WO2022172949A1

WO2022172949A1 - Electronic component and method for manufacturing electronic component

Info

Publication number: WO2022172949A1
Application number: PCT/JP2022/005088
Authority: WO
Inventors: 俊行朝日
Original assignee: パナソニックＩｐマネジメント株式会社
Priority date: 2021-02-12
Filing date: 2022-02-09
Publication date: 2022-08-18

Abstract

An inductor (100) comprises: a coil member (20) on which a conductive wire is wound; a core member (10) which includes a magnetic powder and a binding material for binding the magnetic powder and in which the coil member (20) is embedded; and an insulating sheet member (30) having a coil protection part (31) that overlaps at least a part of the coil member (20) seen from an axial direction along a winding shaft of the coil member (20) and that is disposed between the coil member (20) and the core member (10), and a gap (32) that does not overlap the coil member (20) seen from the axial direction and that is inserted in the core member (10).

Description

Electronic component and method for manufacturing electronic component

The present disclosure relates to electronic components used in various electronic devices.

　Conventionally, electronic components have been introduced into a wide range of electronic devices such as DC-DC converter devices for the purpose of stepping up and down the power supply voltage and smoothing the direct current. As such an electronic component, for example, a powder magnetic core formed by pressure-molding a mixture of metal magnetic powder and resin, and a conductive wire embedded in the powder magnetic core in a wound state and extended outside the powder magnetic core. There is known an inductor using a powder magnetic core including a coil member having lead portions that extend out (see Patent Literature 1).

JP 2016-106436 A

By the way, conventional electronic components such as inductors using powder magnetic cores disclosed in Patent Document 1 may not be suitable for use. In view of the above, an object of the present disclosure is to provide an electronic component that is more suitable for use.

An electronic component according to an aspect of the present disclosure includes a coil member around which a conductive wire is wound, magnetic powder, and a binder that binds the magnetic powder, and a core in which the coil member is embedded. a member, a coil protection portion that overlaps at least a portion of the coil member when viewed in an axial direction along the winding axis of the coil member and is disposed between the coil member and the core member; and an insulating sheet member that does not overlap with the coil member when viewed from above and has a gap portion sandwiched between the core members.

Further, an electronic component according to another aspect of the present disclosure includes a coil member around which a conductive wire is wound, magnetic powder, and a binder that binds the magnetic powder, wherein the coil member An embedded core member and an insulating sheet member are provided, and the sheet member is a first sheet member that overlaps at least a portion of the coil member when viewed in the axial direction along the winding axis of the coil member. A first sheet member disposed between the coil member and the core member on one side of the coil member in the axial direction; a second sheet member disposed between the coil member and the core member on the other side of the coil member in the axial direction.

Further, in the method for manufacturing an electronic component according to an aspect of the present disclosure, a pair of core materials containing magnetic powder and a binder that binds the magnetic powder are prepared, and at least the pair of core materials A sheet member is laminated on one side, and a coil member around which a conductive wire is wound is arranged between the pair of core materials via the laminated sheet members, and the pair of core materials, The sheet member and the coil member are compression molded.

According to the present disclosure, electronic components that are more suitable for use are provided.

FIG. 1 is a schematic perspective view showing the configuration of an electronic component according to an embodiment. FIG. 2 is a schematic plan view showing the configuration of the inductor according to the embodiment. FIG. 3 is a graph showing changes in DC superimposition characteristics depending on the presence or absence of the gap portion of the inductor according to the embodiment. FIG. 4 is a first diagram showing an example of removing the gap portion of the inductor according to the embodiment. FIG. 5 is a second diagram showing an example of removing the gap portion of the inductor according to the embodiment. FIG. 6 is a third diagram showing an example of removing the gap portion of the inductor according to the embodiment. FIG. 7 is a flow chart showing a method of manufacturing an inductor according to the embodiment. FIG. 8 is a first diagram showing the manufacturing process of the inductor 100 according to the embodiment. FIG. 9 is a second diagram showing the manufacturing process of the inductor 100 according to the embodiment. FIG. 10 is a third diagram showing the manufacturing process of the inductor 100 according to the embodiment. FIG. 11 is a fourth diagram showing the manufacturing process of the inductor 100 according to the embodiment. FIG. 12 is a fifth diagram showing the manufacturing process of the inductor 100 according to the embodiment. FIG. 13 is a sixth diagram showing the manufacturing process of the inductor 100 according to the embodiment. FIG. 14 is a seventh diagram showing the manufacturing process of the inductor 100 according to the embodiment.

(Findings leading to disclosure)
2. Description of the Related Art Conventionally, electronic components have been introduced into a wide range of electronic devices such as DC-DC converter devices for the purpose of boosting/boosting a power supply voltage, smoothing a direct current, and the like. Such electronic components are also called inductors. The configuration of the inductor includes, for example, a magnetic core member formed by pressure-molding a mixture of metal magnetic powder and resin, and leads embedded in the powder magnetic core in a wound state of conducting wires and extending to the outside of the powder magnetic core. An inductor using a powder magnetic core including a coil member having a portion is known.

Here, for example, in order for the coil member of the inductor to function as designed, when the conductive wire that constitutes the coil member is wound, It is important to insulate between the A wire rod used for a coil member is usually covered with an insulating coating to restrict electrical conduction with the outside. However, when forming the powder magnetic core, the magnetic powder in which the coil member is embedded is subjected to compression molding by applying a pressure of several tons from the outside. In some cases, defects may occur and the insulating properties may be lost, or the thickness of the insulating coating may become thin, resulting in a decrease in withstand voltage.

Therefore, in the present disclosure, as an electronic component, an inductor including a configuration that suppresses damage to the insulating coating of the coil member during compression molding will be described. In such an inductor, the reliability of the coil member is improved. This provides an inductor that is more suitable for use.

Hereinafter, embodiments will be specifically described with reference to the drawings.

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

In each figure, the X-axis, Y-axis, and Z-axis, which mean three directions perpendicular to each other, are shown, and these axes are used for explanation as necessary. Each axis is attached for explanation and does not limit the direction and orientation in which the inductor is used.

(Embodiment)
[Constitution]
First, an inductor according to an embodiment of the present disclosure will be described with reference to FIG. FIG. 1 is a schematic perspective view showing the configuration of an inductor according to an embodiment. FIG. 1 shows the general shape of a core member 10, which will be described later, and also shows the inside of the core member 10 in a transparent manner. For example, components such as the coil member 20 hidden by being embedded in the core member 10 are shown with thin dashed lines and hatching to express that they can be seen through the core member 10 . Further, in FIG. 1, the sheet member arranged so as to cover the core member 10 is also indicated by a broken line.

As shown in FIG. 1, the inductor 100 of the present embodiment includes a core member 10, a coil member 20 embedded in the core member 10 and made of a wound conductive wire, and an insulating sheet member. 30 and a pair of terminal members 40 electrically connected to the coil member 20 . The inductor 100 can be realized without the pair of terminal members 40 by directly connecting the ends of the coil member 20 drawn out of the core member 10 . That is, the terminal member 40 is not an essential component.

The core member 10 is a molded body obtained by pressure-molding a mixture of metal magnetic powder and resin, which is a binder for binding the magnetic powder, and is a magnetic material called a dust core. is. As shown in FIG. 1, the core member 10 substantially conforms to the shape of the inductor 100. In other words, the shape of the core member 10 at the time of pressure molding allows the inductor 100 to have an arbitrary shape. In other words, the shape of the inductor 100 is not particularly limited, and the contents of the present disclosure can be applied to inductors having any three-dimensional shape such as a cylindrical shape or a polygonal shape, in addition to the quadrangular prism shape exemplified in the present embodiment.

Examples of metal magnetic powders include metal magnetic powders with crystalline compositions such as iron-nickel alloys, iron-silicon alloys, iron-silicon-aluminum alloys, and iron-silicon-chromium alloys, and Iron-silicon-boron-based and iron-silicon-boron-chromium-based metallic magnetic materials of amorphous composition are used.

The core member 10 has a pair of terminal surfaces to which the pair of terminal members 40 are respectively attached, a bottom surface on the negative side of the Z-axis in the figure, a top surface on the positive side of the Z-axis, and side surfaces on the positive and negative sides of the X-axis. It has the shape of a substantially quadrangular prism.

The coil member 20 has a winding portion formed by winding a flat conductor wire having a rectangular cross section with an insulating coating. The wound portion is connected to each of the pair of terminal members 40 by a pair of lead portions (not shown) formed by pulling out both ends of the conductive wire.

The winding portion is embedded inside the core member 10, and a magnetic field is formed in the winding portion by applying a current between the pair of lead portions. The inductor 100 functions as a passive element that stores electrical energy as magnetic energy by forming a magnetic field by the windings of the coil member 20 .

Each of the terminal members 40 is made of a conductor such as phosphor bronze material, copper material, baked silver, resin silver, or metal formed by plating. locking portions extending along each surface from the plate-like portion so as to be locked to the four surfaces of the plate-like portion. The terminal member 40 covers the terminal surface like a cap by each of the locking portions overlapping the top surface, the bottom surface, and the side surfaces.

Here, FIG. 2 is a schematic plan view showing the configuration of the inductor according to the embodiment. In FIG. 2, a plan view seen from the positive side of the Z-axis is shown in the upper part, and a plan view taken along the line XX in the upper part is shown in a plan view seen from the negative side of the Y-axis in the lower part. Here, the winding axis of the winding portion of the coil member 20 is illustrated along the Z-axis direction. Therefore, the upper part of FIG. 2 is also a view seen from the axial direction along the winding axis of the coil member 20 . 2, illustration of a part of the terminal member 40 and the core member 10 is omitted so that the coil member 20 and the sheet member 30 can be seen. In addition, in FIG. 2, for the sake of readability, the hatching of the cross section is not shown except for the dot hatching applied to the sheet member 30. As shown in FIG.

In addition, in the inductor 100, the core member 10 is formed by integrating two members (core material described later) on the Z-axis plus side and the Z-axis minus side. In FIG. 2 above, a cross-sectional view showing the internal configuration of the finished inductor 100 is shown. ). Accordingly, FIG. 2 treats the two members as being one core member 10 .

The sheet member 30 is a film-like member made of a resin material such as epoxy resin, and as shown in FIG. It includes a protection portion 31 and a gap portion 32 which is a portion formed by a surplus portion of the sheet member 30 and which does not overlap with the coil member 20 when viewed in the axial direction. The coil protection part 31 is indicated by high-density dot hatching in the drawing, and is in direct contact with the coil member 20 to absorb the pressure during compression molding of the core member 10 and to protect the wire rod of the coil member 20. It is a part for suppressing damage to the insulating coating attached to the. In the present embodiment, coil protection portion 31 suppresses breakage of the insulating coating, thereby realizing inductor 100 that is more suitable for use. Note that the inductor 100 may be used as a substrate-mounted electronic component, and it is assumed that reflow mounting or the like will be performed. From this point of view, epoxy resin is suitable as the material of the sheet member 30 .

In addition, since the sheet member 30 is a continuous sheet-like member, the coil protection portion 31 is formed in the inductor 100 simply by arranging the sheet member 30 so as to overlap the coil member 20 and performing compression molding. Thus, in the inductor 100, by using the sheet member 30, it is possible to easily suppress damage to the insulating coating.

The gap portion 32 is indicated by dot hatching with a low density in the drawing, and is sandwiched by the core members 10 from the positive side and negative side of the Z-axis as shown in the lower part of FIG.

Here, the function of such a gap portion 32 will be described with reference to FIG. FIG. 3 is a graph showing changes in DC superimposition characteristics depending on the presence or absence of the gap portion of the inductor according to the embodiment. FIG. 3 shows the relationship between the applied current value when the gap portion 32 exists and the relative ratio when the inductance value at the applied voltage value of 0 A is 100%. Since the gap portion 32 exists so as to block the magnetic path of the magnetic field formed in the winding portion, the magnetic characteristics (inductance) of the inductor 100 may be lowered depending on its thickness, position, and area.

On the other hand, as shown in FIG. 3, in the inductor 100 according to the embodiment in which the gap portion 32 is present, the inductance value when the applied current value is increased is lower than that of the inductor according to the comparative example without the gap portion. It was found that the degree of decrease was small and the performance could be exhibited even at a relatively high DC current value. That is, it was found that inductor 100 according to the present embodiment has improved DC superimposition characteristics. Further, the degree of deterioration of the magnetic properties varies depending on how the gap portion 32 is provided. That is, it is possible to remove the gap portion 32 in accordance with the required performance and improve the DC superimposition characteristics while securing the magnetic characteristics.

Therefore, depending on the application of the inductor 100, it is possible to design the inductor 100 that can be used even at a high DC current value by providing the gap portion 32 within an allowable range in consideration of the required magnetic properties. Become. In this embodiment, by using the sheet member 30 , the gap portion 32 is basically formed on the entire surface except for the coil protection portion 31 corresponding to the coil member 20 . In the inductor 100, the characteristics can be freely designed from the viewpoint of the control of the inductance value and the DC superimposition characteristics by trimming the portion corresponding to the gap portion 32 as necessary.

In addition, the sheet member 30 may include a filler 33 as shown in the blowout portion in the lower part of FIG. The filler 33 is, for example, particles such as silica. The filler 33 has a function of maintaining the distance between the core members 10 sandwiching the gap portion 32 .

Note that the filler 33 may be made of a material containing a magnetic substance. By doing so, it is possible to form the sheet member 30 that includes the filler 33 made of silica or the like that does not contain a magnetic material, or that has a magnetic permeability higher than that of the sheet member that does not contain the filler 33 . Therefore, it is possible to suppress the deterioration of the magnetic properties due to the interposition of the sheet member 30, that is, due to the formation of the gap portion 32. FIG.

Next, another example of the configuration of the gap portion 32 of the inductor 100 will be described with reference to FIGS. 4 to 6. FIG. 4 to 6 are diagrams showing an example of removing the gap portion of the inductor according to the embodiment. Note that FIGS. 4 to 6 show an inductor 100 according to another example with the same configuration as that shown in FIG.

For example, as shown in FIG. 4, in another example of the inductor 100, the inner side of the wound portion of the coil member 20 has a portion near the coil protection portion 31 left as a gap portion 32a and the rest is removed. Further, only a portion of the outside of the winding portion of the coil member 20 near the coil protection portion 31 is removed. That is, the gap portion 32a here is in contact with the coil protection portion 31 when viewed from the axial direction inside the winding portion, and is separated from the coil protection portion 31 when viewed from the axial direction outside the winding portion. is doing.

Further, for example, as shown in FIG. 5, in another example of the inductor 100, the inner side of the winding portion of the coil member 20 has a portion near the coil protection portion 31 left as a gap portion 32b and the rest is removed. . Further, the outer side of the winding portion of the coil member 20 is removed except for a portion near the coil protection portion 31 as a gap portion 32b. That is, the gap portion 32b here is in contact with the coil protection portion 31 when viewed from the axial direction on the inner and outer sides of the winding portion (ie, the inner and outer sides of the coil member 20).

Further, for example, as shown in FIG. 6, in another example of the inductor 100, the inside of the winding portion of the coil member 20 has all the gap portions removed. However, even in this case, a slight trimming residue may remain as the gap portion 32c. Further, the outer side of the wound portion of the coil member 20 is removed except for four corners of the rectangular core member 10 viewed from the axial direction along the winding axis as gap portions 32c. That is, the gap portion 32c here is separated from the coil protection portion 31 when viewed from the axial direction outside the winding portion (that is, outside the coil member 20).

Thus, since the gap portion 32b is an air gap in the magnetic path, the magnetic resistance can be adjusted by the thickness of the gap portion 32b, that is, the gap length. Further, the cross-sectional area of the magnetic flux can be adjusted by adjusting the area of the removed gap portion, and the magnetic resistance can also be adjusted. In the inductor 100 according to the present embodiment, the balance between the magnetic characteristics and the DC superimposition characteristics can be adjusted by removing the gap portion by trimming.

[Production method]
A method of manufacturing the inductor 100 according to the present embodiment will be described below with reference to FIGS. 7 to 14. FIG. FIG. 7 is a flow chart showing a method of manufacturing an inductor according to the embodiment.

As shown in FIG. 7, when manufacturing the inductor 100, a core material is first prepared (step S101). The core material indicates a mixture of metal magnetic powder and resin that will be the core member 10 in the manufactured inductor 100 . Here, preparing the core material may mean, for example, filling a molding die or the like with a mixture of uncured metal magnetic powder and resin. It may mean placing the molded member in a predetermined placement position.

In the inductor 100 of the present embodiment, the core member 10, as shown in FIG. In the following manufacturing process, it is also referred to as a lower core). In the manufacture of inductor 100, at least one of the upper and lower cores may be a cured molded member, or, of course, both may be pre-cured mixtures.

In manufacturing the inductor 100, the sheet member 30 is laminated on the prepared core material (step S102). For example, in the cured core material, a space is formed by unevenness to accommodate the coil member 20, but when the sheet member 30 is laminated in this space, a balloon or the like is used so as to follow the space from the opposite side. By applying a vacuum between the sheet member 30 and the core material while pressing the sheet members 30 against each other, it is possible to stack the sheet members 30 along the unevenness. Note that the above steps S101 and S102 are performed for each of the upper core and the lower core. However, it is also possible to realize a configuration in which either the upper core or the lower core is not provided with the sheet member 30 . An example of this will be described later.

After that, the wound coil members 20 are arranged between the upper core and the lower core on which the sheet members 30 are laminated (step S103), and these are compression-molded (step S104).

Several examples of manufacturing the inductor 100 will be described below.

FIG. 8 is the first diagram showing the manufacturing process of the inductor 100 according to the embodiment. 8 and subsequent figures show cross-sectional views from the same viewpoint as in the lower part of FIG. However, here only the core material is dot hatched.

FIG. 8 shows an example in which both the upper core 11 and the lower core 12 are uncured mixtures. As shown in FIG. 8(a), first, the upper core 11 and the lower core 12 are prepared, and the first sheet member 34 as the upper core sheet member and the second sheet member as the lower core sheet member are prepared. 35 are laminated respectively. A coil member 20 is then placed between these core materials, as shown in FIG. 8(b). Then, as shown in FIG. 8(c), compression molding is performed to obtain a shape in which the coil member 20 is embedded in the core material. At this time, the sheet member 30 deforms according to the shape of the coil member 20 to cover the coil member 20 .

For this reason, it is preferable that the sheet member 30 have stretchability that can follow the surface of the coil member 20 . From the standpoint of stretchability of the sheet member 30, for example, a so-called ethylene-based ionomer resin, which is an ethylene-based synthetic resin in which macromolecules are aggregated using the cohesive force of metal ions, is suitable. Such a resin shows fluidity because aggregates are loosened by heating, so that it is possible to form a shape that conforms to the surface of an object or the like. The above-mentioned stretchability includes the meaning of followability or deformability in this way. After that, the inductor 100 is manufactured through firing and mounting of the terminal members 40 . In addition, the first sheet member 34 and the second sheet member 35 may be integrated at their contact points in the finished inductor 100 . That is, the sheet member 30 may include the first sheet member 34 and the second sheet member 35 and be one integrated member. On the other hand, the first sheet member 34 and the second sheet member 35 may remain independently in the finished inductor 100 . That is, the sheet member 30 may be a member including the first sheet member 34 and the second sheet member 35, which are two members independent of each other.

As shown in FIG. 8(d), the upper core 11, the first sheet member 34, the coil member 20, the second sheet member 35, and the lower core 12 are arranged in this order and compression-molded simultaneously with the core material. Lamination of the sheet members 30 may be performed. That is, step S102 and step S104 described in FIG. 7 may be performed simultaneously. At this time, the coil members 20 are arranged before the sheet members 30 are laminated. Thus, the order of steps in manufacturing inductor 100 may be changed as appropriate.

FIG. 9 is a second diagram showing the manufacturing process of the inductor 100 according to the embodiment. FIG. 9 shows an example in which both the upper core 11 and the lower core 12 are hardened molded members. As shown in FIG. 9(a), first, the upper core 11a and the lower core 12a are prepared, and the first sheet member 34 and the second sheet member 35 are respectively laminated. A coil member 20 is then placed between the core materials as in the previous example. Here, in such a hardened core material, a space for accommodating the coil member 20 is provided in accordance with the shape of the coil member 20 and hardened in advance. When arranging the coil members 20 in this formed space, mutual alignment is important.

Therefore, in this example, as shown in FIG. 9A, the space formed in the hardened core material is formed so that the coil member 20 can be easily aligned as it enters the space. The diameter is reduced. In addition, since the space formed in the core material has a shape that decreases in diameter from the central portion to the end portion of the inductor 100 in the axial direction along the winding axis, the first sheet member 34 and the second sheet member 35 When laminating the sheet members 30, the sheet members 30 can be laminated more appropriately because the air can be easily removed by vacuuming. In this manner, the sheet members 30 are appropriately laminated on these core materials, as shown in FIG. 9(b). Then, the coil member 20 is arranged, and as shown in FIG. 9C, compression molding is performed to obtain a shape in which the coil member 20 is embedded in the core material. Also in this example, as shown in FIG. 9D, the upper core 11a, the first sheet member 34, the coil member 20, the second sheet member 35, and the lower core 12a are arranged in this order and compression molded. Lamination of the sheet member 30 to the core material may occur at the same time.

FIG. 10 is a third diagram showing the manufacturing process of the inductor 100 according to the embodiment. 10(a) and 10(b), similarly to the example of FIG. 9, the cured upper core 11a and the lower core 12a are prepared, and the first sheet member 34 and the second sheet member 35 are prepared, respectively. Laminated. In this example, after that, as shown in FIG. 10C, part of the sheet member 30 is removed to form a sheet member 30a. Specifically, the removed portion 34b of the first sheet member 34 is removed, leaving only the first sheet member 34a. Further, by removing the removed portion 35b of the second sheet member 35, only the second sheet member 35a is left. Then, the coil member 20 is arranged, and as shown in FIG. 10(d), compression molding is performed to obtain a shape in which the coil member 20 is embedded in the core material.

FIG. 11 is a fourth diagram showing the manufacturing process of the inductor 100 according to the embodiment. The example of FIG. 11 differs from the above example in that the sheet member is a sheet member 30b made of an adhesive material. Note that "having adhesiveness" means that the sheet member includes an adhesive layer having adhesiveness, or that the sheet member is formed of a material having adhesiveness. In the latter case, an epoxy resin or the like is suitable. The former example will be described below. In (a) of FIG. 11, an insulating film such as polyimide is used as a part of the sheet member. Specifically, the hardened upper core 11a and the lower core 12a are prepared, and the first insulating layer 34c and the second insulating layer 35c made of polyimide resin are laminated, respectively.

Further, as shown in FIG. 11B, a first adhesive layer 34d made of a silicone or acrylic adhesive is laminated on the first insulating layer 34c, and a silicone or acrylic adhesive is laminated on the second insulating layer 35c. A second adhesive layer 35d made of is laminated. Then, the coil member 20 is arranged, and as shown in FIG. 11(c), compression molding is performed to obtain a shape in which the coil member 20 is embedded in the core material. Since the sheet member 30b bonds the upper core 11a and the lower core 12a with the adhesive layer, it is possible to reduce the possibility of the inductor 100 cracking around the sheet member 30. FIG.

FIG. 12 is a fifth diagram showing the manufacturing process of the inductor 100 according to the embodiment. In the example of FIG. 12, the upper core 11 is the uncured mixture and the lower core 12a is the cured molded member. In this example, as shown in FIG. 12(a), the point that the second sheet member 35 is laminated on the lower core 12a is the same as the above example. On the other hand, in this example, as shown in FIG. 12(b), the coil member 20 is arranged on the second sheet member 35, and the first sheet member 34 is further laminated thereon. Thereafter, as shown in FIG. 12(c), the upper core 11 is overlaid, and as shown in FIG. 12(d), compression molding is performed to embed the coil member 20 in the core material. becomes.

Also, in this example, after (c) of FIG. 12, trimming of the sheet member 30 can be performed as shown in (e) of FIG. As a result, as shown in (f) of FIG. 12, a configuration including a sheet member 30a from which a portion is removed can be realized as in the example of FIG.

FIG. 13 is a sixth diagram showing the manufacturing process of the inductor 100 according to the embodiment. In the example of FIG. 13, a hardened lower core 12b is used, but the shape of this lower core 12b is different from that of the lower core 12a. This example also differs from the above other configurations in that the second sheet member 35 is not included. In this example, first, as shown in FIG. 13(a), the coil member 20 is arranged directly on the lower core. At this time, in order to make it easier to align the lower core 12b and the coil member 20, the portion located outside the coil member 20 (that is, the left and right ends in the figure) is removed from the lower core 12b. ing. Then, the first sheet member 34 is laminated to overlap the upper core 11 as shown in FIG. 13(b).

This upper core 11 is an uncured mixture. As shown in FIG. 13(c), when compression molding is performed, coils are placed into the core material such that the upper core 11 makes up for the outer portion of the removed coil member 20 in the lower core 12b. It becomes a shape in which the member 20 is embedded. In this example, the second sheet member 35 is not provided, but the insulating coating of the coil member 20 is protected at least on the first sheet member 34 side. In particular, the side pressed by the uncured core material is highly likely to be subjected to point concentration pressure of the metal magnetic powder. You can enjoy the effect of disclosure.

FIG. 14 is FIG. 7 showing the manufacturing process of the inductor 100 according to the embodiment. The example of FIG. 14 is the same as the example of FIG. 13 except that a second sheet member 35 is provided on the side of the lower core 12b. That is, after the second sheet member 35 is laminated on the lower core 12b in FIG. 14(a), FIG. 14(b) corresponds to FIG. 13(b), and FIG. 14(d) corresponds to FIG. 13(c). Therefore, the description of FIG. 14 is omitted by referring to the description of FIG.

As described above, the inductor 100 according to the embodiment can be manufactured by various methods.

[Effects, etc.]
As described above, the inductor 100 according to the present embodiment includes the coil member 20 around which the conductive wire is wound, the magnetic powder, and the binder that binds the magnetic powder, and the coil member 20 is embedded. a coil protector 31 that overlaps at least a portion of the core member 10 and the coil member 20 when viewed in the axial direction along the winding axis of the coil member 20 and is disposed between the coil member 20 and the core member 10; an insulating sheet member 30 that does not overlap with the coil member 20 when viewed from the axial direction and has a gap portion 32 sandwiched between the core members 10 .

In such an inductor 100 , a coil protection portion 31 that protects the coil member 20 is formed by the sheet member 30 . As a result, the coil protection portion 31 disperses the external force applied to the coil member 20, thereby suppressing damage caused by the external force. Therefore, in the inductor 100, damage to the insulating coating of the coil member 20 is suppressed, and the reliability of the coil member 20 is improved. This provides an inductor 100 that is more suitable for use.

Further, for example, the gap portion 32a may be in contact with the coil protection portion 31 when viewed from the axial direction inside the coil member 20 (that is, on the winding shaft side of the winding portion).

According to this, the magnetic resistance of the inductor 100 can be adjusted based on the configuration of the gap portion 32a.

Further, for example, the gap portion 32a may be spaced apart from the coil protection portion 31 when viewed from the axial direction on the outer side of the coil member 20 (that is, the side opposite to the winding axis of the winding portion).

Also, for example, the sheet member 30 may include a filler 33, and the filler 33 may be made of a material containing a magnetic substance.

According to this, since the filler 33 suppresses a decrease in magnetic permeability even when the gap portion 32 is interposed, a decrease in magnetic characteristics is suppressed even in the inductor 100 using the sheet member 30. That is, the sheet Although the member 30 is used, the inductor 100 having excellent magnetic characteristics can be realized.

Further, the inductor 100 according to the present embodiment includes, for example, a coil member 20 around which a conductive wire is wound, magnetic powder, and a binder that binds the magnetic powder, and the coil member 20 is embedded. and an insulating sheet member 30, wherein the sheet member 30 overlaps at least a part of the coil member 20 when viewed from the axial direction along the winding axis of the coil member 20. 34, which overlaps at least a portion of the coil member 20 when viewed in the axial direction with the first sheet member 34 disposed between the coil member 34 and the core member 10 on one side of the coil member 20 in the axial direction. A second sheet member 35 arranged between the coil member 20 and the core member 10 on the other side of the coil member 20 in the axial direction may also be included.

According to this, the sheet member 30 can be realized by two independent members, the first sheet member 34 and the second sheet member 35 . As a result, the coil protection portion 31 in the sheet member 30 including the first sheet member 34 and the second sheet member 35 disperses the external force applied to the coil member 20, thereby suppressing damage caused by the external force. can be done. Therefore, in the inductor 100, damage to the insulating coating of the coil member 20 is suppressed, and the reliability of the coil member 20 is improved. This provides an inductor 100 that is more suitable for use.

Further, for example, in a cross-sectional view along the axial direction of the inductor 100, the space provided in the core member 10 in which the coil member 20 is accommodated decreases in diameter from the central portion toward the end portions in the axial direction of the coil member 20. It may be tapered.

According to this, due to the tapered shape, there is a space for the sheet member 30 to enter and escape in the side (and inner side) portion in the space of the core member 10, which is the portion corresponding to the tapered inclined surface. is ensured. Thereby, the gap formed between the sheet member 30 and the core member 10 is reduced, and the insertion of the coil member 20 is facilitated.

Also, for example, the sheet member 30 may be made of a stretchable material.

With this, the followability of the sheet member 30 is improved, so the gap formed between the sheet member 30 and the core member 10 is reduced.

Also, for example, the sheet member 30 may be made of a heat-resistant material.

According to this, it is possible to suppress defects such as the generation of voids due to deformation of the sheet member 30 during the mounting process such as reflow.

Also, for example, the sheet member 30 may be made of an adhesive material.

According to this, problems such as the inductor 100 cracking at the boundary of the sheet member 30 can be suppressed.

Further, in the method of manufacturing the inductor 100 according to the present embodiment, a pair of core materials containing magnetic powder and a binder for binding the magnetic powder are prepared, and at least one of the pair of core materials is coated with a sheet. A coil member 20 having a conductive wire wound thereon is arranged between a pair of core materials via the laminated sheet members 30, and the pair of core materials and the sheet members 30 are arranged. , and the coil member 20 are compression molded.

According to this, the inductor 100 having the effects described above can be manufactured.

Also, for example, at least one of the pair of core materials may be pre-cured according to the shape of the coil member 20 to be arranged.

According to this, the inductor 100 can be manufactured using the hardened core material.

Further, for example, the sheet members 30 are laminated on a pair of core materials after the coil members 20 are placed on one of the pair of pre-cured core materials, over the coil members 20 . may be broken.

According to this, the inductor 100 can be manufactured by laminating the sheet member 30 over the coil member 20 on the core material after the coil member 20 is arranged.

Also, for example, the lamination of the sheet member 30 on the pair of core materials and the compression molding of the pair of core materials, the sheet member 30 and the coil member 20 may be performed at the same time.

According to this, the number of man-hours involved in manufacturing the inductor 100 can be reduced.

Further, for example, a part of the laminated sheet member 30 may be removed before compression molding of the pair of core material, sheet member 30 and coil member 20 .

According to this, the magnetic resistance of the inductor 100 can be adjusted by controlling the shape of the gap portion 32 .

The inductor according to the present disclosure is industrially useful as an inductor used in electronic equipment and the like.

Reference Signs List 10

core member

11, 11a

upper core

12, 12a, 12b lower core 20

coil member

30, 30a, 30b sheet member 31

coil protection portion

32, 32a, 32b, 32c gap portion 33

filler

34, 34a first sheet member 34b removed portion 34c first insulating layer 34d first

adhesive layer

35, 35a second sheet member 35b removed portion

35c insulating layer

35d adhesive layer 40 terminal member 100 inductor

Claims

a coil member around which a conductive wire is wound;
a core member including magnetic powder and a binder that binds the magnetic powder, in which the coil member is embedded;
a coil protection portion overlapping at least a portion of the coil member and disposed between the coil member and the core member when viewed in the axial direction along the winding axis of the coil member; and and an insulating sheet member having a gap portion sandwiched between the core members without overlapping with the coil member.
The electronic component according to claim 1, wherein the gap portion is in contact with the coil protection portion inside the coil member when viewed from the axial direction.
The electronic component according to claim 1, wherein the gap portion is located outside the coil member and separated from the coil protection portion when viewed in the axial direction.
The sheet member includes a filler,
The electronic component according to any one of claims 1 to 3, wherein the filler is made of a material containing a magnetic substance.
a coil member around which a conductive wire is wound;
a core member including magnetic powder and a binder that binds the magnetic powder, in which the coil member is embedded;
an insulating sheet member;
The sheet member is
A first sheet member that overlaps at least a portion of the coil member when viewed in an axial direction along the winding axis of the coil member, wherein the coil member and the core member are arranged on one side of the coil member in the axial direction. a first sheet member disposed between;
A second sheet member overlapping at least a portion of the coil member when viewed in the axial direction, the second sheet member being disposed between the coil member and the core member on the other side of the coil member in the axial direction. A sheet member, and an electronic component.
In a cross-sectional view along the axial direction of the electronic component, the space provided in the core member in which the coil member is accommodated is tapered from the central portion toward the end portions in the axial direction of the coil member. The electronic component according to any one of claims 1 to 5, which has a shape.
The electronic component according to any one of claims 1 to 6, wherein the sheet member is made of a stretchable material.
The electronic component according to any one of claims 1 to 7, wherein the sheet member is made of a heat-resistant material.
The electronic component according to any one of claims 1 to 8, wherein the sheet member is made of an adhesive material.
preparing a pair of core materials containing magnetic powder and a binder that binds the magnetic powder;
laminating a sheet member on at least one of the pair of core materials;
Disposing a coil member around which a conductive wire is wound between the pair of core materials via the laminated sheet members,
A method of manufacturing an electronic component, wherein the pair of core materials, the sheet member, and the coil member are compression-molded.
11. The method of manufacturing an electronic component according to claim 10, wherein at least one of the pair of core materials is pre-cured to match the shape of the coil member to be arranged.
Lamination of the sheet member to the pair of core materials is performed over the coil member after the coil member has been placed against one of the pair of pre-cured core materials. The method for manufacturing an electronic component according to claim 11.
Lamination of the sheet member on the pair of core materials, and compression molding of the pair of core materials, the sheet member, and the coil member are performed at the same time. A method for manufacturing the described electronic component.
The electronic device according to any one of claims 10 to 13, further comprising removing a part of the laminated sheet members before compression molding of the pair of core materials, the sheet member, and the coil member. How the parts are made.