of the inductor 100F and the projecting plate portion 35 are welded.

An inductor 100F of Modification 6 includes, as in Modification 5, a magnetic core 10, a coil element having a coil portion 21 and a lead portion 22, and an electrode member 30 as an external terminal (not shown). The electrode member 30 has a bottom plate portion 31 , side plate portions 32 and a plurality of projecting plate portions 35 . The side plate portion 32 has a through opening 33 penetrating in the thickness direction. The drawer portion 22 passes through the through opening 33 and is in contact with the plurality of projecting plate portions 35 . A plurality of projecting plate portions 35 are welded to the drawer portion 22 .

FIG. 14 is a side view of the side plate portion 32 of the inductor 100F. FIG. 14 shows a view of the side plate portion 32 as seen from the X-axis direction.

As shown in FIG. 14 , the side plate portion 32 of the electrode member 30 has a plurality of raised portions 32g rising apart from the side surface 13c of the magnetic core 10 . A plurality of raised portions 32g are provided on both outer sides of the side surface of the drawer portion 22 (drawer side surface 22c). A space is formed between the raised portion 32g and the side surface 13c. For example, the raised portion 32g has an inclination angle α1 of 45° or more and less than 80° with respect to the side surface 13c. The raised height of the raised portion 32 g is lower than the protrusion height of the protruding plate portion 35 .

FIG. 15 is a diagram showing an example of the manufacturing process of the side plate portion 32 of the inductor 100F.

First, as shown in FIG. 15(a), a metal material plate is punched. At this time, as in Modification 5, punching into a predetermined shape is performed so that a region T1b that will become the first protruding plate portion 36 and a region T2 that will become the second protruding plate portion 37 in a post-process remain. . In Modification 6, the lengths of region T1b and region T2 are longer than in Modification 5 in the Z-axis direction, which is the direction from bottom surface 11 to top surface 12 .

Next, as shown in (b) of FIG. 15 , the above regions T1b and T2 are bent to the side opposite to the surface where the side plate portion 32 abuts on the side surface 13c in a post-process, thereby erecting from the side plate portion 32. A first protruding plate portion 36 and a second protruding plate portion 37 are formed. Also, an opening 33j is formed in the space left by the bending process. At this point, the opening 33j of Modification 6 is longer in the Z-axis direction than the through-opening 33 of Modification 5. FIG. Also, the longer the length of the opening 33j, the longer the projecting lengths of the first projecting plate portion 36 and the second projecting plate portion 37 than in the fifth modification.

Next, as shown in FIG. 15(c), the side plate portions 32 located on both outer sides of the side wall connecting the inner wall on the top surface side and the inner wall on the bottom surface side of the opening 33j are molded with a curved mold 99. , the side plate portion 32 is slid along the surface direction (along the Z-axis direction). As a result, the side plate portion 32 molded by the die 99 rises, and raised portions 32g are formed on both outer sides of the drawer side surface 22c of the drawer portion 22. As shown in FIG.

By providing the raised portion 32g on the side plate portion 32 as in the sixth modification, the projection length of each of the first protruding plate portion 36 and the second protruding plate portion 37 can be increased. According to this, it is possible to prevent the area of the projecting plate portion 35 welded to the drawer portion 22 from being reduced. As a result, it is possible to prevent the reliability of the connection between the drawer portion 22 and the protruding plate portion 35 from deteriorating.

FIG. 16 is a diagram showing another example of the side plate portion 32 of Modification 6 of the embodiment.

In the example shown in FIG. 16, the raised portion 32g has an inclination angle α2 of 80° or more with respect to the side surface 13c of the magnetic core 10 as a reference. It should be noted that the inclination angle α2 is preferably 80° or more and 90° or less. By providing the raised portion 32g on the side plate portion 32 in this way, the projecting length of each of the first projecting plate portion 36 and the second projecting plate portion 37 can be further increased. Therefore, it is possible to prevent the area of the projecting plate portion 35 welded to the drawer portion 22 from being reduced. As a result, it is possible to prevent the reliability of the connection between the drawer portion 22 and the protruding plate portion 35 from deteriorating.

FIG. 17 is a diagram showing another example of the side plate portion 32 of Modification 6 of the embodiment.

In the example shown in FIG. 17, the raised portion 32g has a portion that gradually expands from the side surface 13c of the magnetic core 10. In the example shown in FIG. For example, when the raised portion 32g is viewed in cross section, the raised portion 32g has a curved Greek letter omega (Ω) shape. Between the root and the tip of the raised portion 32g, the protrusion gradually swells away from the root and gradually contracts from the intermediate portion between the root and the tip to the tip. The base of the raised portion 32g has an inclination angle α3 of 90° or more with respect to the side surface 13c of the magnetic core 10. As shown in FIG. By providing the raised portion 32g on the side plate portion 32 in this way, the projecting length of each of the first projecting plate portion 36 and the second projecting plate portion 37 can be further increased. Therefore, it is possible to prevent the area of the projecting plate portion 35 welded to the drawer portion 22 from being reduced. As a result, it is possible to prevent the reliability of the connection between the drawer portion 22 and the protruding plate portion 35 from deteriorating.

[Effects, etc.]
As described above, inductor 100 according to the present embodiment includes magnetic core 10 having bottom surface 11, top surface 12, and side surfaces 13a, 13b, 13c, and 13d connected to bottom surface 11 and top surface 12; A coil element having an embedded coil portion 21, a lead portion 22 connected to an end portion of the coil portion 21 and drawn out of the magnetic core 10 from a side surface (for example, a side surface 13c), and a lead portion disposed on the side surface 13c and a plate-like electrode member 30 electrically connected to the coil element via 22 . The electrode member 30 has a side plate portion 32 arranged along the side surface 13c from which the lead portion 22 is drawn, and a plurality of projecting plate portions 35 projecting from the side plate portion 32 in a direction away from the side surface 13c. The side plate portion 32 has a through opening 33 penetrating in the thickness direction of the side plate portion 32 . The drawer portion 22 passes through the through opening 33 and is in contact with the plurality of projecting plate portions 35 . A plurality of projecting plate portions 35 are welded to the drawer portion 22 .

According to this, it is possible to lengthen the length of the connecting portion formed by welding each protruding plate portion 35 and the lead-out portion 22 . As a result, the cross-sectional area of the connecting portion connecting the coil element and the electrode member 30 can be increased, and the reliability of the connection between the coil element and the electrode member 30 can be improved. In addition, since the cross-sectional area of the current path in the connecting portion can be increased, the direct current resistance can be reduced and the reliability of the inductor can be enhanced. Moreover, since the cross-sectional area of the current path in the connecting portion can be increased, it is possible to suppress temperature rise when the inductor is energized, and to improve the reliability of the inductor.

Also, the plurality of protruding plate portions 35 may be parallel to the bottom surface 11 and face each other with the drawer portion 22 interposed therebetween.

According to this, each of the plurality of protruding plate portions 35 can be reliably brought into contact with the drawer portion 22 . Thereby, the reliability of the connection between the coil element and the electrode member 30 can be improved.

Further, each of the projecting plate portions 35 may rise from a portion of the boundary region between the side plate portion 32 and the through opening 33 .

According to this, the plurality of protruding plate portions 35 can be arranged near the drawer portion 22 penetrating through the through opening 33 and brought into contact with the drawer portion 22 reliably. Thereby, the reliability of the connection between the coil element and the electrode member 30 can be improved.

Also, the plurality of protruding plate portions 35 has a first protruding plate portion 36 and a second protruding plate portion 37 positioned closer to the bottom surface 11 than the first protruding plate portion 36 . The drawer portion 22 has a rectangular cross section, and has a drawer top surface 22a parallel to the top surface 12 and a drawer bottom surface 22b positioned closer to the bottom surface 11 than the drawer top surface 22a. The first projecting plate portion 36 may be welded to the drawer top surface 22a, and the second projecting plate portion 37 may be welded to the drawer bottom surface 22b.

According to this structure, each of the first protruding plate portion 36 and the second protruding plate portion 37 can be reliably welded to the drawer portion 22 . Thereby, the reliability of the connection between the coil element and the electrode member 30 can be improved.

Also, the first protruding plate portion 36 may have a protruding plate opening 36 h connected to the through opening 33 of the side plate portion 32 .

According to this, for example, the bending process of the first protruding plate portion 36 can be performed easily and accurately. Therefore, the first projecting plate portion 36 can be reliably brought into contact with the drawer portion 22 . Thereby, the reliability of the connection between the coil element and the electrode member 30 can be improved.

The first protruding plate portion 36 includes a protruding plate main body 36m arranged along the drawer top surface 22a, and a plurality of protruding plate main bodies 36m arranged along the side surface of the drawer portion 22 (drawer side surface 22c) from the protruding plate main body 36m. and a side portion 36n. The projecting plate main body 36m may be welded to the top surface 22a of the drawer, and the side portion 36n may be welded to the side surface of the drawer portion 22 (drawer side surface 22c).

By providing the side portion 36n, the length of the connecting portion formed by welding the projecting plate portion 35 and the lead portion 22 can be further increased. As a result, the cross-sectional area of the connecting portion connecting the coil element and the electrode member 30 can be further increased, and the reliability of the connection between the coil element and the electrode member 30 can be improved.

Further, the first projecting plate portion 36 may have a width of the tip portion 35 e away from the side plate portion 32 narrower than the width of the base portion 35 f near the side plate portion 32 .

By narrowing the width of the tip portion 35e of the first protruding plate portion 36 in this way, for example, when welding the first protruding plate portion 36 to the drawer portion 22, the first protruding plate portion 36 can be The tip portion 35e can be easily melted. Therefore, welding can be performed without applying excessive heat to the first protruding plate portion 36, and heat transfer to the magnetic core 10 side can be suppressed. Thereby, it is possible to suppress the thermal deterioration of the inductor 100C.

Further, the width of the distal end portion 35 e of the plurality of protruding plate portions 35 separated from the side plate portion 32 may be narrower than the width of the distal end portion 22 e of the drawer portion 22 .

By narrowing the width of the tip 35e of the protruding plate portion 35 in this manner, the tip 35e of the protruding plate portion 35 can be easily melted when welding the first protruding plate portion 36 to the drawer portion 22. can be done. Therefore, welding can be performed without applying excessive heat to the projecting plate portion 35, and heat transfer to the magnetic core 10 side can be suppressed. This can suppress the thermal deterioration of the inductor 100D.

Also, the protruding length of the protruding plate portion 35 protruding from the side plate portion 32 may be 1.5 times or more the plate thickness of the protruding plate portion 35 .

According to this, it is possible to increase the connection area by enlarging the fusion zone when the plurality of projecting plate portions 35 and the lead-out portion 22 are welded together. In addition, since the cross-sectional area of the current path in the connecting portion can be increased, the direct current resistance can be reduced and the reliability of the inductor can be enhanced. Moreover, since the cross-sectional area of the current path in the connecting portion can be increased, it is possible to suppress temperature rise when the inductor is energized, and to improve the reliability of the inductor.

A first contact surface 36a of the first protruding plate portion 36 in contact with the top surface 22a of the drawer and a second contact surface 37b of the second protruding plate portion 37 in contact with the bottom surface 22b of the drawer are They may be configured on the same plane.

By forming the first contact surface 36a and the second contact surface 37b on the same surface of the electrode member 30 in this manner, for example, the bending of the first projecting plate portion 36 and the second projecting plate portion 37 can be performed. This can be done easily and accurately. Therefore, the first projecting plate portion 36 can be reliably brought into contact with the drawer portion 22 . Thereby, the reliability of the connection between the coil element and the electrode member 30 can be improved. In addition, the bending of the first protruding plate portion 36 and the second protruding plate portion 37 can be performed at the same time, thereby simplifying the manufacturing process.

Further, the side plate portion 32 of the electrode member 30 may have protuberant portions 32g that rise away from the side surface 13c of the magnetic core 10 on both outer sides of the side surface (lead side surface 22c) of the lead portion 22. As shown in FIG.

By providing the side plate portion 32 with the raised portion 32g in this way, the projection length of each of the first protruding plate portion 36 and the second protruding plate portion 37 can be increased. According to this, it is possible to prevent the area of the projecting plate portion 35 welded to the drawer portion 22 from being reduced. As a result, it is possible to prevent the reliability of the connection between the coil element and the electrode member 30 from deteriorating.

Also, the raised portion 32g may have an inclination angle of 80° or more with respect to the side surface 13c.

Thus, by providing the raised portion 32g having the inclination angle α1 of 80° or more, the projection length of each of the first protruding plate portion 36 and the second protruding plate portion 37 can be increased. According to this, it is possible to prevent the area of the projecting plate portion 35 welded to the drawer portion 22 from being reduced. As a result, it is possible to prevent the reliability of the connection between the coil element and the electrode member 30 from deteriorating.

Also, the raised portion 32g may have a portion that gradually expands from the side surface 13c.

By providing the raised portion 32g having such a swelling portion, the projection length of each of the first protruding plate portion 36 and the second protruding plate portion 37 can be increased. According to this, it is possible to prevent the area of the projecting plate portion 35 welded to the drawer portion 22 from being reduced. As a result, it is possible to prevent the reliability of the connection between the coil element and the electrode member 30 from deteriorating.

(Other embodiments, etc.)
Although the inductors and the like according to the embodiments and modifications of the present disclosure have been described above, the present disclosure is not limited to the above embodiments and modifications. As long as it does not depart from the gist of the present disclosure, various modifications that a person skilled in the art can think of are applied to the embodiment and each modification, and another constructed by combining some components in the embodiment and each modification forms are also included in the scope of the present disclosure.

In the above embodiment, the bottom plate portion 31, the side plate portion 32, the first protruding plate portion 36, the second protruding plate portion 37, and the locking portion 38 of the electrode member 30 are formed of one member made of the same material. Although an example formed by processing has been shown, the present invention is not limited to this. For example, the electrode member 30 is formed by connecting the bottom plate portion 31, the side plate portion 32, the first protruding plate portion 36, the second protruding plate portion 37, and the locking portion 38, which are made of different members. may be formed.

In the embodiment described above, the coil portion 21 and the lead portion 22 of the coil element are formed by processing one member made of the same material, but the present invention is not limited to this. The coil element may be formed by connecting the coil portion 21 and the lead portion 22 which are made of different members.

In the above embodiment, the conductive wire has a rectangular cross section, but the cross section is not limited to this. The conductor wire may have a circular cross-section, and the lead-out portion 22 may be at least partially flattened to facilitate connection with the electrode member 30 . .

In the above-described embodiment, an example in which the lead-out portion 22 is led out from a height closer to the bottom surface 11 than the center of the side surface 13c is shown, but the present invention is not limited to this. The drawer portion 22 may be drawn out from a height closer to the top surface 12 than the center of the side surface 13c.

Further, for example, the present disclosure also includes an electric product or an electric circuit using the inductor described above. Examples of electric products include a power supply device including the above-described inductor, various devices including the power supply device, and the like.

The inductor according to the present disclosure is useful as an inductor used in various devices and equipment.

REFERENCE SIGNS LIST 10 magnetic core 11 bottom surface 11a bottom recessed portion 12 top surface 13a, 13b, 13c, 13d side surface 21 coil portion 22 drawer portion 22a drawer top surface 22b drawer bottom surface 22c drawer side surface 22e tip portion 30 electrode member 31 bottom plate portion 31a bottom crimped portion 32 side plate portion 32g raised portion 33 through opening 33a, 33b inner wall 33i, 33j opening 35 projecting plate portion 35e tip portion 35f root portion 36 first projecting plate portion 36a first contact surface 36h projecting plate opening 36m projecting plate main body 36n side portion 37 second 2 projecting plate portion 37b second contact surface 38 locking portion 38a opening 99 mold 100, 100A, 100B, 100C, 100D, 100E, 100F inductor 131d convex portion L1, L1a, L1b, L2 bending line ws welding mark T1 , T1a, T1b, T2 Regions α1, α2, α3 Tilt angles

Claims (13)

a magnetic core having a bottom surface, a top surface, and side surfaces connected to the bottom surface and the top surface;
a coil element having a coil portion embedded in the magnetic core, and a lead portion connected to an end portion of the coil portion and led out of the magnetic core from the side surface;
a plate-shaped electrode member disposed on the side surface and electrically connected to the coil element via the lead portion;
The electrode member has a side plate portion arranged along the side surface from which the lead portion is drawn, and a plurality of protruding plate portions protruding from the side plate portion in a direction away from the side surface,
The side plate portion has a through opening penetrating in the thickness direction of the side plate portion,
the drawer portion passes through the through opening and contacts the plurality of projecting plate portions;
The plurality of projecting plate portions are welded to the lead portion. Inductor. 2. The inductor according to claim 1, wherein the plurality of projecting plate portions are parallel to the bottom surface and face each other with the lead portion interposed therebetween. The inductor according to claim 1 or 2, wherein each of the plurality of projecting plate portions rises from a portion of a boundary region between the side plate portion and the through opening. The plurality of projecting plate portions have a first projecting plate portion and a second projecting plate portion positioned closer to the bottom surface than the first projecting plate portion,
The drawer part has a rectangular cross section, and has a drawer top face parallel to the top face and a drawer bottom face located closer to the bottom face than the drawer top face,
The first projecting plate portion is welded to the top surface of the drawer,
The second projecting plate portion is welded to the bottom surface of the drawer,
4. The inductor according to claim 2 or 3. The inductor according to claim 4, wherein the first protruding plate portion has a protruding plate opening connected to the through opening of the side plate portion. The first protruding plate portion has a protruding plate body arranged along the top surface of the drawer, and a plurality of side portions arranged along side surfaces of the drawer portion from the protruding plate body,
The projecting plate body is welded to the top surface of the drawer,
The inductor according to claim 4, wherein the side portion is welded to a side surface of the lead portion. 5 . The inductor according to claim 4 , wherein the first protruding plate has a width of a tip portion remote from the side plate portion narrower than a width of a base portion close to the side plate portion. 2 . The inductor according to claim 1 , wherein the plurality of protruding plate portions have a tip width that is narrower than the width of the tip portion of the lead-out portion, which is remote from the side plate portion. The inductor according to claim 1, wherein the projecting length of the projecting plate portion projecting from the side plate portion is 1.5 times or more the plate thickness of the projecting plate portion. A first contact surface of the first protruding plate portion contacting the top surface of the drawer and a second contact surface of the second protruding plate portion contacting the bottom surface of the drawer are formed by the same surface of the electrode member. The inductor according to claim 4, wherein: 2. The inductor according to claim 1, wherein the side plate portions of the electrode member have protuberant portions that rise apart from the side surfaces of the magnetic core on both outer sides of the side surfaces of the lead portions. 12. The inductor according to claim 11, wherein the raised portion has an inclination angle of 80[deg.] or more with respect to the side surface. 12. The inductor according to claim 11, wherein the raised portion has a portion that gradually expands from the side surface.

Images