JP6565315B2 - Coil parts - Google Patents

Description

The present invention relates to a coil component such as an inductor element in which a winding portion in which a winding is wound in a coil shape is embedded in a magnetic molded body made of a magnetic material.

In Patent Document 1, after winding a winding portion composed of a winding having an insulating coating embedded in a magnetic material, an appropriate pressurizing means (for example, a powder press device) is used for winding the winding portion. An inductor is disclosed which is a coil component in which a winding portion is embedded in a magnetic molded body by pressure molding in parallel directions at 0.5 to 2.0 GPa.

JP 2007-13176 A

However, in the conventional coil component disclosed in Patent Document 1, since the windings are in close contact with each other to form a winding part, the winding part is buried in a magnetic material and then press-molded. The produced coil component such as an inductor is plastically deformed so that the winding of the winding portion embedded at the time of pressure molding is crushed in a direction parallel to the winding axis. This plastic deformation causes a compressive stress toward the center of the magnetic molded body formed on the inner peripheral portion of the winding portion, and as a result, the center of the magnetic molded body formed on the inner peripheral portion of the winding portion is at the winding shaft. Parallel tensile stresses are generated. For this reason, there existed a problem that a crack will arise in the magnetic molding formed in the inner peripheral part of a coil | winding part.

Therefore, the present invention has been made to solve the above-described problem, and a winding is formed by winding a winding around a magnetic molded body made of a magnetic material in which a magnetic body and a binder are mixed. An object of the present invention is to provide a highly reliable coil component in which cracks are prevented from occurring in a magnetic molded body formed in an inner peripheral portion of a winding portion in a coil component having an embedded portion.

The present invention solves the above-described conventional problems, and a coil component according to the present invention includes a magnetic molded body made of a magnetic material including a magnetic body and a binder, and a winding embedded in the magnetic molded body. A coil part having at least two or more coils and a connecting conductor electrically connecting the coils adjacent to each other, the two or more coils being spaced apart from each other. It is characterized by being arranged.

The coil component according to the present invention is characterized in that the magnetic material is disposed between the two or more coils.

The coil component according to the present invention is characterized in that at least the two or more coils are stacked and arranged so as to share the winding axis of the winding in the winding axis direction of the winding.

The coil component according to the present invention is characterized in that the two or more coils and a winding portion made of a connecting conductor for electrically connecting the coils close to each other are formed by two types of winding pitches. .

In the coil component according to the present invention, in the two types of winding pitches, the winding pitch that forms the connecting conductors that electrically connect the adjacent coils is the winding pitch that forms the two or more coils. It is characterized by being larger.

The coil component according to the present invention is characterized in that the connecting wire for electrically connecting the coils adjacent to each other is formed by one or less windings.

According to the present invention, the stress in the direction parallel to the winding axis of the coil applied to the winding forming the coil is reduced when pressure forming after the winding portion is buried in the magnetic material. Due to the improvement in the crushing (plastic deformation) in the direction parallel to the winding axis, the generation of the compressive stress toward the center of the magnetic molded body formed on the inner periphery of the winding portion and the compression stress Since the generation of tensile stress in the direction parallel to the winding axis at the center of the magnetic molded body formed on the inner peripheral portion of the winding portion is reduced, the magnetic molded body formed on the inner peripheral portion of the winding portion It is possible to prevent the occurrence of cracks.

It is a top view of the coil component in one Embodiment of this invention. It is a side view of the coil component in one Embodiment of this invention. It is sectional drawing of the AA 'surface in FIG. 1 of the coil components in one Embodiment of this invention. It is a top view of the coil component in other embodiment of this invention. It is a side view of the coil components in other embodiment of this invention. It is sectional drawing of the AA 'surface in FIG. 4 of the coil components in other embodiment of this invention. It is sectional drawing of the BB 'surface in FIG. 4 of the coil components in other embodiment of this invention. It is a top view of the conventional coil components. It is a side view of the conventional coil components. It is sectional drawing of the AA 'surface in FIG. 8 of the conventional coil components.

Hereinafter, a specific configuration of the present invention will be described in detail.

An example of the structure of the coil component of the present embodiment is shown in FIGS. The coil component of the present embodiment includes a magnetic molded body 2 and a winding portion 5 embedded in the magnetic molded body 2.

Moreover, this embodiment is not limited to this, For example, it can also be set as the structure shown in FIG.4, FIG.5, FIG.6 and FIG.

The winding portion 5 is formed between at least two or more coils 4 (for example, the coil 4 (a) and the coil 4 (b)) formed by winding the winding 3, and at least two or more coils 4 ( For example, it consists of a connecting wire 6 that electrically connects the coil 4 (a) and the coil 4 (b). The connection conductor 6 is led out from the end of one of the at least two coils 4 and introduced from the end of another adjacent coil 4 (for example, the end of the coil 4 (a)). And is introduced from the end of the coil 4 (b)). That is, after winding one coil 4 (for example, the coil 4 (a)) of at least two or more coils 4, the winding 3 is not cut, and another coil 4 (which is adjacent to the coil 4 with a gap therebetween) ( For example, the connection conductor 6 is formed between at least two or more coils 4 (for example, between the coils 4 (a) and 4 (b)) by winding the coil 4 (b). At the same time, a gap 8 is formed between each of at least two or more coils 4 (for example, coil 4 (a) and coil 4 (b)).
Of course, each of the at least two or more coils 4 (for example, the coil 4 (a) and the coil 4 (b)) is separately manufactured, and each of the coils 4 (for example, the coil 4 (a) and the coil 4 (b) is manufactured. It is also possible to connect the end portions of the winding 3 in)) with a connection conductor 6 prepared separately.

In addition, as shown in FIGS. 4, 5, 6 and 7, the two or more coils 4 and the coils 4 adjacent to each other (for example, the coil 4 (a) and the coil 4 (b)) are electrically connected. It is also possible to form the winding portion 5 made of the connecting conductor 6 connected to the wire with two kinds of winding pitches. At this time, two or more coils 4 are formed with a winding pitch P2 that forms a connecting wire 6 that electrically connects coils 4 (for example, coil 4 (a) and coil 4 (b)) that are close to each other. By making it larger than the winding pitch P1, a gap 8 can be formed between each of the two or more coils 4 (for example, between the coils 4 (a) and 4 (b)).
Here, as shown in FIG. 7, the winding pitch P <b> 1 is the interval between the windings 3 forming the coil 4, and the winding pitch P <b> 2 is the end of the coil 4 (a), the connecting conductor 6, and the coil 4. This is the interval between the end portions of (b).

The winding pitch P1 for forming two or more coils 4 is preferably the same as the wire diameter of the winding 3 in order to wind many of the windings 3 in a limited size. Therefore, the coil 4 in this case is in contact with the adjacent windings 3.

The winding pitch P2 that forms the connecting wire 6 that electrically connects the coils 4 (for example, the coil 4 (a) and the coil 4 (b)) that are close to each other is a winding pitch that forms two or more coils 4. It may be larger than P1 and may have a size such that the gap 8 is formed between each of the two or more coils 4 (for example, between the coil 4 (a) and the coil 4 (b)). As long as the wire diameter is at least twice as large as the wire diameter.

Further, in order to reduce the height of the coil component, the connecting conductor 6 that electrically connects the coils 4 (for example, the coil 4 (a) and the coil 4 (b)) that are close to each other is connected to the coils 4 that are adjacent to each other (for example, The coil 4 (a) and the coil 4 (b) are preferably connected with a number of turns equal to or less than one.

The coil | winding 3 and the connection conducting wire 6 can be comprised with the insulating coating layer which has coat | covered the outer periphery of the conducting wire as needed, for example.

The material of the conducting wire is not particularly limited, but a conductive material such as a metal such as Al, Cu, Au, Ag, phosphor bronze, etc. can be used. The insulating coating layer is not particularly limited, and for example, polyurethane, polyamideimide, polyimide, polyester, polyester-imide, polyester-nylon, or the like can be used. The cross-sectional shape of the winding 3 is not particularly limited, and may be a circular shape or a rectangular shape. The outer diameter varies depending on the material to be used, but is usually about 0.1 mm to 1.0 mm.

The magnetic molded body 2 is formed by pressure-molding a magnetic material 1 containing a magnetic body and a binder. Although it does not specifically limit as a magnetic body, Ferrite, such as Mn-Zn and Ni-Cu-Zn, Sendust (Fe-Si-Al; Iron-silicon-aluminum), Fe-Si-Cr (Iron-silicon-chromium), Permalloy (Fe—Ni) or the like can be used. Although it does not specifically limit as a binder, For example, an epoxy resin, a phenol resin, a polyimide, a polyamideimide, a silicon resin, or what combined these can be used.

By forming a gap 8 in which the magnetic material 1 (a) is disposed between each of the two or more coils 4 (for example, between the coil 4 (a) and the coil 4 (b)), the magnetic material 1 is wound. Since the gap 8 exhibits a buffering function when being pressure-molded after the portion 5 is buried, the stress in the direction parallel to the winding axis of the coil 4 applied to the winding 3 forming the coil 4 is reduced. The compression toward the center of the magnetic molded body 2 formed on the inner peripheral portion 7 of the winding portion 5 is improved by improving the collapse (plastic deformation) of the winding 3 in the direction parallel to the winding axis of the coil 4. Since the generation of stress and the generation of tensile stress in the direction parallel to the winding axis in the inner peripheral part 7 of the winding part 5 due to the compressive stress are alleviated, it is formed in the inner peripheral part 7 of the winding part 5. It is possible to prevent the occurrence of cracks in the magnetic molded body 2. Here, the magnetic material 1 (a) disposed in the gap 8 is pressure-molded, whereby the magnetic molded body 2 (a) is formed in the gap 8.

The size of the coil component of the present invention is not particularly limited. For example, the width may be about 1.0 mm to 20 mm, the depth may be 1.0 mm to 20 mm, and the height may be about 1.0 mm to 10 mm. In the present embodiment, the case of two coils 4 has been described. Similarly, a coil component of the present invention having three or more coils 4 can also be configured.

The coil component of the present invention can be used, for example, as a circuit element such as a DC / DC converter mounted on a personal computer or a portable electronic device.

Hereinafter, an embodiment of the coil component according to the present invention will be specifically described. Naturally, the coil component of the present invention is not limited to the following examples.

[Example 1]
1, 2 and 3 show coil components in one embodiment of the present invention.

First, a granular magnetic material 1 to be filled in the mold cavity was prepared. An Fe—Si—Cu alloy powder (average particle size 2.0 μm) was prepared as a magnetic material. To 100 g of this magnetic material, a solution containing 1.0% by mass of polysiloxane resin in 100 g of IPA was added and stirred for 20 minutes. After stirring, the stirred product was dried at 150 ° C. for 1 hour. Moreover, drying was performed with stirring. After drying, the material coated with the polysiloxane resin was crushed, and 0.1 mass% of calcium stearate as a lubricant was added to produce a granular magnetic material 1. Here, as a necessary condition for the magnetic material 1, the average particle diameter of the magnetic Fe—Si—Cu alloy powder is in the range of 0.5 to 10 μm. A solution containing 0.1 to 4.0% by mass of resin was added and stirred for 20 minutes. After stirring, the stirred product was dried at 140 to 250 ° C. for 1 hour, or at 140 to 200 ° C. for 1 hour. After drying, the temperature is changed, and further drying is performed for 2 hours at 180 to 250 ° C. for a total of 2 hours while stirring. As a result, 0.1 to 0.4% by mass may be added and granulated.

Two coils 4 (coil 4 (a)) in which the magnetic material 1 thus manufactured is wound with a winding 3 having a circular cross section with a diameter of 0.3 mm, in which a conductive wire made of Cu is covered with an insulating coating made of an enamel layer. And a coil 4 (b)) and a circular cross section having a diameter of 0.3 mm, in which a conductive wire made of Cu is covered with an insulating film made of an enamel layer, and two coils 4 (coil 4 (a) and coil 4 (b)) A mold comprising a connecting wire 6 that electrically connects each other and a winding portion 5 in which a gap 8 between two coils 4 (coil 4 (a) and coil 4 (b)) is formed by 0.3 mm is set. After filling into the cavity and press-molding with a pressure of 0.3 GPa in the direction parallel to the winding axis of the coil 4, the magnetic molded body 2 is taken out from the mold and subjected to heat treatment at 200 ° C. for 1 hour. The siloxane resin is cured, and the coil portion of Example 1 It was obtained. Here, the temperature of the heat treatment may be in the range of 140 to 250 ° C.
The dimensions of the magnetic molded body 2 were 7.0 mm width × 7.0 mm depth × 5.2 mm height.

When the cross-section of the obtained coil component was observed, the magnetic molded body 2 was formed in the gap between the two coils 4 (coil 4 (a) and coil 4 (b)) as shown in FIG. The gap between the coil 4 (coil 4 (a) and coil 4 (b)) was 0.1 mm, but the magnetic molded body 2 formed on the inner periphery 7 of the winding 3 and the winding 3 was crushed. No cracks were found.

[Example 2]
4, 5, 6 and 7 show coil components in another embodiment of the present invention.

As in Example 1, a granular magnetic material 1 to be filled in the mold cavity was prepared. An Fe—Si—Cu alloy powder (average particle size 2.0 μm) was prepared as a magnetic material. 1.0% by mass of 100 g of this magnetic material and polysiloxane resin in 100 g of IPA were added and stirred for 20 minutes. After stirring, the stirred product was dried at 150 ° C. for 1 hour. Moreover, drying was performed with stirring. After drying, the material coated with the polysiloxane resin was crushed, and 0.1 mass% of calcium stearate as a lubricant was added to produce a granular magnetic material 1.

A winding 3 having a circular cross section with a diameter of 0.3 mm, in which a magnetic material 1 produced in this manner is coated with a conductive wire made of Cu with an insulating coating made of an enamel layer, is wound at two winding pitches, and two coils are wound. 4 (coil 4 (a) and coil 4 (b)) and a winding part 5 in which two coils 4 (coil 4 (a) and coil 4 (b)) are electrically connected to each other are formed. Was filled into the mold cavity.
The coil 4 (coil (a) and coil (b)) forming the winding part 5 is formed with a winding pitch P1 of 0.3 mm, and the connecting wire 6 has a winding pitch P2 of 0.9 mm and the number of turns. Is formed by 1/2.
As a result, a gap 8 of 0.3 mm is formed between the two coils 4 (coil 4 (a) and coil 4 (b)).
After the magnetic material 1 is filled in the mold cavity, it is pressure-molded with a pressure of 0.3 GPa in a direction parallel to the winding axis of the coil 4, and then the magnetic molded body 2 is taken out from the mold and is heated at 200 ° C. Heat treatment for a time was performed to cure the polysiloxane resin, and the coil component of Example 2 was obtained.
The dimensions of the magnetic molded body 2 were 7.0 mm width × 7.0 mm depth × 5.2 mm height.

When cross-sectional observation of the obtained coil component was performed, the magnetic molded body 2 was formed in the gap between the two coils 4 (coil 4 (a) and coil 4 (b)) as shown in FIGS. The gap 8 between the two coils 4 (coil 4 (a) and coil 4 (b)) was 0.1 mm, but the winding forming the coil 4 (coil 4 (a) and coil 4 (b)). The crushing of the wire 3 and the connecting conductor 6 and the crack of the magnetic molded body 2 formed on the inner peripheral portion 7 of the winding portion 5 were not confirmed.

[Comparative example]
8, 9 and 10 are examples of conventional coil components.

Similar to Example 1 and Example 2, a granular magnetic material 1 to be filled in a cavity of a mold was prepared. An Fe—Si—Cu alloy powder (average particle size 2.0 μm) was prepared as a magnetic material. 100 g of this magnetic material and a solution containing 1.0% by mass of polysiloxane resin in 100 g of IPA were added and stirred for 20 minutes. After stirring, the stirred product was dried at 150 ° C. for 1 hour. Moreover, drying was performed with stirring. After drying, the material coated with the polysiloxane resin was crushed, and 0.1 mass% of calcium stearate as a lubricant was added to produce a granular magnetic material 1.

A mold having a winding portion 5 in which a winding 3 having a circular cross section with a diameter of 0.3 mm is formed by coating a magnetic material 1 produced in this manner with a conductive wire made of Cu with an insulating coating made of an enamel layer. After filling into the cavity and press-molding with a pressure of 0.3 GPa in a direction parallel to the winding axis of the winding part 5, the magnetic molded body 2 is taken out from the mold and subjected to heat treatment at 200 ° C. for 1 hour. The polysiloxane resin was cured to obtain a coil component.
The dimensions of the magnetic molded body 2 were 7.0 mm width × 7.0 mm depth × 5.2 mm height.

When the cross-section of the obtained coil component was observed, the winding 3 was crushed in a direction parallel to the winding axis of the winding portion 5 as shown in FIG. The wire 3 (a) was crushed larger than the winding 3 (b) at both the upper and lower ends of the winding portion 5. Moreover, the crack 9 was confirmed by the magnetic molding 2 pinched | interposed into the coil | winding 3 (a) which was largely crushed.

The coil component according to the present invention suppresses the collapse (plastic deformation) of the winding forming the winding portion embedded in the magnetic molding, and at the same time, the magnetic molding formed on the inner periphery of the winding portion. It is industrially useful to obtain a coil component that can prevent cracks and has excellent electrical characteristics and reliability.

DESCRIPTION OF SYMBOLS 1 ... Magnetic material 1 (a) ... Magnetic material 2 arrange | positioned in the clearance gap 8 ... Magnetic molded object 2 (a) ... Magnetic molded object 3 formed in the clearance gap 8 ... Winding 3 (a): Winding at the center of the coil 3 (b): Winding 4 above and below the coil ... Coil 4 (a): Upper coil 4 (b): Lower coil 5 ... Winding part 6 ... Connection conductor

7 ... Inner circumference 8 ... Clearance 9 ... Crack

Claims (5)

A coil component having a magnetic molded body that is an integrally molded body made of a magnetic material including a magnetic body and a binder, and a winding portion that is embedded in the magnetic molded body and has a winding wound in a coil shape. And
The winding portion is composed of at least two or more coils and a connecting conductor that electrically connects the coils adjacent to each other, and the two or more coils are arranged with a space therebetween ,
A coil component comprising: two or more coils, and a winding portion formed of a connecting conductor that electrically connects the two or more coils and coils that are close to each other .   The coil component according to claim 1, wherein the magnetic material is disposed between the two or more coils.   The at least 2 or more coils are laminated | stacked and spaced apart so that the winding axis of the said winding part may be shared in the winding axis direction of a winding part, The Claim 1 or Claim 2 characterized by the above-mentioned. Coil parts. The winding pitch for forming the connecting wire for electrically connecting the coils adjacent to each other in the two types of winding pitches is larger than the winding pitch for forming the two or more coils. Item 2. The coil component according to Item 1 . The coil component according to claim 1 or claim 4, characterized in that connecting lines for electrically connecting the coils the proximity to each other are formed by one volume following winding.

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