WO2021205817A1 - Coil structure and inductor element - Google Patents

Coil structure and inductor element Download PDF

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Publication number
WO2021205817A1
WO2021205817A1 PCT/JP2021/010290 JP2021010290W WO2021205817A1 WO 2021205817 A1 WO2021205817 A1 WO 2021205817A1 JP 2021010290 W JP2021010290 W JP 2021010290W WO 2021205817 A1 WO2021205817 A1 WO 2021205817A1
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WO
WIPO (PCT)
Prior art keywords
conductor
plates
portions
plate
coil
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PCT/JP2021/010290
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French (fr)
Japanese (ja)
Inventor
智樹 岡野
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株式会社村田製作所
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Publication of WO2021205817A1 publication Critical patent/WO2021205817A1/en

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/04—Fixed inductances of the signal type  with magnetic core
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F37/00—Fixed inductances not covered by group H01F17/00

Definitions

  • the present invention relates to a coil structure and an inductor element.
  • An inductor element including a ferrite resin that covers a coil and a ferrite core in close contact with each other has been proposed (see, for example, Patent Document 1).
  • the present invention has been made in view of the above reasons, and an object of the present invention is to provide a coil structure and an inductor element in which characteristic changes due to temperature changes are suppressed.
  • the coil structure according to the present invention is It is a coil structure that is wound along the winding axis.
  • the first conductor portion is provided with a second portion which is connected to and has a second portion in which a plurality of conductor plates are laminated in a direction different from the stacking direction of the plurality of conductor plates forming the first portion.
  • the first portion, the bent portion, and the second portion each have irregularities on the side surfaces.
  • the coil structure according to the present invention is
  • the length of the conductor substrate in the direction orthogonal to the laminating direction is defined as the width
  • the plurality of conductor plates may include conductor plates having different widths from each other.
  • the coil structure according to the present invention is
  • the plurality of conductor plates have a first conductor plate and a second conductor substrate having a width shorter than that of the first conductor plate.
  • the second conductor plate may be sandwiched between the two first conductor plates in the stacking direction.
  • the cross-sectional shape of the first conductor portion in the stacking direction may be point-symmetrical.
  • the surface of the first conductor portion may be provided with a recess recessed in the stacking direction.
  • the number of the conductor plates forming the bottom of the recess in the first conductor portion may be smaller than the number of laminated conductor plates forming other than the recess in the first conductor portion.
  • the coil structure according to the present invention is The area of the bottom of the recess may be smaller than the opening area of the recess.
  • the coil structure according to the present invention is A second conductor portion composed of one conductor substrate is connected between the first conductor portion constituting the first turn and the first conductor portion forming the second turn counting from the direction of the winding axis. It may be a thing.
  • the coil structure according to the present invention is In the portion where the first conductor portion and the second conductor portion are connected, the direction in which the first conductor portion extends and the direction in which the second conductor portion extends are orthogonal to each other. good.
  • the inductor element according to the present invention from another point of view is With the coil structure It includes an insulator portion formed of an insulator material and covering the first conductor portion.
  • the present invention is a coil structure wound along a winding axis, and is composed of a plurality of laminated conductor plates, the first portion, the second portion, the first portion, and the first portion.
  • a first conductor portion having a bent portion connected to the two portions is provided. Then, the bent portion is formed so that the stacking direction of the plurality of conductor plates at the first portion and the stacking direction of the plurality of conductor plates at the second portion are different.
  • a fine depression can be formed at the boundary portion between the two conductor plates adjacent in the stacking direction on the side surface orthogonal to the winding axis of the coil in the first conductor portion.
  • the insulator portion when the first conductor portion is covered with the insulator portion, a part of the insulator portion can be covered in a state of being inserted into the recess formed on the side surface of the first conductor portion, so that the first conductor of the insulator portion can be covered. Adhesion to the part is improved. Therefore, when an external force is applied to the insulator portion in a direction orthogonal to the winding axis direction of the coil, it is possible to prevent the insulator portion from peeling off in the direction in which the external force is applied to the coil. When an external force is applied due to a temperature change, the insulator portion does not easily peel off, and changes in the characteristics of the inductor element including the coil structure are suppressed.
  • FIG. 1 It is a perspective view of the inductor element which concerns on Embodiment 1 of this invention. It is a perspective view of a part of the coil which concerns on Embodiment 1.
  • FIG. It is an exploded perspective view for demonstrating the manufacturing method of the inductor element which concerns on Embodiment 1.
  • FIG. It is a perspective view of the laminated body which concerns on Embodiment 1.
  • FIG. It is a perspective view which shows the state after bending process about the laminated body which concerns on Embodiment 1.
  • FIG. It is a perspective view which shows the state after bending process about the laminated body which concerns on Embodiment 1.
  • FIG. It is a perspective view which shows the state after bending process about the laminated body which concerns on Embodiment 1.
  • FIG. It is a perspective view of the inductor element which concerns on Embodiment 2 of this invention.
  • FIG. 2 It is a perspective view of a part of the coil which concerns on Embodiment 2.
  • FIG. It is a top view of the conductor substrate which concerns on Embodiment 2.
  • FIG. It is a top view of another conductor substrate which concerns on Embodiment 2.
  • FIG. It is sectional drawing of a part of the conductor part which concerns on Embodiment 2.
  • FIG. It is a perspective view of the laminated body which concerns on Embodiment 2.
  • FIG. It is a perspective view which shows the state after bending process about the laminated body which concerns on Embodiment 2.
  • It is a perspective view which shows the state after bending process about the laminated body which concerns on Embodiment 2.
  • FIG. It is a side view of the inductor element which concerns on Embodiment 3.
  • FIG. It is a perspective view of a part of the coil which concerns on Embodiment 3.
  • FIG. It is a perspective view of a part of the coil which concerns on Embodiment 3.
  • FIG. It is a top view of the conductor substrate which concerns on Embodiment 3.
  • FIG. It is a top view of the laminated body which concerns on Embodiment 3.
  • FIG. It is a perspective view of the laminated body which concerns on Embodiment 3.
  • FIG. It is a perspective view which shows the state after bending process about the laminated body which concerns on Embodiment 3.
  • It is a perspective view which shows the state after bending process about the laminated body which concerns on Embodiment 3.
  • the inductor element according to the present embodiment includes a coil having a first conductor portion including a portion composed of a plurality of conductor plates laminated in the thickness direction in a plate shape, and an insulator portion formed of an insulator material. , Equipped with.
  • the coil has a coil structure that is wound along a winding shaft.
  • the insulator portion covers at least the entire first conductor portion of the coil in a state of being in close contact with the first conductor portion of the coil.
  • the coil includes a first conductor portion having a plurality of laminated conductor plates, and the first conductor portion is bent in the stacking direction in which the plurality of conductor plates are laminated. That is, the coil is a first portion in which a plurality of conductor plates are laminated, and a bent portion that is connected to the first portion, is laminated with each other, is composed of a plurality of conductor plates, and each of the plurality of conductor plates is curved in the stacking direction. It is provided with a first conductor portion having a second portion connected to the bent portion and in which a plurality of conductor plates are laminated in a direction different from the stacking direction of the plurality of conductor plates forming the first portion. The first portion, the bent portion, and the second portion each have irregularities on the side surfaces.
  • the "conductor plate” also includes a thick plate-shaped conductor.
  • the inductor element 1 includes a coil 10 and an insulator portion 100.
  • the coil 10 has conductor groups 11 and 12.
  • the conductor group 11 has five conductors 111, 112, 113, 114, 115 arranged along the winding axis J1 of the coil 10.
  • the conductor portion 111 is a first conductor portion composed of three conductor plates 1111 which are plate-shaped and laminated in the thickness direction.
  • the conductor portion 111 includes an L-shaped main portion 111a extending in the ⁇ X direction and the + Y direction, and a rising portion 111b rising in the + Z direction from the + Y direction side at the end portion of the main portion 111a on the ⁇ X direction side.
  • the leg portion 111c extending in the ⁇ Z direction from the + Y direction side at the end portion on the + Y direction side of the main portion 111a, the bent portion 111f connected to the main portion 111a and the rising portion 111b, and the main portion 111a and the leg portion 111c. It has a bent portion 111 g connected to and.
  • the bent portion 111f is formed so that the stacking direction of the conductor plate 1111 of the main portion 111a and the stacking direction of the conductor plate 1111 of the rising portion 111b are different (intersect).
  • the bent portion 111g is formed so that the stacking direction of the main portion 111a and the stacking direction of the leg portions 111c are different (intersect).
  • the stacking direction of the three conductor plates 1111 in the conductor portion 111 is orthogonal to the winding axis J1 of the coil 10.
  • the conductor portion 112 is a first conductor portion composed of three conductor plates 1121 which are plate-shaped and laminated in the thickness direction.
  • the conductor portion 112 has a first portion 112a having a portion extending in a direction inclined in the ⁇ X direction rather than a + Y direction and a portion extending in the ⁇ Y direction from each of both ends thereof, and the Y of the first portion 112a.
  • the second portions 112b and 112c rising from both ends in the axial direction in the + Z direction, the bending portions 112f connecting the first portion 112a and the second portion 112b, and the bending connecting to the first portion 112a and the second portion 112c. It has 112 g of a portion.
  • the bent portion 112f is formed so that the stacking direction of the conductor plate 1121 of the first portion 112a and the stacking direction of the conductor plate 1121 of the second portion 112b are different (intersect).
  • the bent portion 112g is formed so that the stacking direction of the conductor plate 1121 of the first portion 112a and the stacking direction of the conductor plate 1121 of the second portion 112c are different (intersect). That is, the conductor portion 112 includes a first portion 112a including the winding axis J1 of the coil 10 and intersects the virtual plane parallel to the XZ plane, and + Z from both ends of the first portion 112a along the above-mentioned virtual plane.
  • the stacking direction of the three conductor plates 1121 in the conductor portion 112 is orthogonal to the winding axis J1 of the coil 10. That is, the conductor portion 112 is a bent portion that is connected to the first portion 112a and the first portion 112a and is composed of three conductor plates 1121 that are laminated to each other, and each of the three conductor plates 1121 is curved in the stacking direction. Second portions 112b, 112c formed by laminating three conductor plates 1121 in a direction different from the laminating direction of the three conductor plates 1121 connected to the bent portions 112f and 112g and forming the first portion 112a. And have.
  • the first portion 112a, the bent portion 112f, 112g and the second portion 112b, 112c each have irregularities on the side surfaces.
  • the unevenness corresponds to the unevenness formed from the fine concave portion formed at the boundary portion of the three conductor plates 1121 and the end surface of the conductor plate 1121.
  • the first portion 112a, the bent portion 112f, 112g and the second portion 112b, 112c are formed continuously and integrally.
  • the conductor portion 113 is a first conductor portion composed of three conductor plates 1131 which are plate-shaped and laminated in the thickness direction.
  • the conductor portion 113 is long and has a first portion 113a having a portion extending in a direction inclined in the ⁇ X direction from the + Y direction and a portion extending in the ⁇ Y direction from each of both end portions thereof, and a long portion 113a.
  • the second portions 113b and 113c rising in the + Z direction from both ends of the first portion 113a in the Y-axis direction, the bent portions 113f connected to the first portion 113a and the second portion 113b, and the first portion 113a. It has a bent portion 113g connected to the second portion 113c.
  • the bent portion 113f is formed so that the stacking direction of the conductor plate 1131 of the first portion 113a and the stacking direction of the conductor plate 1131 of the second portion 113b are different (intersect).
  • the bent portion 113g is formed so that the stacking direction of the conductor plate 1131 of the first portion 113a and the stacking direction of the conductor plate 1131 of the second portion 113c are different (intersect). That is, the conductor portion 113 includes a first portion 113a including the winding axis J1 of the coil 10 and intersects the virtual plane parallel to the XZ plane, and + Z from both ends of the first portion 113a along the above-mentioned virtual plane.
  • the stacking direction of the three conductor plates 1131 in the conductor portion 113 is orthogonal to the winding axis J1 of the coil 10. Further, the first portion 113a, the bent portions 113f, 113g and the second portions 113b, 113c are formed continuously and integrally.
  • the conductor portion 114 is a first conductor portion composed of three conductor plates 1141 which are plate-shaped and laminated in the thickness direction.
  • the conductor portion 114 has a first portion 114a having a portion extending in a direction inclined in the ⁇ X direction rather than a + Y direction and a portion extending in the ⁇ Y direction from each of both end portions thereof, and a Y axis of the main portion 112a.
  • Second portions 114b and 114c rising in the + Z direction from both ends in the direction, bending portions 114f connecting the first portion 114a and the second portion 114b, and bending portions connecting the first portion 114a and the second portion 114c. It has 114 g and.
  • the bent portion 114f is formed so that the stacking direction of the conductor plate 1141 of the first portion 114a and the stacking direction of the conductor plate 1141 of the second portion 114b are different (intersect).
  • the bent portion 114g is formed so that the stacking direction of the conductor plate 1141 of the first portion 114a and the stacking direction of the conductor plate 1141 of the second portion 114c are different (intersect). That is, the conductor portion 114 includes a first portion 114a including the winding axis J1 of the coil 10 and intersects the virtual plane parallel to the XZ plane, and + Z from both ends of the first portion 114a along the above-mentioned virtual plane.
  • the stacking direction of the three conductor plates 1141 in the conductor portion 114 is orthogonal to the winding axis J1 of the coil 10. Further, the first portion 114a, the bent portions 114f, 114g and the second portions 114b, 114c are formed continuously and integrally.
  • the conductor portion 115 is a first conductor portion composed of three conductor plates 1151 which are plate-shaped and laminated in the thickness direction.
  • the conductor portion 115 includes an L-shaped main portion 115a extending in the + X direction and the ⁇ Y direction, and a rising portion 115b rising in the + Z direction from the ⁇ Y direction side at the end portion of the main portion 115a on the + X direction side.
  • the leg portion 115c extending in the ⁇ Z direction from the ⁇ Y direction side at the end portion on the ⁇ Y direction side of the main portion 115a, the bent portion 115f connected to the main portion 115a and the rising portion 115b, the main portion 115a and the leg.
  • the bent portion 115g is formed so that the stacking direction of the conductor plate 1151 of the main portion 115a and the stacking direction of the conductor plate 1151 of the rising portion 115b are different (intersect).
  • the bent portion 115g is formed so that the stacking direction of the conductor plate 1151 of the main portion 115a and the stacking direction of the conductor plate 1151 of the leg portion 115c are different (intersect).
  • the stacking direction of the three conductor plates 1151 in the conductor portion 115 is orthogonal to the winding axis J1 of the coil 10.
  • the conductor portion group 12 has four plate-shaped conductor portions 121, 122, 123, 124.
  • the conductor portion 121 includes the tip end portion of the rising portion 111b of the conductor portion 111, that is, the end portion on the + Z direction side, and the rising portion 111b, which includes the winding axis J1 of the coil 10, and is parallel to the XZ plane.
  • a second conductor erected on the opposite side of the virtual plane that is, between the end of the second portion 112c of the conductor portion 112 located on the ⁇ Y direction side of the virtual plane on the + Z direction side. It is a department.
  • the conductor portion 122 includes an end portion of the second portion 112b of the conductor portion 112 of the two conductor portions 112 and 113 adjacent to each other in the winding axis J1 direction of the coil 10 on the + Z direction side, and a second portion of the conductor portion 112.
  • the 112b is a second conductor portion erected between the second portion 113c of the conductor portion 113 located on the opposite side of the virtual plane and the end portion on the + Z direction side.
  • the conductor portion 122 In the conductor portion 122, the end portion of the second portion 112b on the + Z direction side and the end portion of the second portion 113c on the + Z direction side are welded on the ⁇ Z direction side thereof. Like the conductor portion 122, the conductor portion 123 is erected between the end portion of the second portion 113b of the conductor portion 113 on the + Z direction side and the end portion of the second portion 114c of the conductor portion 114 on the + Z direction side. It is the second conductor part which is made.
  • the conductor portion 124 is erected between the end portion of the second portion 114b of the conductor portion 114 on the + Z direction side and the end portion of the rising portion 115b of the conductor portion 115 on the + Z direction side. This is the second conductor part.
  • one plate-shaped conductor portion 124 is connected between the conductor portion 214 forming the fourth turn and the conductor portion 215 forming the fifth turn counting from the direction of the winding shaft J1. Further, in the portion where the conductor portions 111, 112, 113, 114, 115 and the conductor portions 121, 122, 123, 124 are connected, the direction in which the conductor portions 111, 112, 113, 114, 115 extend and the conductor portion The directions in which 121, 122, 123, and 124 extend are orthogonal to each other.
  • the insulator portion 100 is formed of an insulator material, and as shown in FIGS. 1A and 1B, in a state of being in close contact with the conductor portions 111, 112, 113, 114, 115, the conductor portions 111, 112, 113, 114, It covers 115.
  • a resin containing ferrite powder can be adopted.
  • the ferrite powder Ni—Zn-based ferrite, Mn—Zn-based ferrite, and Ni—Cu—Zn-based ferrite powder can be adopted.
  • the resin a thermoplastic resin such as polypropylene, polyamide or polystyrene or a thermosetting resin such as a phenol resin or an epoxy resin can be adopted.
  • the conductor substrates 171 and 173 show an example of a conductor substrate for manufacturing the two inductor elements 1.
  • the conductor substrates 171 and 173 are manufactured, for example, by punching a metal plate.
  • the conductor substrate 171 includes five conductor plates 1111, 1121, 1131, 1141 and 1151, two L-shaped frame pieces 1611 and 1612 in a plan view, and 14 elongated support pieces 1611a, 1611b, 1612a and 1612b.
  • the unit 171U having the above has a structure in which two units 171U are arranged side by side in the X-axis direction.
  • the five support pieces 1611a extend from the frame piece 1611 in the ⁇ Y direction, and the ends on the ⁇ Y direction side in the longitudinal direction are connected to the conductor plates 1111, 1121, 1131, and 1141.
  • the two support pieces 1611b extend in the ⁇ Y direction from the end portion of the frame piece 1611 on the ⁇ Y direction side, and the end portion on the ⁇ Y direction side is in contact with the conductor plate 1151.
  • the five support pieces 1612a extend from the frame piece 1612 in the + Y direction, and their ends on the + Y direction side in the longitudinal direction are connected to the conductor plates 1121, 1131, 1141, 1151.
  • the two support pieces 1612b extend in the + Y direction from the end portion of the frame piece 1612 on the + Y direction side, and the end portion on the + Y direction side is in contact with the conductor plate 1111.
  • the conductor substrate 173 also includes five conductor plates 1111, 1121, 1131, 1141 and 1151, two L-shaped frame pieces 1611 and 1612 in a plan view, and 14 elongated support pieces 1611a, 1611b, 1612a and 1612b.
  • the unit 173U having the above has a structure in which two units 173U are arranged side by side in the X-axis direction. Further, the conductor substrate 173 has a support piece 1631c extending along the X-axis direction to connect the conductor plates 1111, 1121, 1131, and 1141 to each other, and a conductor plate 1122, 1131 extending along the X-axis direction. It has a support piece 1632c that connects 1141 and 1151 to each other.
  • a laminating step of laminating the two conductor substrates 171 and the conductor substrate 173 to their thickness is performed.
  • the conductor substrate 173 is superposed on the ⁇ Z direction side of the two conductor substrates 171 stacked on each other.
  • the two conductor substrates 171 are welded to each other on the entire surface side facing each other in the Z-axis direction.
  • the conductor substrates 171 and 173 are also welded to each other on the entire surface side facing each other in the Z-axis direction.
  • a laminated body 17 having two units 17U as shown in FIG. 3A is formed.
  • the frame portions 1611 and 1612 of the conductor substrates 171 and 173 are laminated to form the frame portions 161 and 162.
  • the support portions 161a, 161b, 162a, 162b are formed by laminating the support pieces 1611a, 1611b, 1612a, 1612b of the conductor substrates 171 and 173.
  • the laminated body 17 is subjected to a cutting step of cutting the support portion 161a and the support pieces 1631c and 1632c.
  • the portions corresponding to the rising portions 111b and 115b of the conductor portions 111 and 115 and the portions corresponding to the second portions 112b, 112c, 113b, 113c, 114b and 114c of the conductor portions 112, 113 and 114 are bent in the + Z direction.
  • the bending step of bending the portions corresponding to the legs 111c and 115c of the conductor portions 111 and 115 in the ⁇ Z direction is performed.
  • a preparatory step for preparing the four conductor portions 121, 122, 123, 124 is performed.
  • four conductor portions 121, 122, 123, and 124 are manufactured by punching a metal plate.
  • the preparatory step for preparing the four conductor portions 121, 122, 123, and 124 may be performed in parallel with the step of producing and processing the above-mentioned laminated body 17.
  • the end of the rising portion 111b of the conductor portion 111 on the + Z direction side and the end portion of the second portion 112c of the conductor portion 112 on the + Z direction side are welded to the conductor portion 121.
  • the conductor portions 111 and 112 are welded to the conductor portion 121 by using, for example, a spot welding technique using a laser beam.
  • the + Z direction end of the rising portion 115b of the conductor portion 115 and the + Z direction end of the second portion 114b of the conductor portion 114 are welded to the conductor portion 124.
  • the ends of the second portions 112b and 113c of the conductor portions 112 and 113 on the + Z direction side are welded to the conductor portion 122.
  • the + Z direction end of the second portion 112b of the conductor portion 112 and the + Z direction end of the second portion 113c of the conductor portion 113 are welded to the conductor portion 123, and the second portion of the conductor portion 113 is welded.
  • the + Z direction end of the portion 113b and the + Z direction end of the second portion 114c of the conductor portion 114 are welded to the conductor portion 124. In this way, a structure in which the conductor portions 121, 122, 123, and 124 are welded to each unit 17U of the laminated body 17 that is the base of the plurality of coils 10 is formed.
  • the above-mentioned ferrite is used.
  • the insulator portion 100 is formed by injecting a resin containing powder into a mold and then heating and cooling the resin. Then, by cutting the structure for each unit 17U of the laminated body 17, a plurality of inductor elements 1 are generated.
  • the conductor portions 111, 112 including three conductor plates 1111, 1121, 1131, 1141 and 1151 which are plate-shaped and laminated in the thickness direction. , 113, 114, 115, and an insulator portion 100.
  • the stacking directions of the three conductor plates 1111, 1121, 1131, 1141 and 1151 in the conductor portions 111, 112, 113, 114 and 115 are orthogonal to the winding axis J1 of the coil 10.
  • 111, 112, 113, 114, 115 including three conductor plates 1111, 1121, 1131, 1141 and 1151 to be laminated are laminated, and three conductor plates 1111, 1121, 1131, 1141 and 1151 are laminated. It is bent in the stacking direction. As a result, the boundary portion between the two conductor plates 1111, 1121, 1131, 1141 and 1151 adjacent in the stacking direction on the side surface of the conductor portions 111, 112, 113, 114 and 115 orthogonal to the winding axis J1 of the coil 10. Fine dents can be formed in.
  • the conductor portions 111, 112, 113, 114, 115 are covered with the insulator portion 100, a part of the insulator portion 100 enters the recess formed on the side surface of the conductor portions 111, 112, 113, 114, 115. It can be covered in a free state, the anchor effect of the insulator portion 100 can be obtained, and the adhesion of the insulator portion 100 to the conductor portions 111, 112, 113, 114, 115 is improved. Therefore, when an external force is applied to the insulator portion 100 in the direction orthogonal to the winding axis J1 direction of the coil 10, the insulator portion 100 is peeled off in the direction in which the external force is applied to the coil 10. Can be suppressed.
  • the conductor portion 212 has a first portion 212a and a second portion 212c in which the stacking directions of the three conductor plates 1121 are different from each other as described above.
  • the first portion 212a, the bent portion 212g, and the second portion 212c each have irregularities on the side surfaces.
  • the resistance to peeling of the insulator portion 100 when an external force is applied to the first portion 212a in the stacking direction but also the external force in the stacking direction of the second portion 212c, that is, the central axis direction of the coil 10 is increased. It is possible to increase the resistance to peeling of the insulator portion 100 when it is added.
  • the conductor portions 112, 113, 114 are the first portions 112a, 113a, 114a intersecting the virtual plane including the winding shaft J1, and both end portions of the first portions 112a, 113a, 114a, respectively. It has second portions 112b, 113b, 114b, which extend in the + Z direction from.
  • the conductor portion 122 has a plate shape, and connects the end portion of the second portion 112b of the conductor portion 112 on the + Z direction side and the end portion of the second portion 113c of the conductor portion 113 on the + Z direction side.
  • the inductor element according to the present embodiment has a width when a plurality of conductor plates are defined as a width in a direction in which the plurality of conductor plates are laminated and in a direction orthogonal to the winding axis of the coil. Is different from the first embodiment in that the conductor plates are different from each other.
  • the inductor element 2 includes a coil 20 and an insulator portion 100.
  • the coil 20 has conductor groups 21 and 12.
  • the conductor group 21 has five conductors 211, 212, 213, 214, and 215 arranged along the winding axis J2 of the coil 20.
  • the same reference numerals as those in FIG. 1B are attached to the same configurations as those in the first embodiment.
  • the conductor portion 211 is a first conductor portion composed of conductor plates 1111 and 2112 which are plate-shaped and laminated in the thickness direction.
  • the width of the conductor plate 2112 is shorter than the width of the conductor plate 1111. That is, the conductor plates 1111 and 2112 have a width when the length of the conductor plates 1111 and 2112 in the stacking direction of the conductor plates 1111 and 2112 and the direction orthogonal to the winding axis J1 of the coil 20 is defined as the width. Different from each other. A groove 211e is formed on the side surface of the conductor portion 211 orthogonal to the winding axis J2 of the coil 20.
  • the conductor plate 2112 corresponds to the first conductor plate
  • the conductor plate 1111 corresponds to the second conductor plate.
  • the conductor portion 211 includes an L-shaped main portion 211a extending in the ⁇ X direction and the + Y direction, and a rising portion 211b rising in the + Z direction from the + Y direction side at the end portion of the main portion 211a on the ⁇ X direction side.
  • the leg portion 211c extending in the ⁇ Z direction from the + Y direction side at the end portion of the main portion 211a on the + Y direction side, the bent portion 211f connected to the main portion 211a and the rising portion 211b, and the main portion 211a and the leg portion 211c. It has a bent portion 211 g connected to and.
  • the bent portion 211f is formed so that the stacking directions of the conductor plates 1111 and 2112 of the main portion 211a and the stacking directions of the conductor plates 1111 and 2112 of the rising portion 211b are different (intersect).
  • the bent portion 211g is formed so that the stacking directions of the conductor plates 1111 and 2112 of the main portion 211a and the stacking directions of the conductor plates 1111 and 2112 of the leg portions 211c are different (intersect).
  • the conductor portion 212 is a first conductor portion composed of conductor plates 1121 and 2122 which are plate-shaped and laminated in the thickness direction.
  • the width of the conductor plate 2122 is shorter than the width of the conductor plate 1121, and a groove 212e is formed on the side surface of the conductor portion 212 orthogonal to the winding axis J2 of the coil 20.
  • the conductor plate 2122 corresponds to the first conductor plate
  • the conductor plate 1121 corresponds to the second conductor plate.
  • the conductor portion 212 has a first portion 212a having a portion extending in a direction inclined in the ⁇ X direction from the + Y direction and a portion extending in the ⁇ Y direction from each of both ends thereof, and the Y of the first portion 212a.
  • the second portions 212b and 212c rising from both ends in the axial direction in the + Z direction, the bending portions 212f connecting the first portion 212a and the second portion 212b, and the bending connecting to the first portion 212a and the second portion 212c. It has a portion of 212 g.
  • the bent portion 212f is formed so that the stacking directions of the conductor plates 1121 and 2112 of the first portion 212a and the stacking directions of the conductor plates 1121 and 2112 of the second portion 212b are different (intersect).
  • the bent portion 212g is formed so that the stacking directions of the conductor plates 1111 and 2112 of the first portion 212a and the stacking directions of the conductor plates 1111 and 2112 of the second portion 212c are different (intersect). That is, the conductor portion 212 is composed of three conductor plates 1121 and 2122 which are connected to the first portion 212a and the first portion 212a and are laminated with each other, and the three conductor plates 1121 and 2122 are curved in the stacking direction, respectively.
  • Three conductor plates 1121 and 2122 are laminated in a direction different from the stacking direction of the three conductor plates 1121 and 2122 that are connected to the bent portions 212f and 212 g and constitute the first portion 212a. It has a second portion 212b, 212c, and the like.
  • the first portion 212a, the bent portions 212f, 212g and the second portions 212b, 212c each have irregularities on the side surfaces.
  • the unevenness corresponds to the unevenness formed from the end faces of the two conductor plates 1121 and the end faces of the conductor plates 2122 interposed between the two conductor plates 1121.
  • the first portion 212a, the bent portions 212f, 212g and the second portions 212b, 212c are continuously integrally formed.
  • the conductor portion 213 is a first conductor portion composed of conductor plates 1131 and 2132 which are plate-shaped and laminated in the thickness direction.
  • the width of the conductor plate 2132 is shorter than the width of the conductor plate 1131, and a groove 213e is formed on the side surface of the conductor portion 213 orthogonal to the winding axis J2 of the coil 20.
  • the conductor plate 2132 corresponds to the first conductor plate
  • the conductor plate 1131 corresponds to the second conductor plate.
  • the conductor portion 213 is long and has a first portion 213a having a portion extending in a direction inclined in the ⁇ X direction from the + Y direction and a portion extending in the ⁇ Y direction from each of both ends thereof, and a long portion.
  • the second part 213b and 213c rising from both ends of the first part 213a in the Y-axis direction in the + Z direction, the bending part 213f connected to the first part 213a and the second part 213b, and the first part 213a. It has a bent portion 213g connected to a second portion 213c.
  • the bent portion 213f is formed so that the stacking directions of the conductor plates 1131 and 2132 of the first portion 213a and the stacking directions of the conductor plates 1131 and 2132 of the second portion 213b are different (intersect).
  • the bent portion 213g is formed so that the stacking directions of the conductor plates 1131 and 2132 of the first portion 213a and the stacking directions of the conductor plates 1131 and 2132 of the second portion 213c are different (intersect). Further, the first portion 213a, the bent portion 213f, 213g and the second portion 213b, 213c are continuously integrally formed.
  • the conductor portion 214 is a first conductor portion composed of conductor plates 1141 and 2142 which are plate-shaped and laminated in the thickness direction.
  • the width of the conductor plate 2142 is shorter than the width of the conductor plate 1141, and the groove 214e is formed on the side surface of the conductor portion 214 orthogonal to the winding axis J2 of the coil 20.
  • the conductor plate 2142 corresponds to the first conductor plate, and the conductor plate 1141 corresponds to the second conductor plate.
  • the conductor portion 214 has a first portion 214a having a portion extending in a direction inclined in the ⁇ X direction rather than a + Y direction and a portion extending in the ⁇ Y direction from each of both ends thereof, and the Y of the first portion 214a. Bending portions 214b and 214c rising in the + Z direction from both ends in the axial direction, bending portions 214f connecting the first portion 214a and the second portion 214b, and bending connecting to the first portion 214a and the second portion 214c. It has a portion of 214 g and.
  • the bent portion 214f is formed so that the stacking directions of the conductor plates 1141 and 2142 of the first portion 214a and the stacking directions of the conductor plates 1141 and 2142 of the second portion 214b are different (intersect).
  • the bent portion 214g is formed so that the stacking directions of the conductor plates 1141 and 2142 of the first portion 214a and the stacking directions of the conductor plates 1141 and 2142 of the second portion 214c are different (intersect). Further, the first portion 214a, the bent portions 214f, 214g and the second portions 214b, 214c are continuously integrally formed.
  • the conductor portion 215 is a first conductor portion composed of conductor plates 1151 and 2152 which are plate-shaped and laminated in the thickness direction.
  • the width of the conductor plate 2152 is shorter than the width of the conductor plate 1151, and a groove 215e is formed on the side surface of the conductor portion 215 orthogonal to the winding axis J2 of the coil 20.
  • the conductor plate 2152 corresponds to the first conductor plate
  • the conductor plate 1151 corresponds to the second conductor plate.
  • the conductor portion 215 includes an L-shaped main portion 215a extending in the + X direction and the ⁇ Y direction, and a rising portion 215b rising in the + Z direction from the ⁇ Y direction side at the end portion of the main portion 215a on the + X direction side.
  • the leg portion 215c extending in the ⁇ Z direction from the ⁇ Y direction side at the end portion of the main portion 215a on the ⁇ Y direction side, the bent portion 215f connected to the main portion 215a and the rising portion 215b, and the main portion 215a and the leg. It has a bent portion 215 g connected to the portion 215 c.
  • the bent portion 215f is formed so that the stacking directions of the conductor plates 1151 and 2152 of the main portion 215a and the stacking directions of the conductor plates 1151 and 2152 of the rising portion 215b are different (intersect).
  • the bent portion 215g is formed so that the stacking directions of the conductor plates 1151 and 2152 of the main portion 215a and the stacking directions of the conductor plates 1151 and 2152 of the leg portion 215c are different (intersect).
  • the conductor portion 121 is erected between the end portion of the rising portion 211b of the conductor portion 211 on the + Z direction side and the end portion of the second portion 212c of the conductor portion 212 on the + Z direction side shown in FIG. 4B. ..
  • the conductor portion 122 is erected between the end portion of the second portion 212b of the conductor portion 212 on the + Z direction side and the end portion of the second portion 213c of the conductor portion 213 on the + Z direction side.
  • the conductor portion 123 is erected between the end portion of the second portion 213b of the conductor portion 213 on the + Z direction side and the end portion of the second portion 214c of the conductor portion 214 on the + Z direction side.
  • the conductor portion 124 is erected between the end portion of the second portion 214b of the conductor portion 214 on the + Z direction side and the end portion of the rising portion 215b of the conductor portion 215 on the + Z direction side.
  • the inductor element 1 Next, a method of manufacturing the inductor element 1 according to the present embodiment will be described.
  • a preparatory step for preparing the conductor substrate 171 shown in FIG. 5A, the conductor substrate 272 shown in FIG. 5B, and the conductor substrate 173 shown in FIG. 2 is performed.
  • the same reference numerals as those in FIG. 2 are attached to the same configurations as those in the first embodiment.
  • the conductor substrates 171 and 272 show an example of a conductor substrate for manufacturing two inductor elements 2.
  • the conductor substrate 272 is manufactured, for example, by punching a metal plate in the same manner as the conductor substrates 171 and 173.
  • the conductor substrate 171 includes five conductor plates 1111, 1121, 1131, 1141 and 1151, two L-shaped frame pieces 1611 and 1612 in a plan view, and 14 elongated support pieces 1611a. , 1611b, 1612a, 1612b, and two units 171U having a structure in which two units 171U are arranged in the X-axis direction.
  • the conductor substrate 272 includes five conductor plates 2111, 2121, 2131, 2141 and 2151, two L-shaped frame pieces 2621 and 2622 in a plan view, and 14 elongated support pieces 1611a.
  • the widths W21 and W22 in the direction orthogonal to the thickness direction of the conductor plate 2122 of the conductor plate 2122 and orthogonal to the extending direction of the conductor plate 2122 are the widths W21 and W22 of the conductor plate 1121. It is shorter than the widths W11 and W12 in the direction orthogonal to the thickness direction and orthogonal to the extending direction of the conductor plate 1121.
  • the widths W21 and W22 in the direction orthogonal to the thickness direction of the conductor plate 2132 of the conductor plate 2132 and orthogonal to the extending direction of the conductor plate 2132 are orthogonal to the thickness direction of the conductor plate 1131 and the conductor plate 1131. It is shorter than the widths W11 and W12 in the direction orthogonal to the extending direction. Further, the widths W21 and W22 in the direction orthogonal to the thickness direction of the conductor plate 2142 of the conductor plate 2142 and orthogonal to the extending direction of the conductor plate 2142 are orthogonal to the thickness direction of the conductor plate 1141 and the conductor plate 1141.
  • the width W11 and W12 in the direction orthogonal to the extending direction is shorter than the widths W11 and W12 in the direction orthogonal to the extending direction.
  • the width W23 in the direction orthogonal to the thickness direction of the conductor plate 2112 of the conductor plate 2112 and orthogonal to the extending direction of the conductor plate 2112 is orthogonal to the thickness direction of the conductor plate 1112 and extends the conductor plate 1112. It is shorter than the width W13 in the direction orthogonal to the direction.
  • the width W25 in the direction orthogonal to the thickness direction of the conductor plate 2152 of the conductor plate 2152 and orthogonal to the extension direction of the conductor plate 2152 is orthogonal to the thickness direction of the conductor plate 1151 and extends of the conductor plate 1151.
  • the conductor portions 211, 212, 213, 214, 215 have a width shorter than that of the conductor plates 1111, 1121, 1131, 1141 and 1151 and the conductor plates 1111, 1121 and 1131, 1141 and 1151. , 2122, 2132, 2142, 2152.
  • the conductor plates 2112, 2122, 2132, 2142, and 2152 are sandwiched between the two conductor plates 1111, 1121, 1131, 1141, and 1151 in the stacking direction. As a result, as shown in FIG.
  • the cross-sectional shapes of the conductor portions 211, 212, 213, 214, and 215 are laminated with the conductor plates 1111, 1121, 1131, 1141, 1151, 2112, 2122, 2132, 2142, and 2152.
  • the shape is point-symmetrical with respect to a point passing through the central axis J21 along the extending direction of the conductor portions 211, 212, 213, 214, and 215 in the direction.
  • the central axis J21 of the rising portion 211b of the conductor portion 211 is parallel to the Z axis
  • the cross-sectional shape of the rising portion 211b is point-symmetric with respect to the point through which the central axis J21 passes.
  • a laminating step of laminating the conductor substrates 171, 272, and 173 to their thickness is performed.
  • the conductor substrate 272 is superposed on the + Z direction side of the conductor substrate 173, and the conductor substrate 171 is superposed on the + Z direction side of the conductor substrate 272.
  • the conductor substrates 171 and 272 are welded to each other on the entire surface side facing each other in the Z-axis direction.
  • the conductor substrates 272 and 173 are also welded to each other on the entire surface side facing each other in the Z-axis direction.
  • a laminated body 27 having two units 27U as shown in FIG. 7A is formed.
  • the frame portions 261 and 262 are formed by laminating the frame pieces 1611, 1612, 2611 and 2612 of the conductor substrates 171 and 272 and 173.
  • the support portions 161a, 161b, 162a, 162b are formed by laminating the support pieces 1611a, 1611b, 1612a, 1612b of the conductor substrates 171, 272, and 173.
  • the laminated body 27 is subjected to a cutting step of cutting the support portions 161a and 162a and the support pieces 1631c and 1632c.
  • the portions corresponding to the rising portions 211b and 215b of the conductor portions 211 and 215 and the portions corresponding to the second portions 212b, 212c, 213b, 213c, 214b and 214c of the conductor portions 212, 213 and 214 are bent in the + Z direction.
  • the bending step of bending the portions corresponding to the leg portions 211c and 215c of the conductor portions 211 and 215 in the ⁇ Z direction is performed.
  • a preparatory step for preparing the four conductor portions 121, 122, 123, 124 shown in FIG. 4A is performed. Subsequently, the end of the rising portion 211b of the conductor portion 211 on the + Z direction side and the end portion of the second portion 212c of the conductor portion 212 on the + Z direction side are welded to the conductor portion 121. Similarly, the + Z direction end of the rising portion 215b of the conductor portion 215 and the + Z direction end of the second portion 214b of the conductor portion 214 are welded to the conductor portion 224.
  • the end portions of the second portions 212b and 213c of the conductor portions 212 and 213 on the + Z direction side are welded to the conductor portion 122.
  • the + Z direction end of the second portion 212b of the conductor portion 212 and the + Z direction end of the second portion 213c of the conductor portion 213 are welded to the conductor portion 123, and the second portion of the conductor portion 213 is welded.
  • the + Z direction end of the portion 213b and the + Z direction end of the second portion 214c of the conductor portion 214 are welded to the conductor portion 124.
  • the widths W21 and W22 of the conductor plates 2122, 2132 and 2142, respectively, are shorter than the widths W11 and W12 of the conductor plates 1121, 1131 and 1141. Further, the width W23 of the conductor plates 2112 and 2152 is shorter than the width W13 of the conductor plates 1111 and 1151. Further, the width W25 in the direction orthogonal to the thickness direction of the conductor plate 2152 of the conductor plate 2152 and orthogonal to the extending direction of the conductor plate 2152 is orthogonal to the thickness direction of the conductor plate 1152 and extends the conductor plate 1152. It is shorter than the width W15 in the direction orthogonal to the direction.
  • grooves 211e, 212e, 213e, 214e, and 215e can be formed on the side surfaces of the conductor portions 211, 212, 213, 214, and 215 that are orthogonal to the winding axis J2 of the coil 20. Therefore, when the conductor portions 211, 212, 213, 214, and 215 are covered with the insulator portion 100, a part of the insulator portion 100 can be put into the grooves 211e, 212e, 213e, 214e, and 215e.
  • the cross-sectional shape of the conductor portions 211, 212, 213, 214, 215 is a conductor in the stacking direction of the conductor plates 1111, 1121, 1131, 1141, 1151, 2112, 2122, 2132, 2142, 2152.
  • the shape of the portions 211, 212, 213, 214, 215 is symmetric with respect to the central axis along the stretching direction.
  • the insulator portion 100 has the conductor portions 211, 212, 213, 214, 215 in a state where a part of the insulator portion 100 is inserted into the grooves 211e, 212e, 213e, 214e, and 215e of the conductor portions 211, 212, 213, 214, and 215.
  • the anchor effect of the insulator portion 100 can be obtained. Therefore, when an external force is applied to the insulator portion 100 in a direction orthogonal to the winding shaft J2 direction of the coil 20 and away from the winding shaft J2, and orthogonal to the winding shaft J2 direction of the coil 20. In both cases, when an external force is applied in the direction away from the winding shaft J2, it is possible to prevent the insulator portion 100 from peeling off in the direction in which the external force is applied to the coil 20.
  • the inductor element according to the present embodiment is different from the first embodiment in that a recess recessed in the stacking direction of the conductor plates is provided on the surface of the first conductor portion. Further, the number of conductor plates forming the bottom of the recess in the first conductor portion is smaller than the number of laminated conductor plates forming other than the recess in the first conductor portion.
  • the inductor element 3 includes a coil 30 and an insulator portion 100.
  • the same components as those in the first embodiment are designated by the same reference numerals as those in FIG. 1A.
  • the inductor element 3 is arranged on the substrate B1 on which the electronic component E1 is mounted.
  • the inductor element 3 is arranged so as to cover the + Z direction side of the electronic component E1.
  • the coil 30 has conductor groups 21 and 12.
  • the conductor group 21 has five conductors 311, 312, 313, 314, and 315 arranged along the winding axis J3 of the coil 20.
  • FIG. 9A the conductor group 21 has five conductors 311, 312, 313, 314, and 315 arranged along the winding axis J3 of the coil 20.
  • the conductor portion 311 is a first conductor portion composed of conductor plates 1111, 3112, and 3113 which are plate-shaped and laminated in the thickness direction.
  • the conductor portion 311 includes an L-shaped main portion 311a extending in the ⁇ X direction and the + Y direction, and a rising portion 311b rising in the + Z direction from the + Y direction side at the end portion of the main portion 311a on the ⁇ X direction side.
  • the leg portion 311c extending in the ⁇ Z direction from the + Y direction side at the end of the main portion 311a on the + Y direction side, the bent portion 311f connected to the main portion 311a and the rising portion 311b, and the main portion 311a and the leg portion 311c. It has a bent portion 311 g connected to and.
  • the bent portion 311f is formed so that the stacking directions of the conductor plates 1111, 3112, and 3113 of the main portion 311a and the stacking directions of the conductor plates 1111, 3112, and 3113 of the rising portion 311b are different (intersect). NS.
  • the bent portion 311g is formed so that the stacking directions of the conductor plates 1111, 3112, and 3113 of the main portion 311a and the stacking directions of the conductor plates 1111, 3112, and 3113 of the leg portion 311c are different (intersect).
  • the conductor portion 312 is a first conductor portion composed of conductor plates 3121, 3122, and 3123 which are plate-shaped and laminated in the thickness direction.
  • the conductor portion 312 has a first portion 312a having a portion extending in a direction inclined in the ⁇ X direction rather than a + Y direction and a portion extending in the ⁇ Y direction from each of both ends thereof, and the Y of the first portion 312a.
  • the second portion 312b, 312c rising from both ends in the axial direction in the + Z direction, the bending portion 312f connected to the first part 312a and the second part 312b, and the bending connected to the first part 312a and the second part 312c. It has a portion 312 g and.
  • the bent portion 312f is oriented so that the stacking direction of the conductor plates 3121, 3122, 3123 of the first portion 312a and the stacking direction of the conductor plates 3121, 3122, 3123 of the second portion 312b are different (intersect). It is formed.
  • the bent portion 312g is formed so that the stacking direction of the conductor plates 1111 and 2112 of the first portion 212a and the stacking direction of the conductor plate conductor plates 3121, 3122, 3123 of the second portion 312c are different (intersect) directions. NS. Further, the first portion 312a, the bent portion 312f, 312g and the second portion 312b, 312c are continuously integrally formed.
  • the conductor portion 313 is a first conductor portion composed of conductor plates 1131, 3132, and 3133 which are plate-shaped and laminated in the thickness direction.
  • the conductor portion 313 is long and has a first portion 313a having a portion extending in a direction inclined in the ⁇ X direction from the + Y direction and a portion extending in the ⁇ Y direction from each of both ends thereof, and a long portion.
  • the second part 313b, 313c rising from both ends of the first part 313a in the Y-axis direction in the + Z direction, the bending part 313f connected to the first part 313a and the second part 313b, and the first part 313a. It has a bent portion 313g connected to a second portion 313c.
  • the bent portion 313f is oriented so that the stacking direction of the conductor plates 1131, 3132, 3133 of the first portion 313a and the stacking direction of the conductor plates 1131, 3132, 3133 of the second portion 313b are different (intersect). It is formed.
  • the bent portion 313g is formed so that the stacking direction of the conductor plates 1131, 3132, 3133 of the first portion 313a and the stacking direction of the conductor plates 1131, 3132, 3133 of the second portion 313c are different (intersect). NS. Further, the first portion 313a, the bent portion 313f, 313g and the second portion 313b, 313c are continuously integrally formed.
  • the conductor portion 314 is a first conductor portion composed of conductor plates 1141, 3142, and 3143 which are plate-shaped and laminated in the thickness direction.
  • the conductor portion 314 has a first portion 314a having a portion extending in a direction inclined in the ⁇ X direction rather than a + Y direction and a portion extending in the ⁇ Y direction from each of both ends thereof, and the Y of the first portion 314a. Bending connecting to the second part 314b and 314c rising from both ends in the axial direction in the + Z direction, bending part 314f connecting to the first part 314a and the second part 314b, and bending connecting to the first part 314a and the second part 314c. It has a portion 314 g and.
  • the bent portion 314f is arranged so that the stacking directions of the conductor plates 1141, 3142, 3143 of the first portion 314a and the stacking directions of the conductor plates 1141, 3142, 3143 of the second portion 314b are different (intersect). It is formed.
  • the bent portion 314g is formed so that the stacking directions of the conductor plates 1141, 3142, 3143 of the first portion 314a and the stacking directions of the conductor plates 1141, 3142, 3143 of the second portion 314c are different (intersect). NS. Further, the first portion 314a, the bent portion 314f, 314g and the second portion 314b, 314c are continuously integrally formed.
  • the conductor portion 315 is a first conductor portion composed of conductor plates 1151, 3152, and 3153 which are plate-shaped and laminated in the thickness direction.
  • the conductor portion 315 includes an L-shaped main portion 315a extending in the + X direction and the ⁇ Y direction, and a rising portion 315b rising in the + Z direction from the ⁇ Y direction side at the end portion of the main portion 315a on the + X direction side.
  • the leg portion 315c extending in the ⁇ Z direction from the ⁇ Y direction side at the end portion of the main portion 315a on the ⁇ Y direction side, the bent portion 315f connected to the main portion 315a and the rising portion 315b, and the main portion 315a and the leg.
  • the bent portion 315f is formed so that the stacking directions of the conductor plates 1151, 3152, and 3153 of the main portion 315a and the stacking directions of the conductor plates 1151, 3152, and 3153 of the rising portion 315b are different (intersect).
  • the bent portion 315g is formed so that the stacking directions of the conductor plates 1151, 3152, 3153 of the main portion 315a and the stacking directions of the conductor plates 1151, 3152, 3153 of the leg portion 315c are different (intersect).
  • the surfaces of the conductor portions 311, 312, 313, 314, and 315 have conductor plates 1111, 3112, 3113, 3121, 3122, 3123, 1131, 3132, 3133, 1141, 3142, and 3143, respectively.
  • 1151, 3152, and 3153 are provided with recesses 311d, 312d, 313d, 314d, and 315d recessed in the stacking direction.
  • the number of conductor plates forming the bottom of the recesses 311d, 312d, 313d, 314d, and 315d in the conductor portions 311, 312, 313, 314, and 315 is the number of the recesses 311d in the conductor portions 311 and 312, 313, 314, and 315. It is less than the number of laminated conductor plates other than 312d, 313d, 314d, and 315d.
  • the inner shape of the recesses 312d, 313d, and 314d has a shape in which the opening area of the recesses 312d, 313d, and 314d becomes smaller toward the bottom side, that is, the + Z direction side.
  • the area of the bottom of the recesses 311d, 312d, 313d, 314d, and 315d is smaller than the opening area of the recesses 311d, 312d, 313d, 314d, and 315d.
  • the conductor portion 121 is erected between the end of the conductor portion 311 on the + Z direction side of the rising portion 311b and the end portion of the second portion 312c of the conductor portion 312 on the + Z direction side, as shown in FIG. 9A. ..
  • the conductor portion 122 is erected between the end portion of the second portion 312b of the conductor portion 312 on the + Z direction side and the end portion of the second portion 313c of the conductor portion 313 on the + Z direction side.
  • the conductor portion 123 is erected between the end portion of the second portion 313b of the conductor portion 313 on the + Z direction side and the end portion of the second portion 314c of the conductor portion 314 on the + Z direction side.
  • the conductor portion 124 is erected between the end portion of the second portion 314b of the conductor portion 314 on the + Z direction side and the end portion of the rising portion 315b of the conductor portion 315 on the + Z direction side.
  • the inductor element 3 Next, a method of manufacturing the inductor element 3 according to the present embodiment will be described.
  • a preparatory step is performed to prepare the conductor substrate 171 shown in FIG. 2, the conductor substrate 372 shown in FIG. 10A, and the conductor substrate 373 shown in FIG. 10B.
  • the same reference numerals as those in FIG. 2 are attached to the same configurations as those in the first embodiment.
  • the conductor substrates 371 and 372 show an example of a conductor substrate for manufacturing the two inductor elements 2.
  • the conductor substrates 372 and 373 are manufactured by, for example, punching a metal plate in the same manner as the conductor substrate 171.
  • the conductor substrate 372 includes conductor plates 3112, 3122, 3132, 3142, 3152, two L-shaped frame pieces 1611 and 1612 in a plan view, and 14 elongated support pieces 1611a and 1611b. , 1612a, 1612b, and two units 372U having a structure in which two units 372U are arranged in the X-axis direction.
  • the five support pieces 1611a extend from the frame piece 1611 in the ⁇ Y direction, and the ends on the ⁇ Y direction side in the longitudinal direction are arranged on the conductor plate 3111 and the + Y direction side. It is connected to 3141.
  • the five support pieces 1612a include a conductor plate 3122, 3132, 3142 and a conductor plate 3152 extending from the frame piece 1612 in the + Y direction and having an end portion on the + Y direction side in the longitudinal direction arranged on the ⁇ Y direction side. It is connected to the. Further, the conductor substrate 372, the support extending along the X-axis direction and connecting the ends of the conductor plate 3112 and the conductor plate 3122, 3132, 3142 arranged on the + Y direction side to each other on the ⁇ Y direction side are connected to each other.
  • Support piece 3612c that connects the pieces 3611c and the ends of the conductor plates 3122, 3132, 3142 and the conductor plates 3152 that extend along the X-axis direction and are arranged on the ⁇ Y direction side to each other on the + Y direction side. And have.
  • the conductor plates 3121, 3131, 3141 arranged on the + Y direction side and the conductor plates 3122, 3132, 3142 arranged on the ⁇ Y direction side are separated by a distance W31.
  • the conductor substrate 373 also has the same structure as the conductor substrate 372, and the conductor plates 3113, 3123, 3133, 3143, 3153 and the two L-shaped frame pieces 1611 in a plan view, It has a structure in which two units 373U having 1612 and 14 elongated support pieces 1611a, 1611b, 1612a, 1612b are arranged side by side in the X-axis direction.
  • the conductor plates 3123, 3133, 3143 arranged on the + Y direction side and the conductor plates 3123, 3133, 3143 arranged on the ⁇ Y direction side are separated by a distance W32.
  • the distance W32 is set longer than the distance W31.
  • a stepped portion is formed at the peripheral portion of the recesses 311d, 312d, 313d, 314d, and 315d. Since the distance W31 is set shorter than the distance W32, the opening area of the recesses 312d, 313d, and 314d becomes smaller toward the bottom side, that is, the + Z direction side.
  • a laminating step of laminating the conductor substrates 171, 372, and 373 to their thickness is performed.
  • the conductor substrate 372 is superposed on the ⁇ Z direction side of the conductor substrate 171, and the conductor substrate 373 is superposed on the ⁇ Z direction side of the conductor substrate 372.
  • the conductor substrates 171 and 372 are welded to each other on the entire surface side facing each other in the Z-axis direction.
  • the conductor substrates 372 and 373 are also welded to each other on the entire surface side facing each other in the Z-axis direction.
  • a laminated body 37 having two units 37U as shown in FIG. 11A is formed.
  • the frame portions 161 and 162 are formed by laminating the frame pieces 1611 and 1612 of the conductor substrates 171 and 372 and 373.
  • the support portions 161a, 161b, 162a, 162b are formed by laminating the support pieces 1611a, 1611b, 1612a, 1612b of the conductor substrates 171, 372, and 373.
  • the portion corresponding to the bottom of the recesses 311d, 312d, 313d, 314d, 315d in the conductor portions 311, 312, 313, 314, 315 is composed of one conductor plate 1111, 1121, 1131, 1141, 1151. ..
  • the parts other than the recesses 311d, 312d, 313d, 314d, and 315d in the conductor portions 311, 312, 313, 314, and 315 have three conductor plates 1111, 1121, 1131, 1141, 1151, 3112, 3122, 3132, and 3142. , 3152, 3113, 3123, 3133, 3143, 3153. That is, the number of laminated conductor plates 1111, 1121, 1131, 1141 and 1151 in the portions corresponding to the bottoms of the recesses 311d, 312d, 313d, 314d and 315d in the conductor portions 311, 312, 313, 314 and 315 is 1.
  • Conductor plates 1111, 1121, 1131, 1141, 1151, 3112, 3122, 3132, 3142, 3152, 3113 The number of layers of 3123, 3133, 3143, and 3153 is smaller than that of 3.
  • the laminated body 37 is subjected to a cutting step of cutting the support portions 161a and 162a and the support pieces 3611c and 3612c.
  • the portion corresponding to the rising portion 311b and 315b of the conductor portion 311 and 315 and the portion corresponding to the second portion 312b, 312c, 313b, 313c, 314b and 314c of the conductor portion 312, 313 and 314 are bent in the + Z direction.
  • the bending step of bending the portions corresponding to the legs 311c and 315c of the conductor portions 311 and 315 in the ⁇ Z direction is performed.
  • a preparatory step for preparing the four conductor portions 121, 122, 123, 124 shown in FIG. 4A is performed. Subsequently, the + Z direction end of the rising portion 311b of the conductor portion 311 and the + Z direction end of the second portion 312c of the conductor portion 312 are welded to the conductor portion 121. Similarly, the + Z direction end of the rising portion 315b of the conductor portion 315 and the + Z direction end of the second portion 314b of the conductor portion 314 are welded to the conductor portion 124. Further, the ends of the second portions 312b and 313c of the conductor portions 312 and 313 on the + Z direction side are welded to the conductor portion 122.
  • the + Z direction end of the second portion 312b of the conductor portion 312 and the + Z direction end of the second portion 313c of the conductor portion 313 are welded to the conductor portion 123, and the second portion of the conductor portion 313 is welded.
  • the + Z direction end of the portion 313b and the + Z direction end of the second portion 314c of the conductor portion 314 are welded to the conductor portion 124.
  • the resin containing the above-mentioned ferrite powder is injected into the mold, and then heated and cooled to form the insulator portion 100.
  • a plurality of inductor elements 3 are generated.
  • the conductor portions 311, 312, 313, 314, and 315 are respectively located in the thickness direction of the conductor portions 311, 312, 313, 314, and 315.
  • Recessed recesses 311d, 312d, 313d, 314d, and 315d are provided.
  • a relatively large space can be formed on the ⁇ Z direction side of the conductor portions 312, 313, 314 of the inductor element 3. Therefore, the height from the mounting surface of the substrate B1 in the thickness direction of the substrate B1 to the edge of the inductor element 3 on the + Z direction when the inductor element 3 is mounted on the electronic component E1 can be lowered. , The thickness of the module including the inductor element 3 can be reduced.
  • the insulator portion 100 has the conductor portions 311 and 312 in a state where a part of the insulator portion 100 is inserted into the recesses 311d, 312d, 313d, 314d and 315d of the conductor portions 311 and 312, 313, 314 and 315.
  • the anchor effect of the insulator portion 100 can be obtained. Therefore, when an external force is applied to the insulator portion 100 in the direction along the stretching direction of the conductor portions 311, 312, 313, 314, and 315, the direction in which the insulator portion 100 applies the external force to the coil 30. It is possible to prevent the coil from peeling off.
  • the conductor portions 411, 421, 413, 414, 415 have two conductor plates 1111, 1121, 1131, 1141, 1151, and two conductor plates 1111, 1121, 1131, 1141, respectively. It may consist of one conductor plate 4112, 4122, 4132, 4142, 4152 laminated between 1151.
  • the width of the conductor plate 4112 and 4113112 is longer than the width of the conductor plate 1111.
  • the conductor portions 111, 112, 113, 114, 115, 211, 212, 213, 214, 215, 311, 312, 313, 314, 315 of the coils 10, 20, and 30 are three, respectively.
  • An example of a laminated conductor plate has been described.
  • the number of laminated conductor plates constituting the conductor portion of the coil is not limited to three, and two conductor plates may be laminated in the thickness direction, or four or more conductors may be laminated.
  • the plates may be laminated in the thickness direction. Further, for example, as shown in the conductor portions 511, 512, 513, 514, 515 shown in FIG.
  • the two conductor plates 1111, 1121, 1131, 1141, 1151 and the two conductor plates 5112, 5122, 5132, 5142, 5152 And may be alternately laminated in the thickness direction.
  • the width of the conductor plates 5112, 5122, 5132, 5142, 5152 is longer than the width of the conductor plates 1111, 1121, 1131, 1141, 1151.
  • the cross-sectional shape of the conductor portions 511, 512, 513, 514, 515 is such that the conductor portions 511, 512, 1131, 1141, 1151, 5112, 5122, 5132, 5142, 5152 are stacked in the direction of stacking.
  • the shape may be asymmetric with respect to the central axis along the stretching direction of 514 and 515.
  • the present invention is suitable as an inductor element that is compact and allows a relatively large current to flow.

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Abstract

This coil is provided with conductor parts (112, 113, 114) that include: first regions (112a, 113a, 114a) in which three conductor plates are layered; bent sections (112f, 112g, 113f, 113g, 114f, 114g) that connect to the first regions (112a, 113a, 114a); and second regions (112b, 112c, 113b, 113c, 114b, 114c) that connect to the bent sections (112f, 112g, 113f, 113g, 114f, 114g) and that are formed as a result of a plurality of conductor plates being layered in a direction which differs from the layering direction of the plurality of conductor plates constituting the first regions (112a, 113a, 114a). Moreover, the first regions (112a, 113a, 114a), the bent sections (112f, 112g, 113f, 113g, 114f, 114g), and the second regions (112b, 112c, 113b, 113c, 114b, 114c) are each uneven on a lateral surface thereof.

Description

コイル構造およびインダクタ素子Coil structure and inductor element
　本発明は、コイル構造およびインダクタ素子に関する。 The present invention relates to a coil structure and an inductor element.
　金属の導体基板を打ち抜き加工およびプレス加工することにより形成され上側彎曲部と下側彎曲部とが交互に配置された形状を有するプレスコイルと、プレスコイルの内側に挿入されたフェライトコアと、プレスコイルおよびフェライトコアに密着した状態でこれらを覆うフェライト樹脂と、を備えるインダクタ素子が提案されている（例えば特許文献１参照）。 A press coil formed by punching and pressing a metal conductor substrate and having a shape in which upper curved portions and lower curved portions are alternately arranged, a ferrite core inserted inside the press coil, and a press. An inductor element including a ferrite resin that covers a coil and a ferrite core in close contact with each other has been proposed (see, for example, Patent Document 1).
特開平６－８４６４８号公報Japanese Unexamined Patent Publication No. 6-84648
　しかしながら、特許文献１に記載されたインダクタ素子の中には、プレスコイルを形成する金属の熱膨張係数とフェライト樹脂の熱膨張係数との差が比較的大きいものがある。この場合、インダクタ素子が比較的温度変化が大きい環境で使用されると、フェライト樹脂がプレスコイルから剥離してしまいインダクタ素子の特性が変化してしまう虞がある。 However, among the inductor elements described in Patent Document 1, there is a relatively large difference between the coefficient of thermal expansion of the metal forming the press coil and the coefficient of thermal expansion of the ferrite resin. In this case, if the inductor element is used in an environment where the temperature change is relatively large, the ferrite resin may peel off from the press coil and the characteristics of the inductor element may change.
　本発明は、上記事由に鑑みてなされたものであり、温度変化に起因した特性変化が抑制されたコイル構造およびインダクタ素子を提供することを目的とする。 The present invention has been made in view of the above reasons, and an object of the present invention is to provide a coil structure and an inductor element in which characteristic changes due to temperature changes are suppressed.
　上記目的を達成するために、本発明に係るコイル構造は、
　巻回軸に沿って巻回されるコイル構造であって、
　複数の導体板が積層された第１部位と、前記第１部位と繋がり、互いに積層され複数の導体板からなり且つ複数の導体板それぞれが積層方向に湾曲している曲げ部と、前記曲げ部と繋がり且つ前記第１部位を構成する複数の導体板の積層方向と異なる方向に複数の導体板が積層されてなる第２部位と、を有する第１導体部を備え、
　前記第１部位、前記曲げ部および前記第２部位は、それぞれ、側面に凹凸を有する。 In order to achieve the above object, the coil structure according to the present invention is
It is a coil structure that is wound along the winding axis.
A first portion in which a plurality of conductor plates are laminated, a bent portion connected to the first portion, laminated with each other, composed of a plurality of conductor plates, and each of the plurality of conductor plates is curved in the stacking direction, and the bent portion. The first conductor portion is provided with a second portion which is connected to and has a second portion in which a plurality of conductor plates are laminated in a direction different from the stacking direction of the plurality of conductor plates forming the first portion.
The first portion, the bent portion, and the second portion each have irregularities on the side surfaces.
　また、本発明に係るコイル構造は、
　前記複数の導体板が、前記積層方向と直交する方向の導体基板の長さを幅と定義したとき、前記幅の長さが互いに異なる導体板を含む、ものであってもよい。 Further, the coil structure according to the present invention is
When the length of the conductor substrate in the direction orthogonal to the laminating direction is defined as the width, the plurality of conductor plates may include conductor plates having different widths from each other.
　また、本発明に係るコイル構造は、
　前記複数の導体板が、第１導体板と、前記第１導体板よりも前記幅の長さが短い第２導体基板とを有し、
　前記第２導体板が、前記積層方向において、２つの前記第１導体板に挟まれている、ものであってもよい。 Further, the coil structure according to the present invention is
The plurality of conductor plates have a first conductor plate and a second conductor substrate having a width shorter than that of the first conductor plate.
The second conductor plate may be sandwiched between the two first conductor plates in the stacking direction.
　また、本発明に係るコイル構造は、
　前記第１導体部の前記積層方向における断面形状が、点対称であってもよい。 Further, the coil structure according to the present invention is
The cross-sectional shape of the first conductor portion in the stacking direction may be point-symmetrical.
　また、本発明に係るコイル構造は、
　前記第１導体部の表面には、前記積層方向に窪んだ凹部が設けられている、ものであってもよい。 Further, the coil structure according to the present invention is
The surface of the first conductor portion may be provided with a recess recessed in the stacking direction.
　また、本発明に係るコイル構造は、
　前記第１導体部における前記凹部の底部を構成する前記導体板の数が、前記第１導体部における前記凹部以外を構成する導体板の積層数よりも少なくてもよい。 Further, the coil structure according to the present invention is
The number of the conductor plates forming the bottom of the recess in the first conductor portion may be smaller than the number of laminated conductor plates forming other than the recess in the first conductor portion.
　また、本発明に係るコイル構造は、
　前記凹部の底部の面積が、前記凹部の開口面積よりも小さいものであってもよい。 Further, the coil structure according to the present invention is
The area of the bottom of the recess may be smaller than the opening area of the recess.
　また、本発明に係るコイル構造は、
　前記巻回軸の方向から数えて１ターン目を構成する第１導体部と２ターン目を構成する第１導体部との間に、１つの導体基板で構成される第２導体部が接続される、ものであってもよい。 Further, the coil structure according to the present invention is
A second conductor portion composed of one conductor substrate is connected between the first conductor portion constituting the first turn and the first conductor portion forming the second turn counting from the direction of the winding axis. It may be a thing.
　また、本発明に係るコイル構造は、
　前記第１導体部と前記第２導体部とが接続される部分において、前記第１導体部が延在する方向と前記第２導体部が延在する方向とが直交する、ものであってもよい。 Further, the coil structure according to the present invention is
In the portion where the first conductor portion and the second conductor portion are connected, the direction in which the first conductor portion extends and the direction in which the second conductor portion extends are orthogonal to each other. good.
　他の観点から見た本発明に係るインダクタ素子は、
　前記コイル構造と、
　絶縁体材料から形成され前記第１導体部を覆う絶縁体部と、を備える。 The inductor element according to the present invention from another point of view is
With the coil structure
It includes an insulator portion formed of an insulator material and covering the first conductor portion.
　本発明によれば、巻回軸に沿って巻回されるコイル構造であって、積層される複数の導体板を含んで構成される第１部位と、第２部位と、第１部位と第２部位とに繋がる曲げ部とを有する第１導体部を備える。そして、曲げ部が、第１部位における複数の導体板の積層方向と、第２部位における複数の導体板の積層方向が異なるように形成される。これにより、第１導体部におけるコイルの巻回軸に直交する側面における積層方向で隣接する２つの導体板の間の境界部分に微細な窪みを形成することができる。従って、第１導体部を絶縁体部で覆う際、絶縁体部の一部を第１導体部の側面に形成された窪みに入り込んだ状態で覆うことができるので、絶縁体部の第１導体部への密着性が向上する。それ故、絶縁体部に対してコイルの巻回軸方向に直交する方向への外力が加わった場合に絶縁体部がコイルに対して外力の加わる方向へ剥離してしまうことを抑制できるので、温度変化に起因して外力が加わったときに絶縁体部が剥離しにくくコイル構造を含むインダクタ素子の特性変化が抑制される。 According to the present invention, it is a coil structure wound along a winding axis, and is composed of a plurality of laminated conductor plates, the first portion, the second portion, the first portion, and the first portion. A first conductor portion having a bent portion connected to the two portions is provided. Then, the bent portion is formed so that the stacking direction of the plurality of conductor plates at the first portion and the stacking direction of the plurality of conductor plates at the second portion are different. As a result, a fine depression can be formed at the boundary portion between the two conductor plates adjacent in the stacking direction on the side surface orthogonal to the winding axis of the coil in the first conductor portion. Therefore, when the first conductor portion is covered with the insulator portion, a part of the insulator portion can be covered in a state of being inserted into the recess formed on the side surface of the first conductor portion, so that the first conductor of the insulator portion can be covered. Adhesion to the part is improved. Therefore, when an external force is applied to the insulator portion in a direction orthogonal to the winding axis direction of the coil, it is possible to prevent the insulator portion from peeling off in the direction in which the external force is applied to the coil. When an external force is applied due to a temperature change, the insulator portion does not easily peel off, and changes in the characteristics of the inductor element including the coil structure are suppressed.
本発明の実施の形態１に係るインダクタ素子の斜視図である。It is a perspective view of the inductor element which concerns on Embodiment 1 of this invention. 実施の形態１に係るコイルの一部の斜視図である。It is a perspective view of a part of the coil which concerns on Embodiment 1. FIG. 実施の形態１に係るインダクタ素子の製造方法を説明するための分解斜視図である。It is an exploded perspective view for demonstrating the manufacturing method of the inductor element which concerns on Embodiment 1. FIG. 実施の形態１に係る積層体の斜視図である。It is a perspective view of the laminated body which concerns on Embodiment 1. FIG. 実施の形態１に係る積層体について曲げ加工後の状態を示す斜視図である。It is a perspective view which shows the state after bending process about the laminated body which concerns on Embodiment 1. FIG. 実施の形態１に係る積層体について曲げ加工後の状態を示す斜視図である。It is a perspective view which shows the state after bending process about the laminated body which concerns on Embodiment 1. FIG. 本発明の実施の形態２に係るインダクタ素子の斜視図である。It is a perspective view of the inductor element which concerns on Embodiment 2 of this invention. 実施の形態２に係るコイルの一部の斜視図である。It is a perspective view of a part of the coil which concerns on Embodiment 2. FIG. 実施の形態２に係る導体基板の平面図である。It is a top view of the conductor substrate which concerns on Embodiment 2. FIG. 実施の形態２に係る他の導体基板の平面図である。It is a top view of another conductor substrate which concerns on Embodiment 2. FIG. 実施の形態２に係る導体部の一部の断面図である。It is sectional drawing of a part of the conductor part which concerns on Embodiment 2. FIG. 実施の形態２に係る積層体の斜視図である。It is a perspective view of the laminated body which concerns on Embodiment 2. FIG. 実施の形態２に係る積層体について曲げ加工後の状態を示す斜視図である。It is a perspective view which shows the state after bending process about the laminated body which concerns on Embodiment 2. 実施の形態２に係る積層体について曲げ加工後の状態を示す斜視図である。It is a perspective view which shows the state after bending process about the laminated body which concerns on Embodiment 2. 本発明の実施の形態３に係るインダクタ素子の斜視図である。It is a perspective view of the inductor element which concerns on Embodiment 3 of this invention. 実施の形態３に係るインダクタ素子の側面図である。It is a side view of the inductor element which concerns on Embodiment 3. FIG. 実施の形態３に係るコイルの一部の斜視図である。It is a perspective view of a part of the coil which concerns on Embodiment 3. FIG. 実施の形態３に係るコイルの一部の斜視図である。It is a perspective view of a part of the coil which concerns on Embodiment 3. FIG. 実施の形態３に係る導体基板の平面図である。It is a top view of the conductor substrate which concerns on Embodiment 3. FIG. 実施の形態３に係る積層体の平面図である。It is a top view of the laminated body which concerns on Embodiment 3. FIG. 実施の形態３に係る積層体の斜視図である。It is a perspective view of the laminated body which concerns on Embodiment 3. FIG. 実施の形態３に係る積層体について曲げ加工後の状態を示す斜視図である。It is a perspective view which shows the state after bending process about the laminated body which concerns on Embodiment 3. 実施の形態３に係る積層体について曲げ加工後の状態を示す斜視図である。It is a perspective view which shows the state after bending process about the laminated body which concerns on Embodiment 3. 変形例に係る導体部の一部の断面図である。It is sectional drawing of a part of the conductor part which concerns on a modification. 変形例に係る導体部の一部の断面図である。It is sectional drawing of a part of the conductor part which concerns on a modification.
（実施の形態１）
　以下、本発明の実施の形態について図面を参照して詳細に説明する。本実施の形態に係るインダクタ素子は、板状であり厚さ方向に積層された複数の導体板からなる部分を含む第１導体部を有するコイルと、絶縁体材料から形成された絶縁体部と、を備える。ここで、コイルは、巻回軸に沿って巻回されるコイル構造を有する。絶縁体部は、コイルの第１導体部に密着した状態でコイルの少なくとも第１導体部全体を覆っている。そして、コイルは、積層された複数の導体板を有する第１導体部を備えており、第１導体部が、複数の導体板が積層される積層方向に曲がっている。つまり、コイルは、複数の導体板が積層された第１部位と、第１部位と繋がり、互いに積層され複数の導体板からなり且つ複数の導体板それぞれが積層方向に湾曲している曲げ部と、曲げ部と繋がり且つ第１部位を構成する複数の導体板の積層方向と異なる方向に複数の導体板が積層されてなる第２部位と、を有する第１導体部を備えている。そして、第１部位、曲げ部および第２部位は、それぞれ、側面に凹凸を有している。ここで、「導体板」とは、厚みのある板状の導体も含む。 (Embodiment 1)
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The inductor element according to the present embodiment includes a coil having a first conductor portion including a portion composed of a plurality of conductor plates laminated in the thickness direction in a plate shape, and an insulator portion formed of an insulator material. , Equipped with. Here, the coil has a coil structure that is wound along a winding shaft. The insulator portion covers at least the entire first conductor portion of the coil in a state of being in close contact with the first conductor portion of the coil. The coil includes a first conductor portion having a plurality of laminated conductor plates, and the first conductor portion is bent in the stacking direction in which the plurality of conductor plates are laminated. That is, the coil is a first portion in which a plurality of conductor plates are laminated, and a bent portion that is connected to the first portion, is laminated with each other, is composed of a plurality of conductor plates, and each of the plurality of conductor plates is curved in the stacking direction. It is provided with a first conductor portion having a second portion connected to the bent portion and in which a plurality of conductor plates are laminated in a direction different from the stacking direction of the plurality of conductor plates forming the first portion. The first portion, the bent portion, and the second portion each have irregularities on the side surfaces. Here, the "conductor plate" also includes a thick plate-shaped conductor.
　図１Ａに示すように、本実施の形態に係るインダクタ素子１は、コイル１０と、絶縁体部１００と、を備える。コイル１０は、導体部群１１、１２を有する。導体部群１１は、図１Ｂに示すように、コイル１０の巻回軸Ｊ１に沿って配列された５つの導体部１１１、１１２、１１３、１１４、１１５を有する。導体部１１１は、板状であり厚さ方向に積層された３枚の導体板１１１１からなる第１導体部である。導体部１１１は、－Ｘ方向と＋Ｙ方向とに延在するＬ字状の主部１１１ａと、主部１１１ａの－Ｘ方向側の端部における＋Ｙ方向側から＋Ｚ方向へ立ち上がった立上部１１１ｂと、主部１１１ａの＋Ｙ方向側の端部における＋Ｙ方向側から－Ｚ方向へ延出する脚部１１１ｃと、主部１１１ａと立上部１１１ｂとに繋がる曲げ部１１１ｆと、主部１１１ａと脚部１１１ｃとに繋がる曲げ部１１１ｇと、を有する。そして、曲げ部１１１ｆは、主部１１１ａの導体板１１１１の積層方向と、立上部１１１ｂの導体板１１１１の積層方向が異なる（交差する）方向となるように形成される。曲げ部１１１ｇは、主部１１１ａの積層方向と、脚部１１１ｃの積層方向が異なる（交差する）方向となるように形成される。導体部１１１における３つの導体板１１１１の積層方向は、コイル１０の巻回軸Ｊ１と直交している。 As shown in FIG. 1A, the inductor element 1 according to the present embodiment includes a coil 10 and an insulator portion 100. The coil 10 has conductor groups 11 and 12. As shown in FIG. 1B, the conductor group 11 has five conductors 111, 112, 113, 114, 115 arranged along the winding axis J1 of the coil 10. The conductor portion 111 is a first conductor portion composed of three conductor plates 1111 which are plate-shaped and laminated in the thickness direction. The conductor portion 111 includes an L-shaped main portion 111a extending in the −X direction and the + Y direction, and a rising portion 111b rising in the + Z direction from the + Y direction side at the end portion of the main portion 111a on the −X direction side. , The leg portion 111c extending in the −Z direction from the + Y direction side at the end portion on the + Y direction side of the main portion 111a, the bent portion 111f connected to the main portion 111a and the rising portion 111b, and the main portion 111a and the leg portion 111c. It has a bent portion 111 g connected to and. The bent portion 111f is formed so that the stacking direction of the conductor plate 1111 of the main portion 111a and the stacking direction of the conductor plate 1111 of the rising portion 111b are different (intersect). The bent portion 111g is formed so that the stacking direction of the main portion 111a and the stacking direction of the leg portions 111c are different (intersect). The stacking direction of the three conductor plates 1111 in the conductor portion 111 is orthogonal to the winding axis J1 of the coil 10.
　導体部１１２は、板状であり厚さ方向に積層された３枚の導体板１１２１からなる第１導体部である。導体部１１２は、＋Ｙ方向よりも－Ｘ方向へ傾いた方向へ延在する部位とその両端部それぞれから±Ｙ方向へ延在する部位とを有する第１部位１１２ａと、第１部位１１２ａのＹ軸方向における両端部それぞれから＋Ｚ方向へ立ち上がった第２部位１１２ｂ、１１２ｃと、第１部位１１２ａと第２部位１１２ｂとに繋がる曲げ部１１２ｆと、第１部位１１２ａと第２部位１１２ｃとに繋がる曲げ部１１２ｇと、を有する。そして、曲げ部１１２ｆは、第１部位１１２ａの導体板１１２１の積層方向と、第２部位１１２ｂの導体板１１２１の積層方向が異なる（交差する）方向となるように形成される。曲げ部１１２ｇは、第１部位１１２ａの導体板１１２１の積層方向と、第２部位１１２ｃの導体板１１２１の積層方向が異なる（交差する）方向となるように形成される。即ち、導体部１１２は、コイル１０の巻回軸Ｊ１を含み且つＸＺ平面に平行な仮想平面と交差する第１部位１１２ａと、第１部位１１２ａの両端部それぞれから前述の仮想平面に沿って＋Ｚ方向へ延在する第２部位１１２ｂ、１１２ｃと、を有する。導体部１１２における３つの導体板１１２１の積層方向は、コイル１０の巻回軸Ｊ１と直交している。即ち、導体部１１２は、第１部位１１２ａと、第１部位１１２ａと繋がり、互いに積層された３枚の導体板１１２１からなり且つ３枚の導体板１１２１それぞれが積層方向に湾曲している曲げ部１１２ｆ、１１２ｇと、曲げ部１１２ｆ、１１２ｇと繋がり且つ第１部位１１２ａを構成する３枚の導体板１１２１の積層方向と異なる方向に３枚の導体板１１２１が積層されてなる第２部位１１２ｂ、１１２ｃと、を有する。そして、第１部位１１２ａ、曲げ部１１２ｆ、１１２ｇおよび第２部位１１２ｂ、１１２ｃは、それぞれ、側面に凹凸を有している。ここで、凹凸とは、３枚の導体板１１２１の境界部分に形成される微細な凹部と導体板１１２１の端面とから形成された凹凸に相当する。また、第１部位１１２ａ、曲げ部１１２ｆ、１１２ｇおよび第２部位１１２ｂ、１１２ｃは、連続一体に形成されている。 The conductor portion 112 is a first conductor portion composed of three conductor plates 1121 which are plate-shaped and laminated in the thickness direction. The conductor portion 112 has a first portion 112a having a portion extending in a direction inclined in the −X direction rather than a + Y direction and a portion extending in the ± Y direction from each of both ends thereof, and the Y of the first portion 112a. The second portions 112b and 112c rising from both ends in the axial direction in the + Z direction, the bending portions 112f connecting the first portion 112a and the second portion 112b, and the bending connecting to the first portion 112a and the second portion 112c. It has 112 g of a portion. The bent portion 112f is formed so that the stacking direction of the conductor plate 1121 of the first portion 112a and the stacking direction of the conductor plate 1121 of the second portion 112b are different (intersect). The bent portion 112g is formed so that the stacking direction of the conductor plate 1121 of the first portion 112a and the stacking direction of the conductor plate 1121 of the second portion 112c are different (intersect). That is, the conductor portion 112 includes a first portion 112a including the winding axis J1 of the coil 10 and intersects the virtual plane parallel to the XZ plane, and + Z from both ends of the first portion 112a along the above-mentioned virtual plane. It has second sites 112b, 112c that extend in the direction. The stacking direction of the three conductor plates 1121 in the conductor portion 112 is orthogonal to the winding axis J1 of the coil 10. That is, the conductor portion 112 is a bent portion that is connected to the first portion 112a and the first portion 112a and is composed of three conductor plates 1121 that are laminated to each other, and each of the three conductor plates 1121 is curved in the stacking direction. Second portions 112b, 112c formed by laminating three conductor plates 1121 in a direction different from the laminating direction of the three conductor plates 1121 connected to the bent portions 112f and 112g and forming the first portion 112a. And have. The first portion 112a, the bent portion 112f, 112g and the second portion 112b, 112c each have irregularities on the side surfaces. Here, the unevenness corresponds to the unevenness formed from the fine concave portion formed at the boundary portion of the three conductor plates 1121 and the end surface of the conductor plate 1121. Further, the first portion 112a, the bent portion 112f, 112g and the second portion 112b, 112c are formed continuously and integrally.
　導体部１１３は、板状であり厚さ方向に積層された３枚の導体板１１３１からなる第１導体部である。導体部１１３は、長尺であり＋Ｙ方向よりも－Ｘ方向へ傾いた方向へ延在する部位とその両端部それぞれから±Ｙ方向へ延在する部位とを有する第１部位１１３ａと、長尺であり第１部位１１３ａのＹ軸方向における両端部それぞれから＋Ｚ方向へ立ち上がった第２部位１１３ｂ、１１３ｃと、第１部位１１３ａと第２部位１１３ｂとに繋がる曲げ部１１３ｆと、第１部位１１３ａと第２部位１１３ｃとに繋がる曲げ部１１３ｇと、を有する。そして、曲げ部１１３ｆは、第１部位１１３ａの導体板１１３１の積層方向と、第２部位１１３ｂの導体板１１３１の積層方向が異なる（交差する）方向となるように形成される。曲げ部１１３ｇは、第１部位１１３ａの導体板１１３１の積層方向と、第２部位１１３ｃの導体板１１３１の積層方向が異なる（交差する）方向となるように形成される。即ち、導体部１１３は、コイル１０の巻回軸Ｊ１を含み且つＸＺ平面に平行な仮想平面と交差する第１部位１１３ａと、第１部位１１３ａの両端部それぞれから前述の仮想平面に沿って＋Ｚ方向へ延在する第２部位１１３ｂ、１１３ｃと、を有する。導体部１１３における３つの導体板１１３１の積層方向は、コイル１０の巻回軸Ｊ１と直交している。また、第１部位１１３ａ、曲げ部１１３ｆ、１１３ｇおよび第２部位１１３ｂ、１１３ｃは、連続一体に形成されている。 The conductor portion 113 is a first conductor portion composed of three conductor plates 1131 which are plate-shaped and laminated in the thickness direction. The conductor portion 113 is long and has a first portion 113a having a portion extending in a direction inclined in the −X direction from the + Y direction and a portion extending in the ± Y direction from each of both end portions thereof, and a long portion 113a. The second portions 113b and 113c rising in the + Z direction from both ends of the first portion 113a in the Y-axis direction, the bent portions 113f connected to the first portion 113a and the second portion 113b, and the first portion 113a. It has a bent portion 113g connected to the second portion 113c. The bent portion 113f is formed so that the stacking direction of the conductor plate 1131 of the first portion 113a and the stacking direction of the conductor plate 1131 of the second portion 113b are different (intersect). The bent portion 113g is formed so that the stacking direction of the conductor plate 1131 of the first portion 113a and the stacking direction of the conductor plate 1131 of the second portion 113c are different (intersect). That is, the conductor portion 113 includes a first portion 113a including the winding axis J1 of the coil 10 and intersects the virtual plane parallel to the XZ plane, and + Z from both ends of the first portion 113a along the above-mentioned virtual plane. It has second portions 113b, 113c that extend in the direction. The stacking direction of the three conductor plates 1131 in the conductor portion 113 is orthogonal to the winding axis J1 of the coil 10. Further, the first portion 113a, the bent portions 113f, 113g and the second portions 113b, 113c are formed continuously and integrally.
　導体部１１４は、板状であり厚さ方向に積層された３枚の導体板１１４１からなる第１導体部である。導体部１１４は、＋Ｙ方向よりも－Ｘ方向へ傾いた方向へ延在する部位とその両端部それぞれから±Ｙ方向へ延在する部位とを有する第１部位１１４ａと、主部１１２ａのＹ軸方向における両端部それぞれから＋Ｚ方向へ立ち上がった第２部位１１４ｂ、１１４ｃと、第１部位１１４ａと第２部位１１４ｂとに繋がる曲げ部１１４ｆと、第１部位１１４ａと第２部位１１４ｃとに繋がる曲げ部１１４ｇと、を有する。そして、曲げ部１１４ｆは、第１部位１１４ａの導体板１１４１の積層方向と、第２部位１１４ｂの導体板１１４１の積層方向が異なる（交差する）方向となるように形成される。曲げ部１１４ｇは、第１部位１１４ａの導体板１１４１の積層方向と、第２部位１１４ｃの導体板１１４１の積層方向が異なる（交差する）方向となるように形成される。即ち、導体部１１４は、コイル１０の巻回軸Ｊ１を含み且つＸＺ平面に平行な仮想平面と交差する第１部位１１４ａと、第１部位１１４ａの両端部それぞれから前述の仮想平面に沿って＋Ｚ方向へ延在する第２部位１１４ｂ、１１４ｃと、を有する。導体部１１４における３つの導体板１１４１の積層方向は、コイル１０の巻回軸Ｊ１と直交している。また、第１部位１１４ａ、曲げ部１１４ｆ、１１４ｇおよび第２部位１１４ｂ、１１４ｃは、連続一体に形成されている。 The conductor portion 114 is a first conductor portion composed of three conductor plates 1141 which are plate-shaped and laminated in the thickness direction. The conductor portion 114 has a first portion 114a having a portion extending in a direction inclined in the −X direction rather than a + Y direction and a portion extending in the ± Y direction from each of both end portions thereof, and a Y axis of the main portion 112a. Second portions 114b and 114c rising in the + Z direction from both ends in the direction, bending portions 114f connecting the first portion 114a and the second portion 114b, and bending portions connecting the first portion 114a and the second portion 114c. It has 114 g and. The bent portion 114f is formed so that the stacking direction of the conductor plate 1141 of the first portion 114a and the stacking direction of the conductor plate 1141 of the second portion 114b are different (intersect). The bent portion 114g is formed so that the stacking direction of the conductor plate 1141 of the first portion 114a and the stacking direction of the conductor plate 1141 of the second portion 114c are different (intersect). That is, the conductor portion 114 includes a first portion 114a including the winding axis J1 of the coil 10 and intersects the virtual plane parallel to the XZ plane, and + Z from both ends of the first portion 114a along the above-mentioned virtual plane. It has second sites 114b, 114c, which extend in the direction. The stacking direction of the three conductor plates 1141 in the conductor portion 114 is orthogonal to the winding axis J1 of the coil 10. Further, the first portion 114a, the bent portions 114f, 114g and the second portions 114b, 114c are formed continuously and integrally.
　導体部１１５は、板状であり厚さ方向に積層された３枚の導体板１１５１からなる第１導体部である。導体部１１５は、＋Ｘ方向と－Ｙ方向とに延在するＬ字状の主部１１５ａと、主部１１５ａの＋Ｘ方向側の端部における－Ｙ方向側から＋Ｚ方向へ立ち上がった立上部１１５ｂと、主部１１５ａの－Ｙ方向側の端部における－Ｙ方向側から－Ｚ方向へ延出する脚部１１５ｃと、主部１１５ａと立上部１１５ｂとに繋がる曲げ部１１５ｆと、主部１１５ａと脚部１１５ｃとに繋がる曲げ部１１５ｇと、を有する。そして、曲げ部１１５ｆは、主部１１５ａの導体板１１５１の積層方向と、立上部１１５ｂの導体板１１５１の積層方向が異なる（交差する）方向となるように形成される。曲げ部１１５ｇは、主部１１５ａの導体板１１５１の積層方向と、脚部１１５ｃの導体板１１５１の積層方向が異なる（交差する）方向となるように形成される。導体部１１５における３つの導体板１１５１の積層方向は、コイル１０の巻回軸Ｊ１と直交している。 The conductor portion 115 is a first conductor portion composed of three conductor plates 1151 which are plate-shaped and laminated in the thickness direction. The conductor portion 115 includes an L-shaped main portion 115a extending in the + X direction and the −Y direction, and a rising portion 115b rising in the + Z direction from the −Y direction side at the end portion of the main portion 115a on the + X direction side. , The leg portion 115c extending in the −Z direction from the −Y direction side at the end portion on the −Y direction side of the main portion 115a, the bent portion 115f connected to the main portion 115a and the rising portion 115b, the main portion 115a and the leg. It has a bent portion 115g connected to the portion 115c. The bent portion 115f is formed so that the stacking direction of the conductor plate 1151 of the main portion 115a and the stacking direction of the conductor plate 1151 of the rising portion 115b are different (intersect). The bent portion 115g is formed so that the stacking direction of the conductor plate 1151 of the main portion 115a and the stacking direction of the conductor plate 1151 of the leg portion 115c are different (intersect). The stacking direction of the three conductor plates 1151 in the conductor portion 115 is orthogonal to the winding axis J1 of the coil 10.
　導体部群１２は、図１Ａに示すように、４つの板状の導体部１２１、１２２、１２３、１２４を有する。導体部１２１は、図１Ｂに示す、導体部１１１の立上部１１１ｂの先端部、即ち、＋Ｚ方向側の端部と、立上部１１１ｂとはコイル１０の巻回軸Ｊ１を含み且つＸＺ平面に平行な仮想平面を挟んで反対側、即ち、前述の仮想平面の－Ｙ方向側に位置する導体部１１２の第２部位１１２ｃの＋Ｚ方向側の端部と、の間に架設されている第２導体部である。導体部１２１は、その－Ｚ方向側に立上部１１１ｂの＋Ｚ方向側の端部と第２部位１１２ｃの＋Ｚ方向側の端部とが溶着されている。導体部１２２は、コイル１０の巻回軸Ｊ１方向において隣り合う２つの導体部１１２、１１３のうちの導体部１１２の第２部位１１２ｂの＋Ｚ方向側の端部と、導体部１１２の第２部位１１２ｂとは前述の仮想平面を挟んで反対側に位置する導体部１１３の第２部位１１３ｃの＋Ｚ方向側の端部と、の間に架設されている第２導体部である。導体部１２２は、その－Ｚ方向側に第２部位１１２ｂの＋Ｚ方向側の端部と第２部位１１３ｃの＋Ｚ方向側の端部とが溶着されている。導体部１２３は、導体部１２２と同様に、導体部１１３の第２部位１１３ｂの＋Ｚ方向側の端部と、導体部１１４の第２部位１１４ｃの＋Ｚ方向側の端部と、の間に架設されている第２導体部である。導体部１２４は、導体部１２１と同様に、導体部１１４の第２部位１１４ｂの＋Ｚ方向側の端部と、導体部１１５の立上部１１５ｂの＋Ｚ方向側の端部と、の間に架設されている第２導体部である。 As shown in FIG. 1A, the conductor portion group 12 has four plate-shaped conductor portions 121, 122, 123, 124. The conductor portion 121 includes the tip end portion of the rising portion 111b of the conductor portion 111, that is, the end portion on the + Z direction side, and the rising portion 111b, which includes the winding axis J1 of the coil 10, and is parallel to the XZ plane. A second conductor erected on the opposite side of the virtual plane, that is, between the end of the second portion 112c of the conductor portion 112 located on the −Y direction side of the virtual plane on the + Z direction side. It is a department. In the conductor portion 121, the end portion of the rising portion 111b on the + Z direction side and the end portion of the second portion 112c on the + Z direction side are welded on the −Z direction side thereof. The conductor portion 122 includes an end portion of the second portion 112b of the conductor portion 112 of the two conductor portions 112 and 113 adjacent to each other in the winding axis J1 direction of the coil 10 on the + Z direction side, and a second portion of the conductor portion 112. The 112b is a second conductor portion erected between the second portion 113c of the conductor portion 113 located on the opposite side of the virtual plane and the end portion on the + Z direction side. In the conductor portion 122, the end portion of the second portion 112b on the + Z direction side and the end portion of the second portion 113c on the + Z direction side are welded on the −Z direction side thereof. Like the conductor portion 122, the conductor portion 123 is erected between the end portion of the second portion 113b of the conductor portion 113 on the + Z direction side and the end portion of the second portion 114c of the conductor portion 114 on the + Z direction side. It is the second conductor part which is made. Like the conductor portion 121, the conductor portion 124 is erected between the end portion of the second portion 114b of the conductor portion 114 on the + Z direction side and the end portion of the rising portion 115b of the conductor portion 115 on the + Z direction side. This is the second conductor part.
　つまり、巻回軸Ｊ１に沿って周回されるコイル２０において、巻回軸Ｊ１の方向から数えて１ターン目を構成する導体部２１１と２ターン目を構成する導体部２１２との間には、１つの板状の導体部１２１が接続される。また、巻回軸Ｊ１の方向から数えて２ターン目を構成する導体部２１２と３ターン目を構成する導体部２１３との間には、１つの板状の導体部１２２が接続される。更に、巻回軸Ｊ１の方向から数えて３ターン目を構成する導体部２１３と４ターン目を構成する導体部２１４との間には、１つの板状の導体部１２３が接続される。また、巻回軸Ｊ１の方向から数えて４ターン目を構成する導体部２１４と５ターン目を構成する導体部２１５との間には、１つの板状の導体部１２４が接続される。また、導体部１１１、１１２、１１３、１１４、１１５と導体部１２１、１２２、１２３、１２４とが接続される部分において、導体部１１１、１１２、１１３、１１４、１１５が延在する方向と導体部１２１、１２２、１２３、１２４が延在する方向とは、直交している。 That is, in the coil 20 that is revolved along the winding shaft J1, between the conductor portion 211 that constitutes the first turn and the conductor portion 212 that constitutes the second turn counting from the direction of the winding shaft J1. One plate-shaped conductor portion 121 is connected. Further, one plate-shaped conductor portion 122 is connected between the conductor portion 212 forming the second turn and the conductor portion 213 forming the third turn counting from the direction of the winding shaft J1. Further, one plate-shaped conductor portion 123 is connected between the conductor portion 213 forming the third turn and the conductor portion 214 forming the fourth turn counting from the direction of the winding shaft J1. Further, one plate-shaped conductor portion 124 is connected between the conductor portion 214 forming the fourth turn and the conductor portion 215 forming the fifth turn counting from the direction of the winding shaft J1. Further, in the portion where the conductor portions 111, 112, 113, 114, 115 and the conductor portions 121, 122, 123, 124 are connected, the direction in which the conductor portions 111, 112, 113, 114, 115 extend and the conductor portion The directions in which 121, 122, 123, and 124 extend are orthogonal to each other.
　絶縁体部１００は、絶縁体材料から形成され、図１Ａおよび図１Ｂに示すように、導体部１１１、１１２、１１３、１１４、１１５に密着した状態で、導体部１１１、１１２、１１３、１１４、１１５を覆っている。絶縁体材料としては、例えばフェライト粉末を含む樹脂を採用することができる。フェライト粉末としては、Ｎｉ－Ｚｎ系フェライト、Ｍｎ－Ｚｎ系フェライト、Ｎｉ－Ｃｕ－Ｚｎ系フェライトの粉末を採用することができる。また、樹脂としては、ポリプロピレン、ポリアミド、ポリスチレン等の熱可塑性樹脂またはフェノール樹脂、エポキシ樹脂等の熱硬化性樹脂を採用することができる。 The insulator portion 100 is formed of an insulator material, and as shown in FIGS. 1A and 1B, in a state of being in close contact with the conductor portions 111, 112, 113, 114, 115, the conductor portions 111, 112, 113, 114, It covers 115. As the insulator material, for example, a resin containing ferrite powder can be adopted. As the ferrite powder, Ni—Zn-based ferrite, Mn—Zn-based ferrite, and Ni—Cu—Zn-based ferrite powder can be adopted. Further, as the resin, a thermoplastic resin such as polypropylene, polyamide or polystyrene or a thermosetting resin such as a phenol resin or an epoxy resin can be adopted.
　次に、本実施の形態に係るインダクタ素子１の製造方法について説明する。まず、図２に示すように２枚の導体基板１７１と１枚の導体基板１７３を準備する準備工程を行う。なお、図２において、導体基板１７１、１７３は、２つのインダクタ素子１を作製するための導体基板の例を示している。導体基板１７１、１７３は、例えば金属板を打ち抜き加工することにより作製される。導体基板１７１は、５つの導体板１１１１、１１２１、１１３１、１１４１、１１５１と、２つの平面視Ｌ字状の枠片１６１１、１６１２と、１４本の細長の支持片１６１１ａ、１６１１ｂ、１６１２ａ、１６１２ｂと、を有するユニット１７１ＵがＸ軸方向に２つ並んだ構造を有する。ここで、５本の支持片１６１１ａは、枠片１６１１から－Ｙ方向へ延在し長手方向における－Ｙ方向側の端部が導体板１１１１、１１２１、１１３１、１１４１に接続されている。また、２本の支持片１６１１ｂは、枠片１６１１の－Ｙ方向側の端部から－Ｙ方向へ延在し－Ｙ方向側の端部が導体板１１５１に当接している。更に、５本の支持片１６１２ａは、枠片１６１２から＋Ｙ方向へ延在し長手方向における＋Ｙ方向側の端部が導体板１１２１、１１３１、１１４１、１１５１に接続されている。また、２本の支持片１６１２ｂは、枠片１６１２の＋Ｙ方向側の端部から＋Ｙ方向へ延在し＋Ｙ方向側の端部が導体板１１１１に当接している。導体基板１７３も、５つの導体板１１１１、１１２１、１１３１、１１４１、１１５１と、２つの平面視Ｌ字状の枠片１６１１、１６１２と、１４本の細長の支持片１６１１ａ、１６１１ｂ、１６１２ａ、１６１２ｂと、を有するユニット１７３ＵがＸ軸方向に２つ並んだ構造を有する。また、導体基板１７３は、Ｘ軸方向に沿って延在し導体板１１１１、１１２１、１１３１、１１４１同士を互いに接続する支持片１６３１ｃと、Ｘ軸方向に沿って延在し導体板１１２２、１１３１、１１４１、１１５１同士を互いに接続する支持片１６３２ｃと、を有する。 Next, a method of manufacturing the inductor element 1 according to the present embodiment will be described. First, as shown in FIG. 2, a preparatory step for preparing two conductor substrates 171 and one conductor substrate 173 is performed. Note that, in FIG. 2, the conductor substrates 171 and 173 show an example of a conductor substrate for manufacturing the two inductor elements 1. The conductor substrates 171 and 173 are manufactured, for example, by punching a metal plate. The conductor substrate 171 includes five conductor plates 1111, 1121, 1131, 1141 and 1151, two L-shaped frame pieces 1611 and 1612 in a plan view, and 14 elongated support pieces 1611a, 1611b, 1612a and 1612b. The unit 171U having the above has a structure in which two units 171U are arranged side by side in the X-axis direction. Here, the five support pieces 1611a extend from the frame piece 1611 in the −Y direction, and the ends on the −Y direction side in the longitudinal direction are connected to the conductor plates 1111, 1121, 1131, and 1141. Further, the two support pieces 1611b extend in the −Y direction from the end portion of the frame piece 1611 on the −Y direction side, and the end portion on the −Y direction side is in contact with the conductor plate 1151. Further, the five support pieces 1612a extend from the frame piece 1612 in the + Y direction, and their ends on the + Y direction side in the longitudinal direction are connected to the conductor plates 1121, 1131, 1141, 1151. Further, the two support pieces 1612b extend in the + Y direction from the end portion of the frame piece 1612 on the + Y direction side, and the end portion on the + Y direction side is in contact with the conductor plate 1111. The conductor substrate 173 also includes five conductor plates 1111, 1121, 1131, 1141 and 1151, two L-shaped frame pieces 1611 and 1612 in a plan view, and 14 elongated support pieces 1611a, 1611b, 1612a and 1612b. The unit 173U having the above has a structure in which two units 173U are arranged side by side in the X-axis direction. Further, the conductor substrate 173 has a support piece 1631c extending along the X-axis direction to connect the conductor plates 1111, 1121, 1131, and 1141 to each other, and a conductor plate 1122, 1131 extending along the X-axis direction. It has a support piece 1632c that connects 1141 and 1151 to each other.
　次に、２つの導体基板１７１と導体基板１７３とをそれらの厚さ積層する積層工程を行う。ここでは、例えば互いに積層された２つの導体基板１７１の－Ｚ方向側に導体基板１７３を重ね合わせる。ここで、２つの導体基板１７１を、Ｚ軸方向において互いに対向する面側全体において互いに溶着する。また、導体基板１７１、１７３も、Ｚ軸方向において互いに対向する面側全体において互いに溶着する。これにより、図３Ａに示すような２つのユニット１７Ｕを有する積層体１７が形成される。このとき、導体基板１７１、１７３の枠片１６１１、１６１２が積層されることにより、枠部１６１、１６２が形成される。また、導体基板１７１、１７３の支持片１６１１ａ、１６１１ｂ、１６１２ａ、１６１２ｂが積層されることにより、支持部１６１ａ、１６１ｂ、１６２ａ、１６２ｂが形成される。 Next, a laminating step of laminating the two conductor substrates 171 and the conductor substrate 173 to their thickness is performed. Here, for example, the conductor substrate 173 is superposed on the −Z direction side of the two conductor substrates 171 stacked on each other. Here, the two conductor substrates 171 are welded to each other on the entire surface side facing each other in the Z-axis direction. Further, the conductor substrates 171 and 173 are also welded to each other on the entire surface side facing each other in the Z-axis direction. As a result, a laminated body 17 having two units 17U as shown in FIG. 3A is formed. At this time, the frame portions 1611 and 1612 of the conductor substrates 171 and 173 are laminated to form the frame portions 161 and 162. Further, the support portions 161a, 161b, 162a, 162b are formed by laminating the support pieces 1611a, 1611b, 1612a, 1612b of the conductor substrates 171 and 173.
　続いて、図３Ｂおよび図３Ｃに示すように、積層体１７について、支持部１６１ａおよび支持片１６３１ｃ、１６３２ｃを切断する切断工程を行う。その後、導体部１１１、１１５の立上部１１１ｂ、１１５ｂに相当する部分および導体部１１２、１１３、１１４の第２部位１１２ｂ、１１２ｃ、１１３ｂ、１１３ｃ、１１４ｂ、１１４ｃに相当する部分を＋Ｚ方向へ折り曲げるとともに、導体部１１１、１１５の脚部１１１ｃ、１１５ｃに相当する部分を－Ｚ方向へ折り曲げる折り曲げ工程を行う。これにより、立上部１１１ｂ、１１５ｂ、脚部１１１ｃ、１１５ｃおよび第２部位１１２ｂ、１１２ｃ、１１３ｂ、１１３ｃ、１１４ｂ、１１４ｃが形成される。この折り曲げ工程は、積層体１７に含まれる全てのユニット１７Ｕについて行う。 Subsequently, as shown in FIGS. 3B and 3C, the laminated body 17 is subjected to a cutting step of cutting the support portion 161a and the support pieces 1631c and 1632c. After that, the portions corresponding to the rising portions 111b and 115b of the conductor portions 111 and 115 and the portions corresponding to the second portions 112b, 112c, 113b, 113c, 114b and 114c of the conductor portions 112, 113 and 114 are bent in the + Z direction. , The bending step of bending the portions corresponding to the legs 111c and 115c of the conductor portions 111 and 115 in the −Z direction is performed. As a result, the rising portions 111b, 115b, the legs 111c, 115c and the second portions 112b, 112c, 113b, 113c, 114b, 114c are formed. This bending step is performed on all the units 17U included in the laminated body 17.
　次に、図１Ａに示すように、４つの導体部１２１、１２２、１２３、１２４を準備する準備工程を行う。ここでは、例えば金属板を打ち抜き加工することにより４つの導体部１２１、１２２、１２３、１２４を作製する。この４つの導体部１２１、１２２、１２３、１２４を準備する準備工程は、前述の積層体１７を作製および加工する工程と並行して行ってもよい。 Next, as shown in FIG. 1A, a preparatory step for preparing the four conductor portions 121, 122, 123, 124 is performed. Here, for example, four conductor portions 121, 122, 123, and 124 are manufactured by punching a metal plate. The preparatory step for preparing the four conductor portions 121, 122, 123, and 124 may be performed in parallel with the step of producing and processing the above-mentioned laminated body 17.
　続いて、導体部１１１の立上部１１１ｂの＋Ｚ方向側の端部および導体部１１２の第２部位１１２ｃの＋Ｚ方向側の端部を、導体部１２１に溶着する。ここで、導体部１１１、１１２は、例えばレーザ光を用いたスポット溶接技術を利用して導体部１２１に溶着される。同様にして、導体部１１５の立上部１１５ｂの＋Ｚ方向側の端部および導体部１１４の第２部位１１４ｂの＋Ｚ方向側の端部を、導体部１２４に溶着する。また、導体部１１２、１１３の第２部位１１２ｂ、１１３ｃの＋Ｚ方向側の端部を、導体部１２２に溶着する。同様にして、導体部１１２の第２部位１１２ｂの＋Ｚ方向側の端部および導体部１１３の第２部位１１３ｃの＋Ｚ方向側の端部を、導体部１２３に溶着し、導体部１１３の第２部位１１３ｂの＋Ｚ方向側の端部および導体部１１４の第２部位１１４ｃの＋Ｚ方向側の端部を、導体部１２４に溶着する。このようにして、複数のコイル１０の基となる積層体１７の各ユニット１７Ｕに導体部１２１、１２２、１２３、１２４が溶着された構造体が形成される。 Subsequently, the end of the rising portion 111b of the conductor portion 111 on the + Z direction side and the end portion of the second portion 112c of the conductor portion 112 on the + Z direction side are welded to the conductor portion 121. Here, the conductor portions 111 and 112 are welded to the conductor portion 121 by using, for example, a spot welding technique using a laser beam. Similarly, the + Z direction end of the rising portion 115b of the conductor portion 115 and the + Z direction end of the second portion 114b of the conductor portion 114 are welded to the conductor portion 124. Further, the ends of the second portions 112b and 113c of the conductor portions 112 and 113 on the + Z direction side are welded to the conductor portion 122. Similarly, the + Z direction end of the second portion 112b of the conductor portion 112 and the + Z direction end of the second portion 113c of the conductor portion 113 are welded to the conductor portion 123, and the second portion of the conductor portion 113 is welded. The + Z direction end of the portion 113b and the + Z direction end of the second portion 114c of the conductor portion 114 are welded to the conductor portion 124. In this way, a structure in which the conductor portions 121, 122, 123, and 124 are welded to each unit 17U of the laminated body 17 that is the base of the plurality of coils 10 is formed.
　その後、構造体における積層体１７の導体部１１１、１１５の脚部１１１ｃ、１１５ｃおよび導体部１２１、１２２、１２３、１２４を除く部位を覆う金型を構造体に固定した状態で、前述のフェライトの粉末を含む樹脂を金型内に射出した後、加熱、冷却することにより、絶縁体部１００を形成する。そして、構造体を積層体１７のユニット１７Ｕ毎に切断することにより、複数のインダクタ素子１が生成される。 After that, in a state where the mold covering the portions other than the conductor portions 111c, 115c and the conductor portions 121, 122, 123, 124 of the conductor portions 111, 115 of the laminated body 17 in the structure is fixed to the structure, the above-mentioned ferrite is used. The insulator portion 100 is formed by injecting a resin containing powder into a mold and then heating and cooling the resin. Then, by cutting the structure for each unit 17U of the laminated body 17, a plurality of inductor elements 1 are generated.
　以上説明したように、本実施の形態に係るインダクタ素子１によれば、板状であり厚さ方向に積層された３つの導体板１１１１、１１２１、１１３１、１１４１、１１５１からなる導体部１１１、１１２、１１３、１１４、１１５を有するコイル１０と、絶縁体部１００と、を備える。そして、導体部１１１、１１２、１１３、１１４、１１５における３つの導体板１１１１、１１２１、１１３１、１１４１、１１５１の積層方向は、コイル１０の巻回軸Ｊ１と直交している。また、積層される３つの導体板１１１１、１１２１、１１３１、１１４１、１１５１を含んで構成される１１１、１１２、１１３、１１４、１１５が、３つの導体板１１１１、１１２１、１１３１、１１４１、１１５１が積層される積層方向に曲がっている。これにより、導体部１１１、１１２、１１３、１１４、１１５におけるコイル１０の巻回軸Ｊ１に直交する側面における積層方向で隣接する２つの導体板１１１１、１１２１、１１３１、１１４１、１１５１の間の境界部分に微細な窪みを形成することができる。従って、導体部１１１、１１２、１１３、１１４、１１５を絶縁体部１００で覆う際、絶縁体部１００の一部を導体部１１１、１１２、１１３、１１４、１１５の側面に形成された窪みに入り込んだ状態で覆うことができ、絶縁体部１００のアンカー効果が得られ、絶縁体部１００の導体部１１１、１１２、１１３、１１４、１１５への密着性が向上する。それ故、絶縁体部１００に対してコイル１０の巻回軸Ｊ１方向に直交する方向への外力が加わった場合に絶縁体部１００がコイル１０に対して外力の加わる方向へ剥離してしまうことを抑制できる。 As described above, according to the inductor element 1 according to the present embodiment, the conductor portions 111, 112 including three conductor plates 1111, 1121, 1131, 1141 and 1151 which are plate-shaped and laminated in the thickness direction. , 113, 114, 115, and an insulator portion 100. The stacking directions of the three conductor plates 1111, 1121, 1131, 1141 and 1151 in the conductor portions 111, 112, 113, 114 and 115 are orthogonal to the winding axis J1 of the coil 10. Further, 111, 112, 113, 114, 115 including three conductor plates 1111, 1121, 1131, 1141 and 1151 to be laminated are laminated, and three conductor plates 1111, 1121, 1131, 1141 and 1151 are laminated. It is bent in the stacking direction. As a result, the boundary portion between the two conductor plates 1111, 1121, 1131, 1141 and 1151 adjacent in the stacking direction on the side surface of the conductor portions 111, 112, 113, 114 and 115 orthogonal to the winding axis J1 of the coil 10. Fine dents can be formed in. Therefore, when the conductor portions 111, 112, 113, 114, 115 are covered with the insulator portion 100, a part of the insulator portion 100 enters the recess formed on the side surface of the conductor portions 111, 112, 113, 114, 115. It can be covered in a free state, the anchor effect of the insulator portion 100 can be obtained, and the adhesion of the insulator portion 100 to the conductor portions 111, 112, 113, 114, 115 is improved. Therefore, when an external force is applied to the insulator portion 100 in the direction orthogonal to the winding axis J1 direction of the coil 10, the insulator portion 100 is peeled off in the direction in which the external force is applied to the coil 10. Can be suppressed.
　また、本実施の形態に係る導体部２１２は、前述のように３枚の導体板１１２１の積層方向が互いに異なる第１部位２１２ａと第２部位２１２ｃとを有する。そして、第１部位２１２ａ、曲げ部２１２ｇおよび第２部位２１２ｃは、それぞれ、側面に凹凸を有している。これにより、第１部位２１２ａの積層方向への外力が加わった場合における絶縁体部１００の剥離に対する耐性を高めるだけでなく、第２部位２１２ｃの積層方向即ちコイル１０の中心軸方向への外力が加わった場合における絶縁体部１００の剥離に対する耐性を高めることができる。 Further, the conductor portion 212 according to the present embodiment has a first portion 212a and a second portion 212c in which the stacking directions of the three conductor plates 1121 are different from each other as described above. The first portion 212a, the bent portion 212g, and the second portion 212c each have irregularities on the side surfaces. As a result, not only is the resistance to peeling of the insulator portion 100 when an external force is applied to the first portion 212a in the stacking direction, but also the external force in the stacking direction of the second portion 212c, that is, the central axis direction of the coil 10 is increased. It is possible to increase the resistance to peeling of the insulator portion 100 when it is added.
　また、本実施の形態に係る導体部１１２、１１３、１１４は、巻回軸Ｊ１を含む仮想平面と交差する第１部位１１２ａ、１１３ａ、１１４ａと、第１部位１１２ａ、１１３ａ、１１４ａの両端部それぞれから＋Ｚ方向へ延在する第２部位１１２ｂ、１１３ｂ、１１４ｂと、を有する。そして、導体部１２２は、板状であり、導体部１１２の第２部位１１２ｂの＋Ｚ方向側の端部と、導体部１１３の第２部位１１３ｃの＋Ｚ方向側の端部とを接続する。これにより、導体部１１２、１１３、１１４を構成する３つの導体板１１２１、１１３１、１１４１と、導体部１２２、１２３、１２４と、の全てを、金属板を打ち抜くことにより形成することができる。従って、コイル１０の製造が容易になるという利点がある。 Further, the conductor portions 112, 113, 114 according to the present embodiment are the first portions 112a, 113a, 114a intersecting the virtual plane including the winding shaft J1, and both end portions of the first portions 112a, 113a, 114a, respectively. It has second portions 112b, 113b, 114b, which extend in the + Z direction from. The conductor portion 122 has a plate shape, and connects the end portion of the second portion 112b of the conductor portion 112 on the + Z direction side and the end portion of the second portion 113c of the conductor portion 113 on the + Z direction side. As a result, all of the three conductor plates 1121, 1131, 1141 and the conductor portions 122, 123, 124 constituting the conductor portions 112, 113, 114 can be formed by punching out the metal plate. Therefore, there is an advantage that the coil 10 can be easily manufactured.
（実施の形態２）
　本実施の形態に係るインダクタ素子は、複数の導体板が、複数の導体板の積層方向およびコイルの巻回軸と直交する方向の導体板の長さを幅と定義したとき、幅の長さが互いに異なる導体板を含む点が実施の形態１と相違する。 (Embodiment 2)
The inductor element according to the present embodiment has a width when a plurality of conductor plates are defined as a width in a direction in which the plurality of conductor plates are laminated and in a direction orthogonal to the winding axis of the coil. Is different from the first embodiment in that the conductor plates are different from each other.
　図４Ａに示すように、本実施の形態に係るインダクタ素子２は、コイル２０と、絶縁体部１００と、を備える。なお、図４Ａにおいて実施の形態１と同様の構成については図１Ａと同一の符号を付している。コイル２０は、導体部群２１、１２を有する。導体部群２１は、図４Ｂに示すように、コイル２０の巻回軸Ｊ２に沿って配列された５つの導体部２１１、２１２、２１３、２１４、２１５を有する。なお、図４Ｂにおいて、実施の形態１と同様の構成については図１Ｂと同一の符号を付している。導体部２１１は、板状であり厚さ方向に積層された導体板１１１１、２１１２からなる第１導体部である。ここで、導体板２１１２の幅は、導体板１１１１の幅よりも短い。即ち、導体板１１１１、２１１２は、導体板１１１１、２１１２の積層方向およびコイル２０の巻回軸Ｊ１と直交する方向の導体板１１１１、２１１２の長さを幅と定義したとき、幅の長さが互いに異なる。そして、導体部２１１におけるコイル２０の巻回軸Ｊ２に直交する側面には溝２１１ｅが形成されている。なお、導体板２１１２が第１導体板に相当し、導体板１１１１が第２導体板に相当する。導体部２１１は、－Ｘ方向と＋Ｙ方向とに延在するＬ字状の主部２１１ａと、主部２１１ａの－Ｘ方向側の端部における＋Ｙ方向側から＋Ｚ方向へ立ち上がった立上部２１１ｂと、主部２１１ａの＋Ｙ方向側の端部における＋Ｙ方向側から－Ｚ方向へ延出する脚部２１１ｃと、主部２１１ａと立上部２１１ｂとに繋がる曲げ部２１１ｆと、主部２１１ａと脚部２１１ｃとに繋がる曲げ部２１１ｇと、を有する。そして、曲げ部２１１ｆは、主部２１１ａの導体板１１１１、２１１２の積層方向と、立上部２１１ｂの導体板１１１１、２１１２の積層方向が異なる（交差する）方向となるように形成される。曲げ部２１１ｇは、主部２１１ａの導体板１１１１、２１１２の積層方向と、脚部２１１ｃの導体板１１１１、２１１２の積層方向が異なる（交差する）方向となるように形成される。 As shown in FIG. 4A, the inductor element 2 according to the present embodiment includes a coil 20 and an insulator portion 100. In FIG. 4A, the same reference numerals as those in FIG. 1A are attached to the same configurations as those in the first embodiment. The coil 20 has conductor groups 21 and 12. As shown in FIG. 4B, the conductor group 21 has five conductors 211, 212, 213, 214, and 215 arranged along the winding axis J2 of the coil 20. In FIG. 4B, the same reference numerals as those in FIG. 1B are attached to the same configurations as those in the first embodiment. The conductor portion 211 is a first conductor portion composed of conductor plates 1111 and 2112 which are plate-shaped and laminated in the thickness direction. Here, the width of the conductor plate 2112 is shorter than the width of the conductor plate 1111. That is, the conductor plates 1111 and 2112 have a width when the length of the conductor plates 1111 and 2112 in the stacking direction of the conductor plates 1111 and 2112 and the direction orthogonal to the winding axis J1 of the coil 20 is defined as the width. Different from each other. A groove 211e is formed on the side surface of the conductor portion 211 orthogonal to the winding axis J2 of the coil 20. The conductor plate 2112 corresponds to the first conductor plate, and the conductor plate 1111 corresponds to the second conductor plate. The conductor portion 211 includes an L-shaped main portion 211a extending in the −X direction and the + Y direction, and a rising portion 211b rising in the + Z direction from the + Y direction side at the end portion of the main portion 211a on the −X direction side. , The leg portion 211c extending in the −Z direction from the + Y direction side at the end portion of the main portion 211a on the + Y direction side, the bent portion 211f connected to the main portion 211a and the rising portion 211b, and the main portion 211a and the leg portion 211c. It has a bent portion 211 g connected to and. The bent portion 211f is formed so that the stacking directions of the conductor plates 1111 and 2112 of the main portion 211a and the stacking directions of the conductor plates 1111 and 2112 of the rising portion 211b are different (intersect). The bent portion 211g is formed so that the stacking directions of the conductor plates 1111 and 2112 of the main portion 211a and the stacking directions of the conductor plates 1111 and 2112 of the leg portions 211c are different (intersect).
　導体部２１２は、板状であり厚さ方向に積層された導体板１１２１、２１２２からなる第１導体部である。ここで、導体板２１２２の幅は、導体板１１２１の幅よりも短く、導体部２１２におけるコイル２０の巻回軸Ｊ２に直交する側面に溝２１２ｅが形成されている。なお、導体板２１２２が第１導体板に相当し、導体板１１２１が第２導体板に相当する。導体部２１２は、＋Ｙ方向よりも－Ｘ方向へ傾いた方向へ延在する部位とその両端部それぞれから±Ｙ方向へ延在する部位とを有する第１部位２１２ａと、第１部位２１２ａのＹ軸方向における両端部それぞれから＋Ｚ方向へ立ち上がった第２部位２１２ｂ、２１２ｃと、第１部位２１２ａと第２部位２１２ｂとに繋がる曲げ部２１２ｆと、第１部位２１２ａと第２部位２１２ｃとに繋がる曲げ部２１２ｇと、を有する。そして、曲げ部２１２ｆは、第１部位２１２ａの導体板１１２１、２１１２の積層方向と、第２部位２１２ｂの導体板１１２１、２１１２の積層方向が異なる（交差する）方向となるように形成される。曲げ部２１２ｇは、第１部位２１２ａの導体板１１１１、２１１２の積層方向と、第２部位２１２ｃの導体板１１１１、２１１２の積層方向が異なる（交差する）方向となるように形成される。即ち、導体部２１２は、第１部位２１２ａと、第１部位２１２ａと繋がり、互いに積層された３枚の導体板１１２１、２１２２からなり且つ３枚の導体板１１２１、２１２２それぞれが積層方向に湾曲している曲げ部２１２ｆ、２１２ｇと、曲げ部２１２ｆ、２１２ｇと繋がり且つ第１部位２１２ａを構成する３枚の導体板１１２１、２１２２の積層方向と異なる方向に３枚の導体板１１２１、２１２２が積層されてなる第２部位２１２ｂ、２１２ｃと、を有する。そして、第１部位２１２ａ、曲げ部２１２ｆ、２１２ｇおよび第２部位２１２ｂ、２１２ｃは、それぞれ、側面に凹凸を有している。ここで、凹凸とは、２枚の導体板１１２１の端面と２枚の導体板１１２１の間に介在する導体板２１２２の端面とから形成された凹凸に相当する。また、第１部位２１２ａ、曲げ部２１２ｆ、２１２ｇおよび第２部位２１２ｂ、２１２ｃは、連続一体に形成されている。 The conductor portion 212 is a first conductor portion composed of conductor plates 1121 and 2122 which are plate-shaped and laminated in the thickness direction. Here, the width of the conductor plate 2122 is shorter than the width of the conductor plate 1121, and a groove 212e is formed on the side surface of the conductor portion 212 orthogonal to the winding axis J2 of the coil 20. The conductor plate 2122 corresponds to the first conductor plate, and the conductor plate 1121 corresponds to the second conductor plate. The conductor portion 212 has a first portion 212a having a portion extending in a direction inclined in the −X direction from the + Y direction and a portion extending in the ± Y direction from each of both ends thereof, and the Y of the first portion 212a. The second portions 212b and 212c rising from both ends in the axial direction in the + Z direction, the bending portions 212f connecting the first portion 212a and the second portion 212b, and the bending connecting to the first portion 212a and the second portion 212c. It has a portion of 212 g. The bent portion 212f is formed so that the stacking directions of the conductor plates 1121 and 2112 of the first portion 212a and the stacking directions of the conductor plates 1121 and 2112 of the second portion 212b are different (intersect). The bent portion 212g is formed so that the stacking directions of the conductor plates 1111 and 2112 of the first portion 212a and the stacking directions of the conductor plates 1111 and 2112 of the second portion 212c are different (intersect). That is, the conductor portion 212 is composed of three conductor plates 1121 and 2122 which are connected to the first portion 212a and the first portion 212a and are laminated with each other, and the three conductor plates 1121 and 2122 are curved in the stacking direction, respectively. Three conductor plates 1121 and 2122 are laminated in a direction different from the stacking direction of the three conductor plates 1121 and 2122 that are connected to the bent portions 212f and 212 g and constitute the first portion 212a. It has a second portion 212b, 212c, and the like. The first portion 212a, the bent portions 212f, 212g and the second portions 212b, 212c each have irregularities on the side surfaces. Here, the unevenness corresponds to the unevenness formed from the end faces of the two conductor plates 1121 and the end faces of the conductor plates 2122 interposed between the two conductor plates 1121. Further, the first portion 212a, the bent portions 212f, 212g and the second portions 212b, 212c are continuously integrally formed.
　導体部２１３は、板状であり厚さ方向に積層された導体板１１３１、２１３２からなる第１導体部である。ここで、導体板２１３２の幅は、導体板１１３１の幅よりも短く、導体部２１３におけるコイル２０の巻回軸Ｊ２に直交する側面に溝２１３ｅが形成されている。なお、導体板２１３２が第１導体板に相当し、導体板１１３１が第２導体板に相当する。導体部２１３は、長尺であり＋Ｙ方向よりも－Ｘ方向へ傾いた方向へ延在する部位とその両端部それぞれから±Ｙ方向へ延在する部位とを有する第１部位２１３ａと、長尺であり第１部位２１３ａのＹ軸方向における両端部それぞれから＋Ｚ方向へ立ち上がった第２部位２１３ｂ、２１３ｃと、第１部位２１３ａと第２部位２１３ｂとに繋がる曲げ部２１３ｆと、第１部位２１３ａと第２部位２１３ｃとに繋がる曲げ部２１３ｇと、を有する。そして、曲げ部２１３ｆは、第１部位２１３ａの導体板１１３１、２１３２の積層方向と、第２部位２１３ｂの導体板１１３１、２１３２の積層方向が異なる（交差する）方向となるように形成される。曲げ部２１３ｇは、第１部位２１３ａの導体板１１３１、２１３２の積層方向と、第２部位２１３ｃの導体板１１３１、２１３２の積層方向が異なる（交差する）方向となるように形成される。また、第１部位２１３ａ、曲げ部２１３ｆ、２１３ｇおよび第２部位２１３ｂ、２１３ｃは、連続一体に形成されている。 The conductor portion 213 is a first conductor portion composed of conductor plates 1131 and 2132 which are plate-shaped and laminated in the thickness direction. Here, the width of the conductor plate 2132 is shorter than the width of the conductor plate 1131, and a groove 213e is formed on the side surface of the conductor portion 213 orthogonal to the winding axis J2 of the coil 20. The conductor plate 2132 corresponds to the first conductor plate, and the conductor plate 1131 corresponds to the second conductor plate. The conductor portion 213 is long and has a first portion 213a having a portion extending in a direction inclined in the −X direction from the + Y direction and a portion extending in the ± Y direction from each of both ends thereof, and a long portion. The second part 213b and 213c rising from both ends of the first part 213a in the Y-axis direction in the + Z direction, the bending part 213f connected to the first part 213a and the second part 213b, and the first part 213a. It has a bent portion 213g connected to a second portion 213c. The bent portion 213f is formed so that the stacking directions of the conductor plates 1131 and 2132 of the first portion 213a and the stacking directions of the conductor plates 1131 and 2132 of the second portion 213b are different (intersect). The bent portion 213g is formed so that the stacking directions of the conductor plates 1131 and 2132 of the first portion 213a and the stacking directions of the conductor plates 1131 and 2132 of the second portion 213c are different (intersect). Further, the first portion 213a, the bent portion 213f, 213g and the second portion 213b, 213c are continuously integrally formed.
　導体部２１４は、板状であり厚さ方向に積層された導体板１１４１、２１４２からなる第１導体部である。ここで、導体板２１４２の幅は、導体板１１４１の幅よりも短く、導体部２１４におけるコイル２０の巻回軸Ｊ２に直交する側面に溝２１４ｅが形成されている。なお、導体板２１４２が第１導体板に相当し、導体板１１４１が第２導体板に相当する。導体部２１４は、＋Ｙ方向よりも－Ｘ方向へ傾いた方向へ延在する部位とその両端部それぞれから±Ｙ方向へ延在する部位とを有する第１部位２１４ａと、第１部位２１４ａのＹ軸方向における両端部それぞれから＋Ｚ方向へ立ち上がった第２部位２１４ｂ、２１４ｃと、第１部位２１４ａと第２部位２１４ｂとに繋がる曲げ部２１４ｆと、第１部位２１４ａと第２部位２１４ｃとに繋がる曲げ部２１４ｇと、を有する。そして、曲げ部２１４ｆは、第１部位２１４ａの導体板１１４１、２１４２の積層方向と、第２部位２１４ｂの導体板１１４１、２１４２の積層方向が異なる（交差する）方向となるように形成される。曲げ部２１４ｇは、第１部位２１４ａの導体板１１４１、２１４２の積層方向と、第２部位２１４ｃの導体板１１４１、２１４２の積層方向が異なる（交差する）方向となるように形成される。また、第１部位２１４ａ、曲げ部２１４ｆ、２１４ｇおよび第２部位２１４ｂ、２１４ｃは、連続一体に形成されている。 The conductor portion 214 is a first conductor portion composed of conductor plates 1141 and 2142 which are plate-shaped and laminated in the thickness direction. Here, the width of the conductor plate 2142 is shorter than the width of the conductor plate 1141, and the groove 214e is formed on the side surface of the conductor portion 214 orthogonal to the winding axis J2 of the coil 20. The conductor plate 2142 corresponds to the first conductor plate, and the conductor plate 1141 corresponds to the second conductor plate. The conductor portion 214 has a first portion 214a having a portion extending in a direction inclined in the −X direction rather than a + Y direction and a portion extending in the ± Y direction from each of both ends thereof, and the Y of the first portion 214a. Bending portions 214b and 214c rising in the + Z direction from both ends in the axial direction, bending portions 214f connecting the first portion 214a and the second portion 214b, and bending connecting to the first portion 214a and the second portion 214c. It has a portion of 214 g and. The bent portion 214f is formed so that the stacking directions of the conductor plates 1141 and 2142 of the first portion 214a and the stacking directions of the conductor plates 1141 and 2142 of the second portion 214b are different (intersect). The bent portion 214g is formed so that the stacking directions of the conductor plates 1141 and 2142 of the first portion 214a and the stacking directions of the conductor plates 1141 and 2142 of the second portion 214c are different (intersect). Further, the first portion 214a, the bent portions 214f, 214g and the second portions 214b, 214c are continuously integrally formed.
　導体部２１５は、板状であり厚さ方向に積層された導体板１１５１、２１５２からなる第１導体部である。ここで、導体板２１５２の幅は、導体板１１５１の幅よりも短く、導体部２１５におけるコイル２０の巻回軸Ｊ２に直交する側面に溝２１５ｅが形成されている。なお、導体板２１５２が第１導体板に相当し、導体板１１５１が第２導体板に相当する。導体部２１５は、＋Ｘ方向と－Ｙ方向とに延在するＬ字状の主部２１５ａと、主部２１５ａの＋Ｘ方向側の端部における－Ｙ方向側から＋Ｚ方向へ立ち上がった立上部２１５ｂと、主部２１５ａの－Ｙ方向側の端部における－Ｙ方向側から－Ｚ方向へ延出する脚部２１５ｃと、主部２１５ａと立上部２１５ｂとに繋がる曲げ部２１５ｆと、主部２１５ａと脚部２１５ｃとに繋がる曲げ部２１５ｇと、を有する。そして、曲げ部２１５ｆは、主部２１５ａの導体板１１５１、２１５２の積層方向と、立上部２１５ｂの導体板１１５１、２１５２の積層方向が異なる（交差する）方向となるように形成される。曲げ部２１５ｇは、主部２１５ａの導体板１１５１、２１５２の積層方向と、脚部２１５ｃの導体板１１５１、２１５２の積層方向が異なる（交差する）方向となるように形成される。 The conductor portion 215 is a first conductor portion composed of conductor plates 1151 and 2152 which are plate-shaped and laminated in the thickness direction. Here, the width of the conductor plate 2152 is shorter than the width of the conductor plate 1151, and a groove 215e is formed on the side surface of the conductor portion 215 orthogonal to the winding axis J2 of the coil 20. The conductor plate 2152 corresponds to the first conductor plate, and the conductor plate 1151 corresponds to the second conductor plate. The conductor portion 215 includes an L-shaped main portion 215a extending in the + X direction and the −Y direction, and a rising portion 215b rising in the + Z direction from the −Y direction side at the end portion of the main portion 215a on the + X direction side. , The leg portion 215c extending in the −Z direction from the −Y direction side at the end portion of the main portion 215a on the −Y direction side, the bent portion 215f connected to the main portion 215a and the rising portion 215b, and the main portion 215a and the leg. It has a bent portion 215 g connected to the portion 215 c. The bent portion 215f is formed so that the stacking directions of the conductor plates 1151 and 2152 of the main portion 215a and the stacking directions of the conductor plates 1151 and 2152 of the rising portion 215b are different (intersect). The bent portion 215g is formed so that the stacking directions of the conductor plates 1151 and 2152 of the main portion 215a and the stacking directions of the conductor plates 1151 and 2152 of the leg portion 215c are different (intersect).
　導体部１２１は、図４Ｂに示す、導体部２１１の立上部２１１ｂの＋Ｚ方向側の端部と、導体部２１２の第２部位２１２ｃの＋Ｚ方向側の端部と、の間に架設されている。導体部１２２は、導体部２１２の第２部位２１２ｂの＋Ｚ方向側の端部と、導体部２１３の第２部位２１３ｃの＋Ｚ方向側の端部と、の間に架設されている。導体部１２３は、導体部２１３の第２部位２１３ｂの＋Ｚ方向側の端部と、導体部２１４の第２部位２１４ｃの＋Ｚ方向側の端部と、の間に架設されている。導体部１２４は、導体部２１４の第２部位２１４ｂの＋Ｚ方向側の端部と、導体部２１５の立上部２１５ｂの＋Ｚ方向側の端部と、の間に架設されている。 The conductor portion 121 is erected between the end portion of the rising portion 211b of the conductor portion 211 on the + Z direction side and the end portion of the second portion 212c of the conductor portion 212 on the + Z direction side shown in FIG. 4B. .. The conductor portion 122 is erected between the end portion of the second portion 212b of the conductor portion 212 on the + Z direction side and the end portion of the second portion 213c of the conductor portion 213 on the + Z direction side. The conductor portion 123 is erected between the end portion of the second portion 213b of the conductor portion 213 on the + Z direction side and the end portion of the second portion 214c of the conductor portion 214 on the + Z direction side. The conductor portion 124 is erected between the end portion of the second portion 214b of the conductor portion 214 on the + Z direction side and the end portion of the rising portion 215b of the conductor portion 215 on the + Z direction side.
　次に、本実施の形態に係るインダクタ素子１の製造方法について説明する。まず、図５Ａに示す導体基板１７１と、図５Ｂに示す導体基板２７２と、図２に示す導体基板１７３と、を準備する準備工程を行う。なお、図５Ａおよび図５Ｂにおいて、実施の形態１と同様の構成については、図２と同一の符号を付している。また、図５Ａおよび図５Ｂにおいて、導体基板１７１、２７２は、２つのインダクタ素子２を作製するための導体基板の例を示している。導体基板２７２は、導体基板１７１、１７３と同様に、例えば金属板を打ち抜き加工することにより作製される。 Next, a method of manufacturing the inductor element 1 according to the present embodiment will be described. First, a preparatory step for preparing the conductor substrate 171 shown in FIG. 5A, the conductor substrate 272 shown in FIG. 5B, and the conductor substrate 173 shown in FIG. 2 is performed. In addition, in FIG. 5A and FIG. 5B, the same reference numerals as those in FIG. 2 are attached to the same configurations as those in the first embodiment. Further, in FIGS. 5A and 5B, the conductor substrates 171 and 272 show an example of a conductor substrate for manufacturing two inductor elements 2. The conductor substrate 272 is manufactured, for example, by punching a metal plate in the same manner as the conductor substrates 171 and 173.
　導体基板１７１は、図５Ａに示すように、５つの導体板１１１１、１１２１、１１３１、１１４１、１１５１と、２つの平面視Ｌ字状の枠片１６１１、１６１２と、１４本の細長の支持片１６１１ａ、１６１１ｂ、１６１２ａ、１６１２ｂと、を有するユニット１７１ＵがＸ軸方向に２つ並んだ構造を有する。導体基板２７２は、図５Ｂに示すように、５つの導体板２１１１、２１２１、２１３１、２１４１、２１５１と、２つの平面視Ｌ字状の枠片２６２１、２６２２と、１４本の細長の支持片１６１１ａ、１６１１ｂ、１６１２ａ、１６１２ｂと、を有するユニット２７２ＵがＸ軸方向に２つ並んだ構造を有する。ここで、図５Ａおよび図５Ｂに示すように、導体板２１２２の導体板２１２２の厚さ方向に直交し且つ導体板２１２２の延在方向に直交する方向における幅Ｗ２１、Ｗ２２は、導体板１１２１の厚さ方向に直交し且つ導体板１１２１の延在方向に直交する方向における幅Ｗ１１、Ｗ１２よりも短い。また、導体板２１３２の導体板２１３２の厚さ方向に直交し且つ導体板２１３２の延在方向に直交する方向における幅Ｗ２１、Ｗ２２は、導体板１１３１の厚さ方向に直交し且つ導体板１１３１の延在方向に直交する方向における幅Ｗ１１、Ｗ１２よりも短い。更に、導体板２１４２の導体板２１４２の厚さ方向に直交し且つ導体板２１４２の延在方向に直交する方向における幅Ｗ２１、Ｗ２２は、導体板１１４１の厚さ方向に直交し且つ導体板１１４１の延在方向に直交する方向における幅Ｗ１１、Ｗ１２よりも短い。また、導体板２１１２の導体板２１１２の厚さ方向に直交し且つ導体板２１１２の延在方向に直交する方向における幅Ｗ２３は、導体板１１１２の厚さ方向に直交し且つ導体板１１１２の延在方向に直交する方向における幅Ｗ１３よりも短い。更に、導体板２１５２の導体板２１５２の厚さ方向に直交し且つ導体板２１５２の延在方向に直交する方向における幅Ｗ２５は、導体板１１５１の厚さ方向に直交し且つ導体板１１５１の延在方向に直交する方向における幅Ｗ１５よりも短い。即ち、導体部２１１、２１２、２１３、２１４、２１５は、導体板１１１１、１１２１、１１３１、１１４１、１１５１と、導体板１１１１、１１２１、１１３１、１１４１、１１５１よりも幅の長さが短い導体板２１１２、２１２２、２１３２、２１４２、２１５２とを有する。そして、導体板２１１２、２１２２、２１３２、２１４２、２１５２は、積層方向において、２つの導体板１１１１、１１２１、１１３１、１１４１、１１５１に挟まれている。これにより、導体部２１１、２１２、２１３、２１４、２１５それぞれの断面形状が、図６に示すように、導体板１１１１、１１２１、１１３１、１１４１、１１５１、２１１２、２１２２、２１３２、２１４２、２１５２の積層方向において導体部２１１、２１２、２１３、２１４、２１５の延伸方向に沿った中心軸Ｊ２１を通る点に対して点対称な形状となる。例えば、導体部２１１の立上部２１１ｂの中心軸Ｊ２１は、Ｚ軸と平行であり、立上部２１１ｂの断面形状は、中心軸J２１が通る点に対して、点対称である。 As shown in FIG. 5A, the conductor substrate 171 includes five conductor plates 1111, 1121, 1131, 1141 and 1151, two L-shaped frame pieces 1611 and 1612 in a plan view, and 14 elongated support pieces 1611a. , 1611b, 1612a, 1612b, and two units 171U having a structure in which two units 171U are arranged in the X-axis direction. As shown in FIG. 5B, the conductor substrate 272 includes five conductor plates 2111, 2121, 2131, 2141 and 2151, two L-shaped frame pieces 2621 and 2622 in a plan view, and 14 elongated support pieces 1611a. , 1611b, 1612a, 1612b, and two units 272U having a structure in which two units 272U are arranged in the X-axis direction. Here, as shown in FIGS. 5A and 5B, the widths W21 and W22 in the direction orthogonal to the thickness direction of the conductor plate 2122 of the conductor plate 2122 and orthogonal to the extending direction of the conductor plate 2122 are the widths W21 and W22 of the conductor plate 1121. It is shorter than the widths W11 and W12 in the direction orthogonal to the thickness direction and orthogonal to the extending direction of the conductor plate 1121. Further, the widths W21 and W22 in the direction orthogonal to the thickness direction of the conductor plate 2132 of the conductor plate 2132 and orthogonal to the extending direction of the conductor plate 2132 are orthogonal to the thickness direction of the conductor plate 1131 and the conductor plate 1131. It is shorter than the widths W11 and W12 in the direction orthogonal to the extending direction. Further, the widths W21 and W22 in the direction orthogonal to the thickness direction of the conductor plate 2142 of the conductor plate 2142 and orthogonal to the extending direction of the conductor plate 2142 are orthogonal to the thickness direction of the conductor plate 1141 and the conductor plate 1141. It is shorter than the widths W11 and W12 in the direction orthogonal to the extending direction. Further, the width W23 in the direction orthogonal to the thickness direction of the conductor plate 2112 of the conductor plate 2112 and orthogonal to the extending direction of the conductor plate 2112 is orthogonal to the thickness direction of the conductor plate 1112 and extends the conductor plate 1112. It is shorter than the width W13 in the direction orthogonal to the direction. Further, the width W25 in the direction orthogonal to the thickness direction of the conductor plate 2152 of the conductor plate 2152 and orthogonal to the extension direction of the conductor plate 2152 is orthogonal to the thickness direction of the conductor plate 1151 and extends of the conductor plate 1151. It is shorter than the width W15 in the direction orthogonal to the direction. That is, the conductor portions 211, 212, 213, 214, 215 have a width shorter than that of the conductor plates 1111, 1121, 1131, 1141 and 1151 and the conductor plates 1111, 1121 and 1131, 1141 and 1151. , 2122, 2132, 2142, 2152. The conductor plates 2112, 2122, 2132, 2142, and 2152 are sandwiched between the two conductor plates 1111, 1121, 1131, 1141, and 1151 in the stacking direction. As a result, as shown in FIG. 6, the cross-sectional shapes of the conductor portions 211, 212, 213, 214, and 215 are laminated with the conductor plates 1111, 1121, 1131, 1141, 1151, 2112, 2122, 2132, 2142, and 2152. The shape is point-symmetrical with respect to a point passing through the central axis J21 along the extending direction of the conductor portions 211, 212, 213, 214, and 215 in the direction. For example, the central axis J21 of the rising portion 211b of the conductor portion 211 is parallel to the Z axis, and the cross-sectional shape of the rising portion 211b is point-symmetric with respect to the point through which the central axis J21 passes.
　次に、導体基板１７１、２７２、１７３をそれらの厚さ積層する積層工程を行う。ここでは、例えば導体基板１７３の＋Ｚ方向側に導体基板２７２を重ね合わせ、導体基板２７２の＋Ｚ方向側に導体基板１７１を重ね合わせる。ここで、導体基板１７１、２７２を、Ｚ軸方向において互いに対向する面側全体において互いに溶着する。また、導体基板２７２、１７３も、Ｚ軸方向において互いに対向する面側全体において互いに溶着する。これにより、図７Ａに示すような２つのユニット２７Ｕを有する積層体２７が形成される。このとき、導体基板１７１、２７２、１７３の枠片１６１１、１６１２、２６１１、２６１２が積層されることにより、枠部２６１、２６２が形成される。また、導体基板１７１、２７２、１７３の支持片１６１１ａ、１６１１ｂ、１６１２ａ、１６１２ｂが積層されることにより、支持部１６１ａ、１６１ｂ、１６２ａ、１６２ｂが形成される。 Next, a laminating step of laminating the conductor substrates 171, 272, and 173 to their thickness is performed. Here, for example, the conductor substrate 272 is superposed on the + Z direction side of the conductor substrate 173, and the conductor substrate 171 is superposed on the + Z direction side of the conductor substrate 272. Here, the conductor substrates 171 and 272 are welded to each other on the entire surface side facing each other in the Z-axis direction. Further, the conductor substrates 272 and 173 are also welded to each other on the entire surface side facing each other in the Z-axis direction. As a result, a laminated body 27 having two units 27U as shown in FIG. 7A is formed. At this time, the frame portions 261 and 262 are formed by laminating the frame pieces 1611, 1612, 2611 and 2612 of the conductor substrates 171 and 272 and 173. Further, the support portions 161a, 161b, 162a, 162b are formed by laminating the support pieces 1611a, 1611b, 1612a, 1612b of the conductor substrates 171, 272, and 173.
　続いて、図７Ｂおよび図７Ｃに示すように、積層体２７について、支持部１６１ａ、１６２ａおよび支持片１６３１ｃ、１６３２ｃを切断する切断工程を行う。その後、導体部２１１、２１５の立上部２１１ｂ、２１５ｂに相当する部分および導体部２１２、２１３、２１４の第２部位２１２ｂ、２１２ｃ、２１３ｂ、２１３ｃ、２１４ｂ、２１４ｃに相当する部分を＋Ｚ方向へ折り曲げるとともに、導体部２１１、２１５の脚部２１１ｃ、２１５ｃに相当する部分を－Ｚ方向へ折り曲げる折り曲げ工程を行う。 Subsequently, as shown in FIGS. 7B and 7C, the laminated body 27 is subjected to a cutting step of cutting the support portions 161a and 162a and the support pieces 1631c and 1632c. After that, the portions corresponding to the rising portions 211b and 215b of the conductor portions 211 and 215 and the portions corresponding to the second portions 212b, 212c, 213b, 213c, 214b and 214c of the conductor portions 212, 213 and 214 are bent in the + Z direction. , The bending step of bending the portions corresponding to the leg portions 211c and 215c of the conductor portions 211 and 215 in the −Z direction is performed.
　次に、図４Ａに示す４つの導体部１２１、１２２、１２３、１２４を準備する準備工程を行う。続いて、導体部２１１の立上部２１１ｂの＋Ｚ方向側の端部および導体部２１２の第２部位２１２ｃの＋Ｚ方向側の端部を、導体部１２１に溶着する。同様にして、導体部２１５の立上部２１５ｂの＋Ｚ方向側の端部および導体部２１４の第２部位２１４ｂの＋Ｚ方向側の端部を、導体部２２４に溶着する。また、導体部２１２、２１３の第２部位２１２ｂ、２１３ｃの＋Ｚ方向側の端部を、導体部１２２に溶着する。同様にして、導体部２１２の第２部位２１２ｂの＋Ｚ方向側の端部および導体部２１３の第２部位２１３ｃの＋Ｚ方向側の端部を、導体部１２３に溶着し、導体部２１３の第２部位２１３ｂの＋Ｚ方向側の端部および導体部２１４の第２部位２１４ｃの＋Ｚ方向側の端部を、導体部１２４に溶着する。 Next, a preparatory step for preparing the four conductor portions 121, 122, 123, 124 shown in FIG. 4A is performed. Subsequently, the end of the rising portion 211b of the conductor portion 211 on the + Z direction side and the end portion of the second portion 212c of the conductor portion 212 on the + Z direction side are welded to the conductor portion 121. Similarly, the + Z direction end of the rising portion 215b of the conductor portion 215 and the + Z direction end of the second portion 214b of the conductor portion 214 are welded to the conductor portion 224. Further, the end portions of the second portions 212b and 213c of the conductor portions 212 and 213 on the + Z direction side are welded to the conductor portion 122. Similarly, the + Z direction end of the second portion 212b of the conductor portion 212 and the + Z direction end of the second portion 213c of the conductor portion 213 are welded to the conductor portion 123, and the second portion of the conductor portion 213 is welded. The + Z direction end of the portion 213b and the + Z direction end of the second portion 214c of the conductor portion 214 are welded to the conductor portion 124.
　その後、積層体２７の各ユニット２７Ｕに導体部２２１、２２２、２２３、２２４が溶着された構造体における積層体２７の導体部２１１、２１５の脚部２１１ｃ、２１５ｃおよび導体部１２１、１２２、１２３、１２４を除く部位を覆う金型を構造体に固定した状態で、前述のフェライトの粉末を含む樹脂を金型内に射出した後、加熱、冷却することにより、絶縁体部１００を形成する。その後、構造体を積層体２７のユニット２７Ｕ毎に切断することにより、複数のインダクタ素子２が生成される。 After that, in the structure in which the conductor portions 221, 222, 223, and 224 are welded to each unit 27U of the laminated body 27, the conductor portions 211c and 215c of the laminated body 27 and the conductor portions 121, 122, 123, In a state where the mold covering the portion other than 124 is fixed to the structure, the resin containing the above-mentioned ferrite powder is injected into the mold, and then heated and cooled to form the insulator portion 100. After that, by cutting the structure for each unit 27U of the laminated body 27, a plurality of inductor elements 2 are generated.
　以上説明したように、本実施の形態に係るインダクタ素子２によれば、導体板２１２２、２１３２、２１４２それぞれの幅Ｗ２１、Ｗ２２が、導体板１１２１、１１３１、１１４１の幅Ｗ１１、Ｗ１２よりも短い。また、導体板２１１２、２１５２の幅Ｗ２３は、導体板１１１１、１１５１の幅Ｗ１３よりも短い。更に、導体板２１５２の導体板２１５２の厚さ方向に直交し且つ導体板２１５２の延在方向に直交する方向における幅Ｗ２５は、導体板１１５２の厚さ方向に直交し且つ導体板１１５２の延在方向に直交する方向における幅Ｗ１５よりも短い。これにより、導体部２１１、２１２、２１３、２１４、２１５におけるコイル２０の巻回軸Ｊ２に直交する側面に溝２１１ｅ、２１２ｅ、２１３ｅ、２１４ｅ、２１５ｅを形成することができる。従って、導体部２１１、２１２、２１３、２１４、２１５を絶縁体部１００で覆う際、絶縁体部１００の一部を溝２１１ｅ、２１２ｅ、２１３ｅ、２１４ｅ、２１５ｅに入り込んだ状態にすることができる。それ故、絶縁体部１００に対してコイル２０の巻回軸Ｊ２方向に直交する方向への外力が加わった場合に絶縁体部１００がコイル２０に対して外力の加わる方向へ剥離してしまうことを抑制できる。 As described above, according to the inductor element 2 according to the present embodiment, the widths W21 and W22 of the conductor plates 2122, 2132 and 2142, respectively, are shorter than the widths W11 and W12 of the conductor plates 1121, 1131 and 1141. Further, the width W23 of the conductor plates 2112 and 2152 is shorter than the width W13 of the conductor plates 1111 and 1151. Further, the width W25 in the direction orthogonal to the thickness direction of the conductor plate 2152 of the conductor plate 2152 and orthogonal to the extending direction of the conductor plate 2152 is orthogonal to the thickness direction of the conductor plate 1152 and extends the conductor plate 1152. It is shorter than the width W15 in the direction orthogonal to the direction. As a result, grooves 211e, 212e, 213e, 214e, and 215e can be formed on the side surfaces of the conductor portions 211, 212, 213, 214, and 215 that are orthogonal to the winding axis J2 of the coil 20. Therefore, when the conductor portions 211, 212, 213, 214, and 215 are covered with the insulator portion 100, a part of the insulator portion 100 can be put into the grooves 211e, 212e, 213e, 214e, and 215e. Therefore, when an external force is applied to the insulator portion 100 in the direction orthogonal to the winding axis J2 direction of the coil 20, the insulator portion 100 is peeled off in the direction in which the external force is applied to the coil 20. Can be suppressed.
　また、本実施の形態に係る導体部２１１、２１２、２１３、２１４、２１５の断面形状は、導体板１１１１、１１２１、１１３１、１１４１、１１５１、２１１２、２１２２、２１３２、２１４２、２１５２の積層方向において導体部２１１、２１２、２１３、２１４、２１５の延伸方向に沿った中心軸に対して対称な形状となる。そして、絶縁体部１００は、その一部が導体部２１１、２１２、２１３、２１４、２１５の溝２１１ｅ、２１２ｅ、２１３ｅ、２１４ｅ、２１５ｅに入り込んだ状態で導体部２１１、２１２、２１３、２１４、２１５を覆うことにより、絶縁体部１００のアンカー効果が得られる。従って、絶縁体部１００に対して、コイル２０の巻回軸Ｊ２方向に直交し且つ巻回軸Ｊ２から離れる方向への外力が加わった場合と、コイル２０の巻回軸Ｊ２方向に直交し且つ巻回軸Ｊ２から離れる方向への外力が加わった場合と、の両方の場合において、絶縁体部１００がコイル２０に対して外力の加わる方向へ剥離してしまうことを抑制できる。 Further, the cross-sectional shape of the conductor portions 211, 212, 213, 214, 215 according to the present embodiment is a conductor in the stacking direction of the conductor plates 1111, 1121, 1131, 1141, 1151, 2112, 2122, 2132, 2142, 2152. The shape of the portions 211, 212, 213, 214, 215 is symmetric with respect to the central axis along the stretching direction. Then, the insulator portion 100 has the conductor portions 211, 212, 213, 214, 215 in a state where a part of the insulator portion 100 is inserted into the grooves 211e, 212e, 213e, 214e, and 215e of the conductor portions 211, 212, 213, 214, and 215. By covering the insulator portion 100, the anchor effect of the insulator portion 100 can be obtained. Therefore, when an external force is applied to the insulator portion 100 in a direction orthogonal to the winding shaft J2 direction of the coil 20 and away from the winding shaft J2, and orthogonal to the winding shaft J2 direction of the coil 20. In both cases, when an external force is applied in the direction away from the winding shaft J2, it is possible to prevent the insulator portion 100 from peeling off in the direction in which the external force is applied to the coil 20.
（実施の形態３）
　本実施の形態に係るインダクタ素子は、第１導体部の表面に、導体板の積層方向に窪んだ凹部が設けられている点が実施の形態１と相違する。また、第１導体部における凹部の底部を構成する導体板の数が、第１導体部における凹部以外を構成する導体板の積層数よりも少ない。 (Embodiment 3)
The inductor element according to the present embodiment is different from the first embodiment in that a recess recessed in the stacking direction of the conductor plates is provided on the surface of the first conductor portion. Further, the number of conductor plates forming the bottom of the recess in the first conductor portion is smaller than the number of laminated conductor plates forming other than the recess in the first conductor portion.
　図８Ａに示すように、本実施の形態に係るインダクタ素子３は、コイル３０と、絶縁体部１００と、を備える。なお、図８Ａにおいて実施の形態１と同様の構成については図１Ａと同一の符号を付している。このインダクタ素子３は、電子部品Ｅ１が実装された基板Ｂ１上に配設される。ここで、インダクタ素子３は、図８Ｂに示すように、電子部品Ｅ１の＋Ｚ方向側を覆うように配設される。コイル３０は、導体部群２１、１２を有する。導体部群２１は、図９Ａに示すように、コイル２０の巻回軸Ｊ３に沿って配列された５つの導体部３１１、３１２、３１３、３１４、３１５を有する。なお、図９Ａにおいて、実施の形態１と同様の構成については図１Ｂと同一の符号を付している。導体部３１１は、板状であり厚さ方向に積層された導体板１１１１、３１１２、３１１３からなる第１導体部である。導体部３１１は、－Ｘ方向と＋Ｙ方向とに延在するＬ字状の主部３１１ａと、主部３１１ａの－Ｘ方向側の端部における＋Ｙ方向側から＋Ｚ方向へ立ち上がった立上部３１１ｂと、主部３１１ａの＋Ｙ方向側の端部における＋Ｙ方向側から－Ｚ方向へ延出する脚部３１１ｃと、主部３１１ａと立上部３１１ｂとに繋がる曲げ部３１１ｆと、主部３１１ａと脚部３１１ｃとに繋がる曲げ部３１１ｇと、を有する。そして、曲げ部３１１ｆは、主部３１１ａの導体板１１１１、３１１２、３１１３の積層方向と、立上部３１１ｂの導体板１１１１、３１１２、３１１３の積層方向が異なる（交差する）方向となるように形成される。曲げ部３１１ｇは、主部３１１ａの導体板１１１１、３１１２、３１１３の積層方向と、脚部３１１ｃの導体板１１１１、３１１２、３１１３の積層方向が異なる（交差する）方向となるように形成される。 As shown in FIG. 8A, the inductor element 3 according to the present embodiment includes a coil 30 and an insulator portion 100. In FIG. 8A, the same components as those in the first embodiment are designated by the same reference numerals as those in FIG. 1A. The inductor element 3 is arranged on the substrate B1 on which the electronic component E1 is mounted. Here, as shown in FIG. 8B, the inductor element 3 is arranged so as to cover the + Z direction side of the electronic component E1. The coil 30 has conductor groups 21 and 12. As shown in FIG. 9A, the conductor group 21 has five conductors 311, 312, 313, 314, and 315 arranged along the winding axis J3 of the coil 20. In FIG. 9A, the same reference numerals as those in FIG. 1B are attached to the same configurations as those in the first embodiment. The conductor portion 311 is a first conductor portion composed of conductor plates 1111, 3112, and 3113 which are plate-shaped and laminated in the thickness direction. The conductor portion 311 includes an L-shaped main portion 311a extending in the −X direction and the + Y direction, and a rising portion 311b rising in the + Z direction from the + Y direction side at the end portion of the main portion 311a on the −X direction side. , The leg portion 311c extending in the −Z direction from the + Y direction side at the end of the main portion 311a on the + Y direction side, the bent portion 311f connected to the main portion 311a and the rising portion 311b, and the main portion 311a and the leg portion 311c. It has a bent portion 311 g connected to and. The bent portion 311f is formed so that the stacking directions of the conductor plates 1111, 3112, and 3113 of the main portion 311a and the stacking directions of the conductor plates 1111, 3112, and 3113 of the rising portion 311b are different (intersect). NS. The bent portion 311g is formed so that the stacking directions of the conductor plates 1111, 3112, and 3113 of the main portion 311a and the stacking directions of the conductor plates 1111, 3112, and 3113 of the leg portion 311c are different (intersect).
　導体部３１２は、板状であり厚さ方向に積層された導体板３１２１、３１２２、３１２３からなる第１導体部である。導体部３１２は、＋Ｙ方向よりも－Ｘ方向へ傾いた方向へ延在する部位とその両端部それぞれから±Ｙ方向へ延在する部位とを有する第１部位３１２ａと、第１部位３１２ａのＹ軸方向における両端部それぞれから＋Ｚ方向へ立ち上がった第２部位３１２ｂ、３１２ｃと、第１部位３１２ａと第２部位３１２ｂとに繋がる曲げ部３１２ｆと、第１部位３１２ａと第２部位３１２ｃとに繋がる曲げ部３１２ｇと、を有する。そして、曲げ部３１２ｆは、第１部位３１２ａの導体板３１２１、３１２２、３１２３の積層方向と、第２部位３１２ｂの導体板３１２１、３１２２、３１２３の積層方向が異なる（交差する）方向となるように形成される。曲げ部３１２ｇは、第１部位２１２ａの導体板１１１１、２１１２の積層方向と、第２部位３１２ｃの導体板導体板３１２１、３１２２、３１２３の積層方向が異なる（交差する）方向となるように形成される。また、第１部位３１２ａ、曲げ部３１２ｆ、３１２ｇおよび第２部位３１２ｂ、３１２ｃは、連続一体に形成されている。 The conductor portion 312 is a first conductor portion composed of conductor plates 3121, 3122, and 3123 which are plate-shaped and laminated in the thickness direction. The conductor portion 312 has a first portion 312a having a portion extending in a direction inclined in the −X direction rather than a + Y direction and a portion extending in the ± Y direction from each of both ends thereof, and the Y of the first portion 312a. The second portion 312b, 312c rising from both ends in the axial direction in the + Z direction, the bending portion 312f connected to the first part 312a and the second part 312b, and the bending connected to the first part 312a and the second part 312c. It has a portion 312 g and. The bent portion 312f is oriented so that the stacking direction of the conductor plates 3121, 3122, 3123 of the first portion 312a and the stacking direction of the conductor plates 3121, 3122, 3123 of the second portion 312b are different (intersect). It is formed. The bent portion 312g is formed so that the stacking direction of the conductor plates 1111 and 2112 of the first portion 212a and the stacking direction of the conductor plate conductor plates 3121, 3122, 3123 of the second portion 312c are different (intersect) directions. NS. Further, the first portion 312a, the bent portion 312f, 312g and the second portion 312b, 312c are continuously integrally formed.
　導体部３１３は、板状であり厚さ方向に積層された導体板１１３１、３１３２、３１３３からなる第１導体部である。導体部３１３は、長尺であり＋Ｙ方向よりも－Ｘ方向へ傾いた方向へ延在する部位とその両端部それぞれから±Ｙ方向へ延在する部位とを有する第１部位３１３ａと、長尺であり第１部位３１３ａのＹ軸方向における両端部それぞれから＋Ｚ方向へ立ち上がった第２部位３１３ｂ、３１３ｃと、第１部位３１３ａと第２部位３１３ｂとに繋がる曲げ部３１３ｆと、第１部位３１３ａと第２部位３１３ｃとに繋がる曲げ部３１３ｇと、を有する。そして、曲げ部３１３ｆは、第１部位３１３ａの導体板１１３１、３１３２、３１３３の積層方向と、第２部位３１３ｂの導体板１１３１、３１３２、３１３３の積層方向が異なる（交差する）方向となるように形成される。曲げ部３１３ｇは、第１部位３１３ａの導体板１１３１、３１３２、３１３３の積層方向と、第２部位３１３ｃの導体板１１３１、３１３２、３１３３の積層方向が異なる（交差する）方向となるように形成される。また、第１部位３１３ａ、曲げ部３１３ｆ、３１３ｇおよび第２部位３１３ｂ、３１３ｃは、連続一体に形成されている。 The conductor portion 313 is a first conductor portion composed of conductor plates 1131, 3132, and 3133 which are plate-shaped and laminated in the thickness direction. The conductor portion 313 is long and has a first portion 313a having a portion extending in a direction inclined in the −X direction from the + Y direction and a portion extending in the ± Y direction from each of both ends thereof, and a long portion. The second part 313b, 313c rising from both ends of the first part 313a in the Y-axis direction in the + Z direction, the bending part 313f connected to the first part 313a and the second part 313b, and the first part 313a. It has a bent portion 313g connected to a second portion 313c. Then, the bent portion 313f is oriented so that the stacking direction of the conductor plates 1131, 3132, 3133 of the first portion 313a and the stacking direction of the conductor plates 1131, 3132, 3133 of the second portion 313b are different (intersect). It is formed. The bent portion 313g is formed so that the stacking direction of the conductor plates 1131, 3132, 3133 of the first portion 313a and the stacking direction of the conductor plates 1131, 3132, 3133 of the second portion 313c are different (intersect). NS. Further, the first portion 313a, the bent portion 313f, 313g and the second portion 313b, 313c are continuously integrally formed.
　導体部３１４は、板状であり厚さ方向に積層された導体板１１４１、３１４２、３１４３からなる第１導体部である。導体部３１４は、＋Ｙ方向よりも－Ｘ方向へ傾いた方向へ延在する部位とその両端部それぞれから±Ｙ方向へ延在する部位とを有する第１部位３１４ａと、第１部位３１４ａのＹ軸方向における両端部それぞれから＋Ｚ方向へ立ち上がった第２部位３１４ｂ、３１４ｃと、第１部位３１４ａと第２部位３１４ｂとに繋がる曲げ部３１４ｆと、第１部位３１４ａと第２部位３１４ｃとに繋がる曲げ部３１４ｇと、を有する。そして、曲げ部３１４ｆは、第１部位３１４ａの導体板１１４１、３１４２、３１４３の積層方向と、第２部位３１４ｂの導体板１１４１、３１４２、３１４３の積層方向が異なる（交差する）方向となるように形成される。曲げ部３１４ｇは、第１部位３１４ａの導体板１１４１、３１４２、３１４３の積層方向と、第２部位３１４ｃの導体板１１４１、３１４２、３１４３の積層方向が異なる（交差する）方向となるように形成される。また、第１部位３１４ａ、曲げ部３１４ｆ、３１４ｇおよび第２部位３１４ｂ、３１４ｃは、連続一体に形成されている。 The conductor portion 314 is a first conductor portion composed of conductor plates 1141, 3142, and 3143 which are plate-shaped and laminated in the thickness direction. The conductor portion 314 has a first portion 314a having a portion extending in a direction inclined in the −X direction rather than a + Y direction and a portion extending in the ± Y direction from each of both ends thereof, and the Y of the first portion 314a. Bending connecting to the second part 314b and 314c rising from both ends in the axial direction in the + Z direction, bending part 314f connecting to the first part 314a and the second part 314b, and bending connecting to the first part 314a and the second part 314c. It has a portion 314 g and. The bent portion 314f is arranged so that the stacking directions of the conductor plates 1141, 3142, 3143 of the first portion 314a and the stacking directions of the conductor plates 1141, 3142, 3143 of the second portion 314b are different (intersect). It is formed. The bent portion 314g is formed so that the stacking directions of the conductor plates 1141, 3142, 3143 of the first portion 314a and the stacking directions of the conductor plates 1141, 3142, 3143 of the second portion 314c are different (intersect). NS. Further, the first portion 314a, the bent portion 314f, 314g and the second portion 314b, 314c are continuously integrally formed.
　導体部３１５は、板状であり厚さ方向に積層された導体板１１５１、３１５２、３１５３からなる第１導体部である。導体部３１５は、＋Ｘ方向と－Ｙ方向とに延在するＬ字状の主部３１５ａと、主部３１５ａの＋Ｘ方向側の端部における－Ｙ方向側から＋Ｚ方向へ立ち上がった立上部３１５ｂと、主部３１５ａの－Ｙ方向側の端部における－Ｙ方向側から－Ｚ方向へ延出する脚部３１５ｃと、主部３１５ａと立上部３１５ｂとに繋がる曲げ部３１５ｆと、主部３１５ａと脚部３１５ｃとに繋がる曲げ部３１５ｇと、を有する。そして、曲げ部３１５ｆは、主部３１５ａの導体板１１５１、３１５２、３１５３の積層方向と、立上部３１５ｂの導体板１１５１、３１５２、３１５３の積層方向が異なる（交差する）方向となるように形成される。曲げ部３１５ｇは、主部３１５ａの導体板１１５１、３１５２、３１５３の積層方向と、脚部３１５ｃの導体板１１５１、３１５２、３１５３の積層方向が異なる（交差する）方向となるように形成される。 The conductor portion 315 is a first conductor portion composed of conductor plates 1151, 3152, and 3153 which are plate-shaped and laminated in the thickness direction. The conductor portion 315 includes an L-shaped main portion 315a extending in the + X direction and the −Y direction, and a rising portion 315b rising in the + Z direction from the −Y direction side at the end portion of the main portion 315a on the + X direction side. , The leg portion 315c extending in the −Z direction from the −Y direction side at the end portion of the main portion 315a on the −Y direction side, the bent portion 315f connected to the main portion 315a and the rising portion 315b, and the main portion 315a and the leg. It has a bent portion 315 g connected to the portion 315c. The bent portion 315f is formed so that the stacking directions of the conductor plates 1151, 3152, and 3153 of the main portion 315a and the stacking directions of the conductor plates 1151, 3152, and 3153 of the rising portion 315b are different (intersect). NS. The bent portion 315g is formed so that the stacking directions of the conductor plates 1151, 3152, 3153 of the main portion 315a and the stacking directions of the conductor plates 1151, 3152, 3153 of the leg portion 315c are different (intersect).
　導体部３１１、３１２、３１３、３１４、３１５の表面には、それぞれ、図９Ｂに示すように、導体板１１１１、３１１２、３１１３、３１２１、３１２２、３１２３、１１３１、３１３２、３１３３、１１４１、３１４２、３１４３、１１５１、３１５２、３１５３の積層方向に窪んだ凹部３１１ｄ、３１２ｄ、３１３ｄ、３１４ｄ、３１５ｄが設けられている。また、導体部３１１、３１２、３１３、３１４、３１５における凹部３１１ｄ、３１２ｄ、３１３ｄ、３１４ｄ、３１５ｄの底部を構成する導体板の数は、導体部３１１、３１２、３１３、３１４、３１５における凹部３１１ｄ、３１２ｄ、３１３ｄ、３１４ｄ、３１５ｄ以外を構成する導体板の積層数よりも少ない。ここで、凹部３１２ｄ、３１３ｄ、３１４ｄの内側の形状は、凹部３１２ｄ、３１３ｄ、３１４ｄの開口面積がその底側、即ち、＋Ｚ方向側ほど小さくなる形状を有する。つまり、凹部３１１ｄ、３１２ｄ、３１３ｄ、３１４ｄ、３１５ｄの底部の面積は、凹部３１１ｄ、３１２ｄ、３１３ｄ、３１４ｄ、３１５ｄの開口面積よりも小さい。 As shown in FIG. 9B, the surfaces of the conductor portions 311, 312, 313, 314, and 315 have conductor plates 1111, 3112, 3113, 3121, 3122, 3123, 1131, 3132, 3133, 1141, 3142, and 3143, respectively. , 1151, 3152, and 3153 are provided with recesses 311d, 312d, 313d, 314d, and 315d recessed in the stacking direction. The number of conductor plates forming the bottom of the recesses 311d, 312d, 313d, 314d, and 315d in the conductor portions 311, 312, 313, 314, and 315 is the number of the recesses 311d in the conductor portions 311 and 312, 313, 314, and 315. It is less than the number of laminated conductor plates other than 312d, 313d, 314d, and 315d. Here, the inner shape of the recesses 312d, 313d, and 314d has a shape in which the opening area of the recesses 312d, 313d, and 314d becomes smaller toward the bottom side, that is, the + Z direction side. That is, the area of the bottom of the recesses 311d, 312d, 313d, 314d, and 315d is smaller than the opening area of the recesses 311d, 312d, 313d, 314d, and 315d.
　導体部１２１は、図９Ａに示す、導体部３１１の立上部３１１ｂの＋Ｚ方向側の端部と、導体部３１２の第２部位３１２ｃの＋Ｚ方向側の端部と、の間に架設されている。導体部１２２は、導体部３１２の第２部位３１２ｂの＋Ｚ方向側の端部と、導体部３１３の第２部位３１３ｃの＋Ｚ方向側の端部と、の間に架設されている。導体部１２３は、導体部３１３の第２部位３１３ｂの＋Ｚ方向側の端部と、導体部３１４の第２部位３１４ｃの＋Ｚ方向側の端部と、の間に架設されている。導体部１２４は、導体部３１４の第２部位３１４ｂの＋Ｚ方向側の端部と、導体部３１５の立上部３１５ｂの＋Ｚ方向側の端部と、の間に架設されている。 The conductor portion 121 is erected between the end of the conductor portion 311 on the + Z direction side of the rising portion 311b and the end portion of the second portion 312c of the conductor portion 312 on the + Z direction side, as shown in FIG. 9A. .. The conductor portion 122 is erected between the end portion of the second portion 312b of the conductor portion 312 on the + Z direction side and the end portion of the second portion 313c of the conductor portion 313 on the + Z direction side. The conductor portion 123 is erected between the end portion of the second portion 313b of the conductor portion 313 on the + Z direction side and the end portion of the second portion 314c of the conductor portion 314 on the + Z direction side. The conductor portion 124 is erected between the end portion of the second portion 314b of the conductor portion 314 on the + Z direction side and the end portion of the rising portion 315b of the conductor portion 315 on the + Z direction side.
　次に、本実施の形態に係るインダクタ素子３の製造方法について説明する。まず、図２に示す導体基板１７１と、図１０Ａに示す導体基板３７２と、図１０Ｂに示す導体基板３７３と、を準備する準備工程を行う。なお、図１０Ａおよび図１０Ｂにおいて、実施の形態１と同様の構成については、図２と同一の符号を付している。また、図１０Ａおよび図１０Ｂにおいて、導体基板３７１、３７２は、２つのインダクタ素子２を作製するための導体基板の例を示している。導体基板３７２、３７３は、導体基板１７１と同様に、例えば金属板を打ち抜き加工することにより作製される。 Next, a method of manufacturing the inductor element 3 according to the present embodiment will be described. First, a preparatory step is performed to prepare the conductor substrate 171 shown in FIG. 2, the conductor substrate 372 shown in FIG. 10A, and the conductor substrate 373 shown in FIG. 10B. In addition, in FIG. 10A and FIG. 10B, the same reference numerals as those in FIG. 2 are attached to the same configurations as those in the first embodiment. Further, in FIGS. 10A and 10B, the conductor substrates 371 and 372 show an example of a conductor substrate for manufacturing the two inductor elements 2. The conductor substrates 372 and 373 are manufactured by, for example, punching a metal plate in the same manner as the conductor substrate 171.
　導体基板３７２は、図１０Ａに示すように、導体板３１１２、３１２２、３１３２、３１４２、３１５２と、２つの平面視Ｌ字状の枠片１６１１、１６１２と、１４本の細長の支持片１６１１ａ、１６１１ｂ、１６１２ａ、１６１２ｂと、を有するユニット３７２ＵがＸ軸方向に２つ並んだ構造を有する。ここで、５本の支持片１６１１ａは、枠片１６１１から－Ｙ方向へ延在し長手方向における－Ｙ方向側の端部が導体板３１１１と＋Ｙ方向側に配置された導体板３１２１、３１３１、３１４１とに接続されている。また、５本の支持片１６１２ａは、枠片１６１２から＋Ｙ方向へ延在し長手方向における＋Ｙ方向側の端部が－Ｙ方向側に配置された導体板３１２２、３１３２、３１４２と導体板３１５２とに接続されている。また、導体基板３７２、Ｘ軸方向に沿って延在し導体板３１１２と＋Ｙ方向側に配置された導体板３１２２、３１３２、３１４２とのそれぞれの－Ｙ方向側の端部同士を互いに接続する支持片３６１１ｃと、Ｘ軸方向に沿って延在し－Ｙ方向側に配置された導体板３１２２、３１３２、３１４２と導体板３１５２とのそれぞれの＋Ｙ方向側の端部同士を互いに接続する支持片３６１２ｃと、を有する。ここで、＋Ｙ方向側に配置された導体板３１２１、３１３１、３１４１と、－Ｙ方向側に配置された導体板３１２２、３１３２、３１４２との間は、距離Ｗ３１だけ離間している。 As shown in FIG. 10A, the conductor substrate 372 includes conductor plates 3112, 3122, 3132, 3142, 3152, two L-shaped frame pieces 1611 and 1612 in a plan view, and 14 elongated support pieces 1611a and 1611b. , 1612a, 1612b, and two units 372U having a structure in which two units 372U are arranged in the X-axis direction. Here, the five support pieces 1611a extend from the frame piece 1611 in the −Y direction, and the ends on the −Y direction side in the longitudinal direction are arranged on the conductor plate 3111 and the + Y direction side. It is connected to 3141. Further, the five support pieces 1612a include a conductor plate 3122, 3132, 3142 and a conductor plate 3152 extending from the frame piece 1612 in the + Y direction and having an end portion on the + Y direction side in the longitudinal direction arranged on the −Y direction side. It is connected to the. Further, the conductor substrate 372, the support extending along the X-axis direction and connecting the ends of the conductor plate 3112 and the conductor plate 3122, 3132, 3142 arranged on the + Y direction side to each other on the −Y direction side are connected to each other. Support piece 3612c that connects the pieces 3611c and the ends of the conductor plates 3122, 3132, 3142 and the conductor plates 3152 that extend along the X-axis direction and are arranged on the −Y direction side to each other on the + Y direction side. And have. Here, the conductor plates 3121, 3131, 3141 arranged on the + Y direction side and the conductor plates 3122, 3132, 3142 arranged on the −Y direction side are separated by a distance W31.
　また、図１０Ｂに示すように、導体基板３７３も、導体基板３７２と同様の構造を有し、導体板３１１３、３１２３、３１３３、３１４３、３１５３と、２つの平面視Ｌ字状の枠片１６１１、１６１２と、１４本の細長の支持片１６１１ａ、１６１１ｂ、１６１２ａ、１６１２ｂと、を有するユニット３７３ＵがＸ軸方向に２つ並んだ構造を有する。ここで、＋Ｙ方向側に配置された導体板３１２３、３１３３、３１４３と、－Ｙ方向側に配置された導体板３１２３、３１３３、３１４３との間は、距離Ｗ３２だけ離間している。そして、距離Ｗ３２は、距離Ｗ３１よりも長く設定されている。これにより、凹部３１１ｄ、３１２ｄ、３１３ｄ、３１４ｄ、３１５ｄの周部に階段状の部分が形成されている。そして、距離Ｗ３１は、距離Ｗ３２よりも短く設定されているため、凹部３１２ｄ、３１３ｄ、３１４ｄの開口面積は、底側、即ち、＋Ｚ方向側ほど小さくなる。 Further, as shown in FIG. 10B, the conductor substrate 373 also has the same structure as the conductor substrate 372, and the conductor plates 3113, 3123, 3133, 3143, 3153 and the two L-shaped frame pieces 1611 in a plan view, It has a structure in which two units 373U having 1612 and 14 elongated support pieces 1611a, 1611b, 1612a, 1612b are arranged side by side in the X-axis direction. Here, the conductor plates 3123, 3133, 3143 arranged on the + Y direction side and the conductor plates 3123, 3133, 3143 arranged on the −Y direction side are separated by a distance W32. The distance W32 is set longer than the distance W31. As a result, a stepped portion is formed at the peripheral portion of the recesses 311d, 312d, 313d, 314d, and 315d. Since the distance W31 is set shorter than the distance W32, the opening area of the recesses 312d, 313d, and 314d becomes smaller toward the bottom side, that is, the + Z direction side.
　次に、導体基板１７１、３７２、３７３をそれらの厚さ積層する積層工程を行う。ここでは、例えば導体基板１７１の－Ｚ方向側に導体基板３７２を重ね合わせ、導体基板３７２の－Ｚ方向側に導体基板３７３を重ね合わせる。ここで、導体基板１７１、３７２を、Ｚ軸方向において互いに対向する面側全体において互いに溶着する。また、導体基板３７２、３７３も、Ｚ軸方向において互いに対向する面側全体において互いに溶着する。これにより、図１１Ａに示すような２つのユニット３７Ｕを有する積層体３７が形成される。このとき、導体基板１７１、３７２、３７３の枠片１６１１、１６１２が積層されることにより、枠部１６１、１６２が形成される。また、導体基板１７１、３７２、３７３の支持片１６１１ａ、１６１１ｂ、１６１２ａ、１６１２ｂが積層されることにより、支持部１６１ａ、１６１ｂ、１６２ａ、１６２ｂが形成される。また、導体部３１１、３１２、３１３、３１４、３１５における凹部３１１ｄ、３１２ｄ、３１３ｄ、３１４ｄ、３１５ｄの底部に対応する部分は、１つの導体板１１１１、１１２１、１１３１、１１４１、１１５１から構成されている。一方、導体部３１１、３１２、３１３、３１４、３１５における凹部３１１ｄ、３１２ｄ、３１３ｄ、３１４ｄ、３１５ｄ以外の部分は、３つの導体板１１１１、１１２１、１１３１、１１４１、１１５１、３１１２、３１２２、３１３２、３１４２、３１５２、３１１３、３１２３、３１３３、３１４３、３１５３から構成されている。即ち、導体部３１１、３１２、３１３、３１４、３１５における凹部３１１ｄ、３１２ｄ、３１３ｄ、３１４ｄ、３１５ｄの底部に対応する部分の導体板１１１１、１１２１、１１３１、１１４１、１１５１の積層数は１であり、導体部３１１、３１２、３１３、３１４、３１５における凹部３１１ｄ、３１２ｄ、３１３ｄ、３１４ｄ、３１５ｄ以外の部分の導体板１１１１、１１２１、１１３１、１１４１、１１５１、３１１２、３１２２、３１３２、３１４２、３１５２、３１１３、３１２３、３１３３、３１４３、３１５３の積層数３に比べて少なくなっている。 Next, a laminating step of laminating the conductor substrates 171, 372, and 373 to their thickness is performed. Here, for example, the conductor substrate 372 is superposed on the −Z direction side of the conductor substrate 171, and the conductor substrate 373 is superposed on the −Z direction side of the conductor substrate 372. Here, the conductor substrates 171 and 372 are welded to each other on the entire surface side facing each other in the Z-axis direction. Further, the conductor substrates 372 and 373 are also welded to each other on the entire surface side facing each other in the Z-axis direction. As a result, a laminated body 37 having two units 37U as shown in FIG. 11A is formed. At this time, the frame portions 161 and 162 are formed by laminating the frame pieces 1611 and 1612 of the conductor substrates 171 and 372 and 373. Further, the support portions 161a, 161b, 162a, 162b are formed by laminating the support pieces 1611a, 1611b, 1612a, 1612b of the conductor substrates 171, 372, and 373. Further, the portion corresponding to the bottom of the recesses 311d, 312d, 313d, 314d, 315d in the conductor portions 311, 312, 313, 314, 315 is composed of one conductor plate 1111, 1121, 1131, 1141, 1151. .. On the other hand, the parts other than the recesses 311d, 312d, 313d, 314d, and 315d in the conductor portions 311, 312, 313, 314, and 315 have three conductor plates 1111, 1121, 1131, 1141, 1151, 3112, 3122, 3132, and 3142. , 3152, 3113, 3123, 3133, 3143, 3153. That is, the number of laminated conductor plates 1111, 1121, 1131, 1141 and 1151 in the portions corresponding to the bottoms of the recesses 311d, 312d, 313d, 314d and 315d in the conductor portions 311, 312, 313, 314 and 315 is 1. Conductor plates 1111, 1121, 1131, 1141, 1151, 3112, 3122, 3132, 3142, 3152, 3113 The number of layers of 3123, 3133, 3143, and 3153 is smaller than that of 3.
　続いて、図１１Ｂおよび図１１Ｃに示すように、積層体３７について、支持部１６１ａ、１６２ａおよび支持片３６１１ｃ、３６１２ｃを切断する切断工程を行う。その後、導体部３１１、３１５の立上部３１１ｂ、３１５ｂに相当する部分および導体部３１２、３１３、３１４の第２部位３１２ｂ、３１２ｃ、３１３ｂ、３１３ｃ、３１４ｂ、３１４ｃに相当する部分を＋Ｚ方向へ折り曲げるとともに、導体部３１１、３１５の脚部３１１ｃ、３１５ｃに相当する部分を－Ｚ方向へ折り曲げる折り曲げ工程を行う。 Subsequently, as shown in FIGS. 11B and 11C, the laminated body 37 is subjected to a cutting step of cutting the support portions 161a and 162a and the support pieces 3611c and 3612c. After that, the portion corresponding to the rising portion 311b and 315b of the conductor portion 311 and 315 and the portion corresponding to the second portion 312b, 312c, 313b, 313c, 314b and 314c of the conductor portion 312, 313 and 314 are bent in the + Z direction. , The bending step of bending the portions corresponding to the legs 311c and 315c of the conductor portions 311 and 315 in the −Z direction is performed.
　次に、図４Ａに示す４つの導体部１２１、１２２、１２３、１２４を準備する準備工程を行う。続いて、導体部３１１の立上部３１１ｂの＋Ｚ方向側の端部および導体部３１２の第２部位３１２ｃの＋Ｚ方向側の端部を、導体部１２１に溶着する。同様にして、導体部３１５の立上部３１５ｂの＋Ｚ方向側の端部および導体部３１４の第２部位３１４ｂの＋Ｚ方向側の端部を、導体部１２４に溶着する。また、導体部３１２、３１３の第２部位３１２ｂ、３１３ｃの＋Ｚ方向側の端部を、導体部１２２に溶着する。同様にして、導体部３１２の第２部位３１２ｂの＋Ｚ方向側の端部および導体部３１３の第２部位３１３ｃの＋Ｚ方向側の端部を、導体部１２３に溶着し、導体部３１３の第２部位３１３ｂの＋Ｚ方向側の端部および導体部３１４の第２部位３１４ｃの＋Ｚ方向側の端部を、導体部１２４に溶着する。 Next, a preparatory step for preparing the four conductor portions 121, 122, 123, 124 shown in FIG. 4A is performed. Subsequently, the + Z direction end of the rising portion 311b of the conductor portion 311 and the + Z direction end of the second portion 312c of the conductor portion 312 are welded to the conductor portion 121. Similarly, the + Z direction end of the rising portion 315b of the conductor portion 315 and the + Z direction end of the second portion 314b of the conductor portion 314 are welded to the conductor portion 124. Further, the ends of the second portions 312b and 313c of the conductor portions 312 and 313 on the + Z direction side are welded to the conductor portion 122. Similarly, the + Z direction end of the second portion 312b of the conductor portion 312 and the + Z direction end of the second portion 313c of the conductor portion 313 are welded to the conductor portion 123, and the second portion of the conductor portion 313 is welded. The + Z direction end of the portion 313b and the + Z direction end of the second portion 314c of the conductor portion 314 are welded to the conductor portion 124.
　その後、積層体３７の各ユニット３７Ｕに導体部３２１、３２２、３２３、３２４が溶着された構造体における積層体３７の導体部３１１、３１５の脚部３１１ｃ、３１５ｃおよび導体部１２１、１２２、１２３、１２４を除く部位を覆う金型を構造体に固定した状態で、前述のフェライトの粉末を含む樹脂を金型内に射出した後、加熱、冷却することにより、絶縁体部１００を形成する。その後、構造体を積層体３７のユニット３７Ｕ毎に切断することにより、複数のインダクタ素子３が生成される。 After that, the conductor portions 321c, 315c and the conductor portions 121, 122, 123 of the conductor portions 311 and 315 of the laminated body 37 in the structure in which the conductor portions 321, 322, 323, and 324 are welded to each unit 37U of the laminated body 37, In a state where the mold covering the portion other than 124 is fixed to the structure, the resin containing the above-mentioned ferrite powder is injected into the mold, and then heated and cooled to form the insulator portion 100. After that, by cutting the structure for each unit 37U of the laminated body 37, a plurality of inductor elements 3 are generated.
　以上説明したように、本実施の形態に係るインダクタ素子３によれば、導体部３１１、３１２、３１３、３１４、３１５のそれぞれに、導体部３１１、３１２、３１３、３１４、３１５の厚さ方向に窪んだ凹部３１１ｄ、３１２ｄ、３１３ｄ、３１４ｄ、３１５ｄが設けられている。これにより、インダクタ素子３の導体部３１２、３１３、３１４の－Ｚ方向側に比較的大きな空間を形成することができる。従って、インダクタ素子３を電子部品Ｅ１に重ねて実装したときの基板Ｂ１の厚さ方向における基板Ｂ１の実装面からインダクタ素子３の＋Ｚ方向側の端縁までの高さを低くすることができるので、インダクタ素子３を備えるモジュールの薄型化を図ることができる。 As described above, according to the inductor element 3 according to the present embodiment, the conductor portions 311, 312, 313, 314, and 315 are respectively located in the thickness direction of the conductor portions 311, 312, 313, 314, and 315. Recessed recesses 311d, 312d, 313d, 314d, and 315d are provided. As a result, a relatively large space can be formed on the −Z direction side of the conductor portions 312, 313, 314 of the inductor element 3. Therefore, the height from the mounting surface of the substrate B1 in the thickness direction of the substrate B1 to the edge of the inductor element 3 on the + Z direction when the inductor element 3 is mounted on the electronic component E1 can be lowered. , The thickness of the module including the inductor element 3 can be reduced.
　また、本実施の形態に係る絶縁体部１００は、その一部が導体部３１１、３１２、３１３、３１４、３１５の凹部３１１ｄ、３１２ｄ、３１３ｄ、３１４ｄ、３１５ｄに入り込んだ状態で導体部３１１、３１２、３１３、３１４、３１５を覆うことにより、絶縁体部１００のアンカー効果が得られる。従って、絶縁体部１００に対して、導体部３１１、３１２、３１３、３１４、３１５の延伸方向に沿った方向への外力が加わった場合、絶縁体部１００がコイル３０に対して外力の加わる方向へ剥離してしまうことを抑制できる。 Further, the insulator portion 100 according to the present embodiment has the conductor portions 311 and 312 in a state where a part of the insulator portion 100 is inserted into the recesses 311d, 312d, 313d, 314d and 315d of the conductor portions 311 and 312, 313, 314 and 315. By covering 313, 314, and 315, the anchor effect of the insulator portion 100 can be obtained. Therefore, when an external force is applied to the insulator portion 100 in the direction along the stretching direction of the conductor portions 311, 312, 313, 314, and 315, the direction in which the insulator portion 100 applies the external force to the coil 30. It is possible to prevent the coil from peeling off.
　以上、本発明の各実施の形態について説明したが、本発明は前述の各実施の形態の構成に限定されるものではない。例えば図１２Ａに示すように、導体部４１１、４１２、４１３、４１４、４１５が、それぞれ、２つの導体板１１１１、１１２１、１１３１、１１４１、１１５１と、２つの導体板１１１１、１１２１、１１３１、１１４１、１１５１の間に積層された１つの導体板４１１２、４１２２、４１３２、４１４２、４１５２と、からなるものであってもよい。ここで、導体板４１１２、４１１３１１２の幅は、導体板１１１１の幅よりも長い。 Although each embodiment of the present invention has been described above, the present invention is not limited to the configuration of each of the above-described embodiments. For example, as shown in FIG. 12A, the conductor portions 411, 421, 413, 414, 415 have two conductor plates 1111, 1121, 1131, 1141, 1151, and two conductor plates 1111, 1121, 1131, 1141, respectively. It may consist of one conductor plate 4112, 4122, 4132, 4142, 4152 laminated between 1151. Here, the width of the conductor plate 4112 and 4113112 is longer than the width of the conductor plate 1111.
　各実施の形態では、コイル１０、２０、３０の導体部１１１、１１２、１１３、１１４、１１５、２１１、２１２、２１３、２１４、２１５、３１１、３１２、３１３、３１４、３１５が、それぞれ、３つの導体板を積層してなるものの例について説明した。但し、コイルの導体部を構成する導体板の積層数は、３つに限定されるものではなく、２つの導体板を厚さ方向に積層したものであってもよいし、４つ以上の導体板を厚さ方向に積層したものであってもよい。また、例えば図１２Ｂに示す導体部５１１、５１２、５１３、５１４、５１５のように、２つの導体板１１１１、１１２１、１１３１、１１４１、１１５１と、２つの導体板５１１２、５１２２、５１３２、５１４２、５１５２と、を厚さ方向に交互に積層したものであってもよい。ここで、導体板５１１２、５１２２、５１３２、５１４２、５１５２の幅は、導体板１１１１、１１２１、１１３１、１１４１、１１５１の幅よりも長い。また、導体部５１１、５１２、５１３、５１４、５１５の断面形状は、導体板１１１１、１１２１、１１３１、１１４１、１１５１、５１１２、５１２２、５１３２、５１４２、５１５２の積層方向において導体部５１１、５１２、５１３、５１４、５１５の延伸方向に沿った中心軸に対して非対称な形状であってもよい。 In each embodiment, the conductor portions 111, 112, 113, 114, 115, 211, 212, 213, 214, 215, 311, 312, 313, 314, 315 of the coils 10, 20, and 30 are three, respectively. An example of a laminated conductor plate has been described. However, the number of laminated conductor plates constituting the conductor portion of the coil is not limited to three, and two conductor plates may be laminated in the thickness direction, or four or more conductors may be laminated. The plates may be laminated in the thickness direction. Further, for example, as shown in the conductor portions 511, 512, 513, 514, 515 shown in FIG. 12B, the two conductor plates 1111, 1121, 1131, 1141, 1151 and the two conductor plates 5112, 5122, 5132, 5142, 5152 And may be alternately laminated in the thickness direction. Here, the width of the conductor plates 5112, 5122, 5132, 5142, 5152 is longer than the width of the conductor plates 1111, 1121, 1131, 1141, 1151. Further, the cross-sectional shape of the conductor portions 511, 512, 513, 514, 515 is such that the conductor portions 511, 512, 1131, 1141, 1151, 5112, 5122, 5132, 5142, 5152 are stacked in the direction of stacking. The shape may be asymmetric with respect to the central axis along the stretching direction of 514 and 515.
　本発明は、本発明の広義の精神と範囲を逸脱することなく、様々な実施の形態及び変形が可能とされるものである。また、上述した実施の形態は、この発明を説明するためのものであり、本発明の範囲を限定するものではない。すなわち、本発明の範囲は、実施の形態ではなく、請求の範囲によって示される。そして、請求の範囲内及びそれと同等の発明の意義の範囲内で施される様々な変形が、この発明の範囲内とみなされる。 The present invention enables various embodiments and modifications without departing from the broad spirit and scope of the present invention. Moreover, the above-described embodiment is for explaining the present invention, and does not limit the scope of the present invention. That is, the scope of the present invention is indicated not by the embodiment but by the claims. And various modifications made within the scope of the claims and within the equivalent meaning of the invention are considered to be within the scope of the invention.
　本出願は、２０２０年４月７日に出願された日本国特許出願特願２０２０－０６９４２３号に基づく。本明細書中に日本国特許出願特願２０２０－０６９４２３号の明細書、特許請求の範囲および図面全体を参照として取り込むものとする。 This application is based on Japanese Patent Application No. 2020-069423 filed on April 7, 2020. The specification, claims and drawings of Japanese Patent Application No. 2020-069423 are incorporated herein by reference.
　本発明は、小型であり且つ比較的大電流が流れるインダクタ素子として好適である。 The present invention is suitable as an inductor element that is compact and allows a relatively large current to flow.
１，２，３：インダクタ素子、１０,２０,３０：コイル、１１,１２,２１,３１：導体部群、１７,２７,３７：積層体、１７Ｕ，２７Ｕ，３７Ｕ，１７１Ｕ，１７３Ｕ，３７２Ｕ，３７３Ｕ：ユニット、１００：絶縁体部、１１１,１１２,１１３,１１４,１１５,１２１，１２２，１２３，１２４，２１１,２１２,２１３,２１４,２１５,３１１,３１２,３１３,３１４,３１５：導体部、１１１ａ、１１５ａ：主部、１１１ｂ,１１５ｂ：立上部、１１１ｃ，１１５ｃ：脚部、１１２ａ,１１３ａ,１１４ａ：第１部位、１１２ｂ,１１２ｃ,１１３ｂ,１１３ｃ,１１４ｂ,１１４ｃ：第２部位、１１２ｆ、１１２ｇ、１１３ｆ、１１３ｇ、１１４ｆ、１１４ｇ：曲げ部、１６１,１６２：枠部、１６１ａ,１６１ｂ,１６２ａ,１６２ｂ：支持部、１７１，１７３：導体基板、２１１ｅ,２１２ｅ,２１３ｅ,２１４ｅ,２１５ｅ：溝、３１１ｄ,３１２ｄ,３１３ｄ,３１４ｄ,３１５ｄ：凹部、１１１１,１１２１,１１３１,１１４１,１１５１,２１１２,２１２２,２１３２,２１４２,２１５２,３１１２,３１１３,３１２２,３１２３,３１３２,３１３３,３１４２,３１４３,３１５２,３１５３,４１１２,４１２２,４１３２,４１４２,４１５２,５１１２,５１２２,５１３２,５１４２,５１５２：導体板、１６１１,１６１２：枠片、１６１１ａ,１６１１ｂ,１６１２ａ,１６１２ｂ，１６３１ｃ，１６３２ｃ，３６１２ｃ：支持片、Ｂ１：基板、Ｅ１：電子部品、Ｊ１,Ｊ２,Ｊ３：巻回軸 1,2,3: Inductor element 10,20,30: Coil, 11,12,21,31: Conductor group, 17,27,37: Laminated body, 17U, 27U, 37U, 171U, 173U, 372U, 373U: Unit, 100: Insulator part, 111,112,113,114,115,121,122,123,124,211,212,213,214,215,311,312,313,314,315: Conductor part , 111a, 115a: Main part, 111b, 115b: Rising part, 111c, 115c: Leg part, 112a, 113a, 114a: First part, 112b, 112c, 113b, 113c, 114b, 114c: Second part, 112f, 112g, 113f, 113g, 114f, 114g: Bending part, 161, 162: Frame part, 161a, 161b, 162a, 162b: Support part, 171, 173: Conductor substrate, 211e, 212e, 213e, 214e, 215e: Groove, 311d, 312d, 313d, 314d, 315d: Recesses 1111,1121,1131,1141,1151,2112,2122,2132,2142,2152,3112,3113,3122,3123,3132,3133,3142,3143,3152, 3153,4112,4122,4132,4142,4152,5112,5122,5132,5122,5152: Conductor plate, 1611,1612: Frame piece, 1611a, 1611b, 1612a, 1612b, 1631c, 1632c, 3612c: Support piece, B1 : Substrate, E1: Electronic component, J1, J2, J3: Winding shaft

Claims (10)

  1. 　巻回軸に沿って巻回されるコイル構造であって、
    　複数の導体板が積層された第１部位と、前記第１部位と繋がり、互いに積層され複数の導体板からなり且つ複数の導体板それぞれが積層方向に湾曲している曲げ部と、前記曲げ部と繋がり且つ前記第１部位を構成する複数の導体板の積層方向と異なる方向に複数の導体板が積層されてなる第２部位と、を有する第１導体部を備え、
    　前記第１部位、前記曲げ部および前記第２部位は、それぞれ、側面に凹凸を有する、
    　コイル構造。     It is a coil structure that is wound along the winding axis.
    A first portion in which a plurality of conductor plates are laminated, a bent portion connected to the first portion, laminated with each other, composed of a plurality of conductor plates, and each of the plurality of conductor plates is curved in the stacking direction, and the bent portion. The first conductor portion is provided with a second portion which is connected to and has a second portion in which a plurality of conductor plates are laminated in a direction different from the stacking direction of the plurality of conductor plates forming the first portion.
    The first portion, the bent portion, and the second portion each have irregularities on the side surfaces.
    Coil structure.
  2. 　前記複数の導体板は、前記積層方向と直交する第１方向の導体板の長さを幅と定義したとき、前記幅の長さが互いに異なる導体板を含む、
    　請求項１に記載のコイル構造。     The plurality of conductor plates include conductor plates having different widths from each other when the length of the conductor plates in the first direction orthogonal to the stacking direction is defined as the width.
    The coil structure according to claim 1.
  3. 　前記複数の導体板は、第１導体板と、前記第１導体板よりも前記幅の長さが短い第２導体板とを有し、
    　前記第２導体板は、前記積層方向において、２つの前記第１導体板に挟まれている、
    　請求項２に記載のコイル構造。     The plurality of conductor plates include a first conductor plate and a second conductor plate having a width shorter than that of the first conductor plate.
    The second conductor plate is sandwiched between the two first conductor plates in the stacking direction.
    The coil structure according to claim 2.
  4. 　前記第１導体部の前記積層方向における断面形状は、点対称である、
    　請求項１から３のいずれか１項に記載のコイル構造。     The cross-sectional shape of the first conductor portion in the stacking direction is point symmetric.
    The coil structure according to any one of claims 1 to 3.
  5. 　前記第１導体部の表面には、前記積層方向に窪んだ凹部が設けられている、
    　請求項１から４のいずれか１項に記載のコイル構造。     The surface of the first conductor portion is provided with a recess recessed in the stacking direction.
    The coil structure according to any one of claims 1 to 4.
  6. 　前記第１導体部における前記凹部の底部を構成する前記導体板の数は、前記第１導体部における前記凹部以外を構成する導体板の積層数よりも少ない、
    　請求項５に記載のコイル構造。     The number of the conductor plates forming the bottom of the recess in the first conductor portion is smaller than the number of laminated conductor plates forming other than the recess in the first conductor portion.
    The coil structure according to claim 5.
  7. 　前記凹部の底部の面積は、前記凹部の開口面積よりも小さい、
    　請求項５または６に記載のコイル構造。     The area of the bottom of the recess is smaller than the opening area of the recess.
    The coil structure according to claim 5 or 6.
  8. 　前記巻回軸の方向から数えて１ターン目を構成する第１導体部と２ターン目を構成する第１導体部との間には、１つの導体板で構成される第２導体部が接続される、
    　請求項１から７のいずれか１項に記載のコイル構造。     A second conductor portion composed of one conductor plate is connected between the first conductor portion constituting the first turn and the first conductor portion forming the second turn counting from the direction of the winding axis. Be done,
    The coil structure according to any one of claims 1 to 7.
  9. 　前記第１導体部と前記第２導体部とが接続される部分において、前記第１導体部が延在する方向と前記第２導体部が延在する方向とは、直交している、
    　請求項８に記載のコイル構造。     In the portion where the first conductor portion and the second conductor portion are connected, the direction in which the first conductor portion extends and the direction in which the second conductor portion extends are orthogonal to each other.
    The coil structure according to claim 8.
  10. 　請求項１から９のいずれか１項に記載のコイル構造と、
    　絶縁体材料から形成され前記第１導体部を覆う絶縁体部と、を備える、
    　インダクタ素子。     The coil structure according to any one of claims 1 to 9.
    An insulator portion formed of an insulator material and covering the first conductor portion is provided.
    Inductor element.
PCT/JP2021/010290 2020-04-07 2021-03-15 Coil structure and inductor element WO2021205817A1 (en)

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0742112B2 (en) * 1991-01-11 1995-05-10 株式会社大真空 Oxygen-deficient metal titanate fiber and method for producing the same
JP3089948U (en) * 2002-05-14 2002-11-22 コーセル株式会社 Coil structure
JP2011187600A (en) * 2010-03-08 2011-09-22 Yaskawa Electric Corp Electromagnetic coil device and transformer
JP2014007195A (en) * 2012-06-21 2014-01-16 Fcm Kk Coil
WO2019193802A1 (en) * 2018-04-04 2019-10-10 株式会社村田製作所 Inductor element and method for manufacturing inductor element
JP2019530217A (en) * 2016-08-31 2019-10-17 ヴィシェイ デール エレクトロニクス エルエルシー Inductor with high current coil with low DC resistance

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0742112B2 (en) * 1991-01-11 1995-05-10 株式会社大真空 Oxygen-deficient metal titanate fiber and method for producing the same
JP3089948U (en) * 2002-05-14 2002-11-22 コーセル株式会社 Coil structure
JP2011187600A (en) * 2010-03-08 2011-09-22 Yaskawa Electric Corp Electromagnetic coil device and transformer
JP2014007195A (en) * 2012-06-21 2014-01-16 Fcm Kk Coil
JP2019530217A (en) * 2016-08-31 2019-10-17 ヴィシェイ デール エレクトロニクス エルエルシー Inductor with high current coil with low DC resistance
WO2019193802A1 (en) * 2018-04-04 2019-10-10 株式会社村田製作所 Inductor element and method for manufacturing inductor element

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