JP4544225B2 - Coil parts - Google Patents

Description

  The present invention relates to a coil component, and relates to a coil component that satisfies the required characteristics of low resistance and large current.

Conventionally, in order to change the characteristics of a circuit in an electric circuit, a coil component including a choke coil having a drum core and an outer peripheral core and having a conductive wire wound around the drum core is disposed. In this coil component, it is necessary to form a predetermined gap (gap) between the drum core forming the magnetic path and the outer core in order to obtain desired characteristics such as magnetic saturation characteristics. In order to form this gap, as disclosed in Patent Document 1, a protrusion is provided on the outer peripheral core, and a means for forming a gap and controlling the gap is disclosed by contacting the protrusion and the drum core. Has been.
JP 2002-313635 A

  However, in the conventional coil component, since the outer core protrusion is in contact with the drum core to manage the gap, the magnetic flux passes through the protrusion, so that magnetic saturation is likely to occur in the minute current region, and the inductance value L increases. Was. In this case, the response speed of the power supply circuit IC included in the electric circuit may be slow, and the voltage conversion efficiency of the power supply circuit may deteriorate. In this case, loss occurs, which causes a problem that the life of the battery connected to the circuit is reduced.

  Accordingly, an object of the present invention is to provide a quantitatively stable coil component in which a change in inductance value is small even in a minute current region.

In order to solve the above problems, the present invention provides a drum core having a core portion configured in a column shape and a pair of flange portions provided on the core portion at both axial ends of the central axis of the core portion; Insulating coated conductor wound around the core, a plurality of split cores arranged so as to surround the outer periphery of the drum core, and a non-magnetic material having electrical insulation provided in a predetermined portion between the drum core and the split core Provided is a coil component having a layer and an electrode provided on at least one of a drum core and a plurality of divided cores and having a connecting portion to which an end portion of an insulating coated conductor is connected. In this coil component, the pair of flange portions has an outer peripheral surface formed around the axis of the central axis, the plurality of divided cores each have an inner peripheral surface facing the outer peripheral surface, and the nonmagnetic layer is the winding core portion. except, with over the entire periphery of each of the outer peripheral surface provided between the outer surface and the inner circumferential surfaces of the pair of flange portions, and the plurality of divided cores and the drum core is connected via a non-magnetic layer, single A plurality of protrusions projecting toward the outer peripheral surface are provided on the inner peripheral surface of the split core, and the one split core and the drum core are connected in a state where the protrusions are in contact with the nonmagnetic layer .

  According to such a configuration, since the drum core and the split core are coupled via the nonmagnetic layer, the drum core and the split core can be brought into contact with each other. Since the gap between the drum core and the split core can be controlled by the nonmagnetic layer, the accuracy of the gap can be improved.

In addition, since the nonmagnetic layer is provided between the outer peripheral surface of the pair of flanges and the inner peripheral surface of the split core, a space for winding the winding can be increased, and the winding length can be increased. If they are the same, the number of turns can be increased, and if the number of turns is the same, the winding length can be shortened. Therefore, when the same inductance value is realized, the resistance can be suppressed low. Even with the same inductance value, the resistance can be reduced by using a thicker winding. By providing the protrusion, a large gap can be taken between the split core and the drum core in a state where the split core and the drum core are not in contact with each other, and the width of the gap adjustment can be increased. By forming the nonmagnetic layer on the entire outer peripheral surface, the nonmagnetic layer can be easily formed on the drum core. In addition, the degree of freedom in the position of drawing out the insulated conductor and the position of the split core can be increased. Since the nonmagnetic layer is provided over the entire circumference of each outer peripheral surface, more accurate gap control can be performed.

  Moreover, it is preferable that the nonmagnetic layer is also provided between one protrusion and another protrusion. According to such a configuration, the nonmagnetic layer can be used as an adhesive for connecting the drum core and the split core. Since the protrusions are at both ends of the nonmagnetic layer, the nonmagnetic layer as an adhesive can be made to have an equal thickness.

  According to the coil component of the present invention, it is possible to provide a quantitatively stable coil component with little change in inductance value even in a minute current region.

  Hereinafter, the coil component which concerns on embodiment of this invention is demonstrated based on FIGS. As shown in FIG. 1, the coil component 1 has an outer shape of about 3 mm square and is surface-mounted with a reflow solder on a printed circuit board or the like, and is applied to a power supply circuit of an electronic device such as a mobile phone or a hard disk device. For example, it is preferably used at a switching frequency of 250 KHz to 2 MHz.

  As shown in FIG. 1, the coil component 1 is mainly composed of a drum core 2 and an outer peripheral core 3, and a winding 7 is wound around a core portion 23 (FIG. 2) to be described later. The outer core 3 is provided with a first electrode 61 and a second electrode 62 which will be described later.

  As shown in FIG. 2, the drum core 2 is made of a magnetic material such as ferrite as a base material, and as shown in FIG. 2, the substantially cylindrical core portion 23 and the first flange portion provided coaxially at both ends in the central axis direction of the core portion 23. 21 and the second flange 22. The first brim part 21 and the second brim part 22 are each configured in a disk shape having substantially the same shape, and the first side surface 21A and the second side face are provided as outer peripheral surfaces that respectively serve as the buttock facing surfaces at the outer peripheral position of the disc. Two side surfaces 22 </ b> A are defined, and a first outer surface 21 </ b> B and a second outer surface 22 </ b> B are defined on the opposite sides of the connection surface with the core portion 23.

  The first side surface 21A of the drum core 2 is coated with a nonmagnetic layer 82, the first outer surface 21B is coated with a nonmagnetic layer 83, the second side surface 22A is coated with a nonmagnetic layer 85, and the second outer surface 22B is coated with a nonmagnetic layer. Covered with a layer 86. The nonmagnetic layer 82 and the nonmagnetic layer 83 (collectively referred to as nonmagnetic layer 84), the nonmagnetic layer 85 and the nonmagnetic layer 86 (collectively referred to as nonmagnetic layer 87) are made of a nonmagnetic insulating material as a base material. Yes. The nonmagnetic insulating material is provided only on the first side surface 21A and the second side surface 22A on the surface facing the outer peripheral core 3 of the drum core 2, and is a core other than the first side surface 21A and the second side surface 22A. It is not provided on the surface of the portion 23. Therefore, the core part 23 is in a state where at least the nonmagnetic layer is not provided.

  The winding 7 wound around the core portion 23 is configured by applying an insulating urethane coating to a copper wire, and both ends thereof are a first electrode 61 and a second electrode 62 (FIGS. 1 and 4) described later. ).

  As shown in FIG. 1, the outer peripheral core 3 includes a first divided core 4 and a second divided core 5. Since the first divided core 4 and the second divided core 5 have the same shape, only the first divided core 4 will be described below unless otherwise specified.

  The first split core 4 is made of a magnetic material such as ferrite as a base material, and as shown in FIG. 3, the inner curved surface 4A that is the outer core facing the first side surface 21A and the second side surface 22A (FIG. 2). have. The inner curved surface 4A is formed in an arc shape, and the length in the arc direction is configured to be slightly more than ¼ of the circumferential length of the first side surface 21A and the second side surface 22A.

  In the inner curved surface 4 </ b> A, the first split core 4 in the direction from the first collar 21 to the second collar 22 in a direction perpendicular to the arc direction, that is, in a state where the first split core 4 is arranged at the outer peripheral position of the drum core 2. As shown in FIG. 1, the thickness is configured to substantially cover the thickness (axial length) direction of the drum core 2.

  As shown in FIG. 3, a first protrusion 41 and a second protrusion 42 are provided on the inner curved surface 4 </ b> A at positions near both ends in the arc direction. The first projecting portion 41 and the second projecting portion 42 extend in directions that coincide with the axial direction of the drum core 2, and are respectively formed on the nonmagnetic layer 82 and the nonmagnetic layer 85 on the first side surface 21 </ b> A and the second side surface 22 </ b> A. It is in contact. Therefore, since the drum core 2 and the first divided core 4 are connected via the nonmagnetic layer 82 and the nonmagnetic layer 83, the drum core 2 and the first divided core 4 can be brought into contact with each other. Since the gap between the drum core 2 and the first divided core 4 can be controlled by the nonmagnetic layer 82 and the nonmagnetic layer 83, the accuracy of the gap can be improved.

  Moreover, between the inner curved surface 4A and the first side surface 21A and the second side surface 22A, as shown in FIGS. 1 and 4, it is fixed by an adhesive 71 using a nonmagnetic insulating material as a base material. The inner curved surface 5A is fixed between the first side surface 21A and the second side surface 22A with an adhesive 73 made of a nonmagnetic insulating material. The adhesive 71 and the adhesive 73 are preferably made of the same material as the nonmagnetic layer 82 and the nonmagnetic layer 85. Since the 1st projection part 41 and the 2nd projection part 42 exist in the both ends of the adhesive agent 73 which is a nonmagnetic layer, the adhesive agent 73 can be made uniform thickness and a uniform gap can be comprised. Further, since the first protruding portion 41 and the second protruding portion 42 are provided, a large gap is provided between the first divided core 4 and the drum core 2 in a state where the first divided core 4 and the drum core 2 are not in contact with each other. This can widen the gap adjustment range.

  As shown in FIGS. 1, 4, and 5, the first electrode 61 is disposed on the outer surface 4 </ b> B that is the outer peripheral position of the first split core 4 in a state where the first split core 4 is disposed at the outer peripheral position of the drum core 2. Is fixed by an adhesive 75. As shown in FIG. 5, the first electrode 61 is disposed up to the lower surface 4 </ b> C of the first divided core 4, i.e., the board mounting surface, and when the coil component 1 is surface mounted on the board (not shown), The electrode is electrically connected.

  A connecting portion 61A is provided at the end of the first electrode 61 so as to be disposed between the first divided core 4 and the second divided core 5, and the winding portion 7A is connected to the connecting portion 61A. One end is arranged and electrically connected by welding or the like as shown in FIG. A similar second electrode 62 is also fixed to the second divided core 5 via an adhesive 77 and arranged up to the board mounting surface of the second divided core 5. Further, at the end portion of the second electrode 62, a connecting portion 62A is provided so as to be disposed between the first divided core 4 and the second divided core 5, and the winding portion 7A is wound around the connecting portion 62A. The other end is arranged and electrically connected by welding or the like.

  The operation of the coil component 1 configured as described above will be described. When the coil component 1 is energized, a magnetic flux is generated between the drum core 2 and the outer core 3. A magnetic gap is formed between the drum core 2 and the outer core 3 by the nonmagnetic layer 82 and the nonmagnetic layer 85 formed between the first side surface 21A and the second side surface 22A and the inner curved surface 4A or the inner curved surface 5A. Is formed. This magnetic gap is preferably formed by controlling the thicknesses of the nonmagnetic layer 82 and the nonmagnetic layer 85. By providing this magnetic gap, the time at which magnetic saturation occurs is delayed, and a rapid change in inductance value accompanying a change in current is suppressed.

  For example, as shown in FIG. 6, the direct current superposition characteristics of the coil component 1 change depending on the presence or absence of the nonmagnetic layer 84 and the nonmagnetic layer 87. That is, when there is no nonmagnetic layer, as shown by the broken line in the figure, the inductance value is about 15 microhenries or more in the minute current region, but when the current is over 900 milliamperes, it becomes 2 microhenries. As the current increases, the inductance value decreases. On the other hand, when there is a nonmagnetic layer, the inductance value is maintained in the range of about 10 to 8 microhenries over a current range of about 800 milliamperes or more from a minute region.

  As described above in detail, according to the coil component 1 according to the first embodiment, the magnetic gap is provided between the drum core 2 and the outer core 3 by providing the nonmagnetic layer 82 and the nonmagnetic layer 85. Can be reliably formed. Further, the nonmagnetic layer 82 and the nonmagnetic layer 85 prevent the first protrusion 41 and the second protrusion 42 from coming into contact with the flange 21 and the flange 22, so that the inductance value in the minute current region can be reduced. By suppressing the increase, the decrease in the response of the coil component 1 and the decrease in the voltage conversion efficiency, the power loss can be reduced and the battery life can be improved. Since the magnetic gap is formed by the nonmagnetic layer 82 and the nonmagnetic layer 85, the time when magnetic saturation occurs can be delayed, the change of the inductance value due to the current is reduced, and the inductance value is maintained even at a larger current. I'm leaning.

  In the coil component 1, since a nonmagnetic layer is not formed around the winding core portion 23, the winding can be wound by being defined by the first flange portion 21, the second flange portion 22, and the winding core portion 23. A large cross-sectional area can be secured. For this reason, if the winding length is the same, the number of turns can be increased to increase the inductance value. If the number of turns is the same, the winding length can be shortened, and in order to obtain the same inductance value, it is also possible to use a winding having a larger cross-sectional area, so that the resistance value as the coil component 1 can be reduced. It is possible to reduce the loss and further improve the power efficiency.

  The connecting portion 61A and the connecting portion 62A for electrical connection between the winding 7 and the outside are disposed between the first divided core 4 and the second divided core 5, and the outer surface 21B and the outer surface The size of the coil component 1 can be reduced as compared with the case where the connecting portion is provided outside 22B, and the integration efficiency of the circuit can be improved.

  Further, by providing the non-magnetic layer 83 or the non-magnetic layer 86 having electrical insulation, it is possible to ensure insulation between the drum core 2 and the substrate when mounted on a printed circuit board.

  A coil component according to a second embodiment of the present invention will be described with reference to FIGS. The coil component 100 according to the second embodiment is different from the coil component 1 in the shape of the outer peripheral core 130. As shown in FIG. 7, the coil component 100 is mainly composed of a drum core 2 and an outer peripheral core 130, and the winding 7 is wound around the core portion 23, similar to the coil component 1. The outer core 130 is provided with a first electrode 61 and a second electrode 62 as in the outer core 3.

  The base material and configuration of the drum core 2 are the same as those of the coil component 1. The outer core 130 is composed of a third divided core 140 and a fourth divided core 150. Since the third divided core 140 and the fourth divided core 150 have the same shape, only the third divided core 140 will be described below unless otherwise specified.

  The third divided core 140 uses, for example, a Ni—Cu—Zn-based magnetic material as a base material, and has an inner curved surface 140A that is an outer peripheral core facing surface facing the first side surface 21A and the second side surface 22A of the drum core 2. ing. The inner curved surface 140A is configured in an arc shape like the inner phase 4A, and the arc direction length is configured to be slightly more than ¼ of the circumferential length of the first side surface 21A and the second side surface 22A. Has been. Further, the thickness of the inner curved surface 140 </ b> A in the direction orthogonal to the arc direction is configured to substantially cover the thickness (axial length) direction of the drum core 2.

  The first protrusion 41 and the second protrusion 42 provided on the inner curved surface 4 </ b> A of the first divided core 4 are not provided on the third divided core 140. Therefore, the inner curved surface 140 </ b> A can directly contact the nonmagnetic layer 82 and the nonmagnetic layer 85 of the first side surface 21 </ b> A and the second side surface 22 </ b> A of the drum core 2. Further, the inner curved surface 140A and the first side surface 21A and the second side surface 22A are fixed by an adhesive 71 based on a nonmagnetic insulating material. The inner curved surface 150A and the first side surface 21A and the second side surface 22A are fixed by an adhesive 73 made of a nonmagnetic insulating material as a base material.

  As shown in FIGS. 7 and 8, the first electrode 61 is attached to the outer surface 140 </ b> B that is the outer peripheral position of the third split core 140 in a state where the third split core 140 is disposed at the outer peripheral position of the drum core 2. 75 is fixed. The first electrode 61 is disposed up to the lower surface 140C of the third divided core 140, that is, the board mounting surface, and is electrically connected to the electrode on the board when the coil component 100 is surface mounted on the board (not shown). Is done. The end portion of the first electrode 61 is provided with a connecting portion 61A so as to be disposed between the third divided core 140 and the fourth divided core 150. One end is arranged and connected. A similar second electrode 62 is also fixed to the fourth divided core 150 via an adhesive 77 and arranged up to the board mounting surface of the fourth divided core 150. Further, at the end of the second electrode 62, a connecting portion 62A is provided so as to be disposed between the third divided core 140 and the fourth divided core 150, and the winding portion 7A is wound around the connecting portion 62A. The other end is arranged and connected.

  Thus, by forming the outer peripheral core 130 with the third divided core 140 and the fourth divided core 150 having no protrusion, the inner curved surface 140A and the inner curved surface 150A can be brought closer to the drum core 2, and the first embodiment In addition to the effect of the coil component 1 according to the form, further downsizing is possible. By reducing the magnetic gap between the outer peripheral core 130 and the drum core 2, it is possible to reliably delay the time at which magnetic saturation occurs.

  The coil component according to the present invention is not limited to the above-described embodiment, and various modifications and improvements can be made within the scope described in the claims. For example, the nonmagnetic layer 82 is provided on the entire circumference of the first side surface 21A, and the nonmagnetic layer 85 is provided on the entire periphery of the second side surface 22A. The nonmagnetic layer 85 may be provided only between the second side surface 22A and the inner curved surface 5A only between the inner curved surface 4A. Either the nonmagnetic layer 83 or the nonmagnetic layer 86 may be used. At this time, it is preferable that the side on which the nonmagnetic layer is provided is the substrate mounting surface. Further, the drum core and the outer peripheral core only have to be made of a magnetic material, and it is assumed that Mn—Zn-based or Ni—Cu—Zn-based ferrite is used as a base material.

  The coil component of the present invention can be used for a power supply circuit of an electronic device such as a mobile phone or a hard disk device.

The perspective view of the coil components by 1st Embodiment. The side view of the drum core of the coil components by 1st Embodiment. The perspective view of the outer periphery core of the coil components by 1st Embodiment. FIG. 3 is a schematic plan view of the coil component according to the first embodiment. Sectional drawing of the coil components by 1st Embodiment. The graph which compared the direct current superimposition characteristic of the coil components by 1st Embodiment by the presence or absence of a nonmagnetic layer. The perspective view of the coil components by 2nd Embodiment. Sectional drawing of the coil components by 2nd Embodiment.

Explanation of symbols

  1: Coil parts 2: Drum core 3: Outer core 4: First divided core 4A: Inner curved surface 4B: Outer surface 5: Second divided core 7: Winding 21: First flange 21A: First side 22: Second Eaves part 22A: Second side surface 23: Core part 82, 83, 84, 85, 86, 87: Nonmagnetic layer

Claims (2)

A drum core having a core portion configured in a column shape and a pair of flange portions provided on the core portion at both axial ends of the central axis of the core portion;
An insulation coated conductor wound around the core;
A plurality of split cores arranged to surround the outer periphery of the drum core;
A nonmagnetic layer provided in a predetermined portion between the drum core and the split core and having electrical insulation;
An electrode having a connecting portion provided on at least one of the drum core or the plurality of divided cores and connected to an end of the winding; and
The pair of collars have outer peripheral surfaces formed around the central axis,
The plurality of divided cores each have an inner peripheral surface facing the outer peripheral surface,
The nonmagnetic layer is provided between the outer peripheral surface and the inner peripheral surface of the pair of flanges and extends over the entire circumference of each of the outer peripheral surfaces except for the core portion .
The plurality of split cores and the drum core are connected via the nonmagnetic layer ,
A plurality of protrusions projecting toward the outer peripheral surface are provided on the inner peripheral surface of the one split core,
The coil component , wherein the one split core and the drum core are connected in a state in which the protrusion is in contact with the nonmagnetic layer . The coil component according to claim 1 , wherein the nonmagnetic layer is also provided between one of the protrusions and the other protrusion .

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