Coil structure

Abstract

The coil structure of the present invention includes: a substrate having a coil conductor; a first magnetic core arranged on one main surface side of the substrate; a second magnetic core arranged on the other main surface side of the substrate; and an insulating component formed by an insulating material, wherein the first magnetic core has: a main body extending in a first direction along the main surface of the substrate; a first leg extending from the main body through the substrate and extending toward the second magnetic core; and a second leg extending from the main body through the substrate and extending toward the second magnetic core at a position sandwiching the coil conductor between the first leg in the first direction, wherein the insulating component has: a bottom wall at least respectively located between the first leg and the second magnetic core; and a side wall extending along at least any of the first leg and the second leg and between any of the legs and the coil conductor.

Description

Technical Field

[0001] The present disclosure relates to a coil structure. Background Art

[0002] Conventionally, as a coil structure, there is a known coil structure described in International Publication No. 2018 / 193504. The coil structure includes: a substrate having a coil conductor; a first magnetic core disposed on one side of the substrate; and a second magnetic core disposed on the other side of the substrate. The first magnetic core is an E-type magnetic core, and the second magnetic core is an I-type magnetic core. Summary of the invention

[0003] Here, in the coil structure as described above, it is required to achieve miniaturization and improve performance.

[0004] An object of the present disclosure is to provide a coil structure capable of achieving miniaturization and improving performance.

[0005] The coil structure disclosed in the present invention includes: a substrate having a coil conductor; a first magnetic core arranged on one main surface side of the substrate; a second magnetic core arranged on the other main surface side of the substrate; and an insulating component formed by an insulating material, wherein the first magnetic core has: a main body extending in a first direction along the main surface of the substrate; a first leg extending from the main body through the substrate and extending toward the second magnetic core; and a second leg extending from the main body through the substrate and extending toward the second magnetic core at a position sandwiching the coil conductor between the first leg in the first direction, wherein the insulating component has: a bottom wall at least respectively located between the first leg and the second magnetic core; and a side wall extending along at least any of the first leg and the second leg and located between any of the legs and the coil conductor.

[0006] In the coil structure of the present disclosure, the insulating component has a bottom wall portion respectively between the first leg and the second magnetic core. Thus, the insulating component can adjust the L value of the first magnetic core and the second magnetic core. Here, the insulating component has a side wall portion extending along at least any leg of the first leg and the second leg and between any leg and the coil conductor. In this case, the side wall portion can act as a positioning portion for the first magnetic core. Therefore, when a gap is formed between the first leg of the first magnetic core and the second magnetic core, the fixing, positioning and confirmation of the insulating component can be easily performed. In this way, since the process can be easily performed, the deviation between the components can be prevented and the performance of the coil structure can be improved. In addition, the side wall portion is between any leg and the coil conductor. In this case, when it is necessary to ensure the insulation distance between the leg and the coil conductor, the insulating component is arranged between the leg and the coil conductor, so that the distance between the leg and the coil conductor can be shortened. Thus, the miniaturization of the coil structure can be achieved.

[0007] The pair of first legs may extend from both ends of the main body in the first direction, and the second leg is disposed on the inner circumference of the coil conductor between the pair of first legs. In this case, the coil structure of the present disclosure can be applied to the EI core.

[0008] The insulating member may include a first side wall extending along the inner side surface of the first leg in the first direction and interposed between the first leg and the coil conductor, thereby shortening the distance between the first leg and the coil conductor in the first direction.

[0009] The insulating member may include a second side wall extending along a side surface of the second leg in the first direction and interposed between the second leg and the coil conductor, thereby shortening the distance between the second leg and the coil conductor in the first direction.

[0010] The direction along the main surface of the substrate and intersecting the first direction is defined as the second direction, and the insulating component may include a third side wall portion extending along the side surface of the second leg portion in the second direction and interposed between the second leg portion and the coil conductor. In this case, the distance between the second leg portion and the coil conductor in the second direction can be shortened.

[0011] The insulating member may include an upper wall portion extending in the first direction along the main body portion between the first leg portion and the second leg portion. In this case, the distance between the main body and the coil conductor can be shortened.

[0012] The insulating member may include a fourth side wall extending along the side surface of the first leg portion on the outside in the first direction. In this case, when there is another conductor on the outside in the first direction of the first leg, the distance in the first direction between the conductor and the first leg can be shortened.

[0013] A heat sink may be disposed in the gap between the second leg and the second magnetic core, thereby forming a heat dissipation path between the second leg where heat is easily accumulated and the second magnetic core.

[0014] The insulating component may include a second side wall extending along the side surface of the second leg in the first direction and between the second leg and the coil conductor, the second side wall extending to a position closer to the second magnetic core than the lower surface of the second leg. In this case, the heat sink can be blocked near the end of the second side wall on the second magnetic core side.

[0015] According to the present disclosure, it is possible to provide a coil structure that can achieve miniaturization and improved performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a perspective view showing a coil structure according to an embodiment of the present disclosure.

[0017] Figure 2 It is an expanded stereogram of the coil structure.

[0018] Figure 3 yes Figure 2 An enlarged perspective view of the first magnetic core and the insulating component is shown.

[0019] Figure 4 is along Figure 1 An enlarged cross-sectional view taken along line IV-IV.

[0020] Figure 5 It is an enlarged cross-sectional view of a coil structure of a comparative example. DETAILED DESCRIPTION

[0021] Reference Figure 1 to Figure 4 , illustrating the coil structure of an embodiment of the present disclosure. Figure 1 is a perspective view showing a coil structure 100 according to an embodiment of the present disclosure. Figure 2 is an expanded perspective view of the coil structure 100 . Figure 3 yes Figure 2 An enlarged perspective view of the first magnetic core 1 and the insulating component 3 is shown in FIG. Figure 4 is along Figure 1 An enlarged cross-sectional view taken along line IV-IV.

[0022] like Figure 1 and Figure 2 As shown, the coil structure 100 includes a substrate 50, a first magnetic core 1, a second magnetic core 2 and an insulating component 3. The relative direction of the first magnetic core 1 and the second magnetic core 2 relative to each other is set as the Z-axis direction. In addition, the side of the first magnetic core 1 is set as the positive side in the Z-axis direction. Let the direction perpendicular to the Z-axis direction and along the substrate 50 be the X-axis direction, and the direction perpendicular to the Z-axis direction and the X-axis direction be the Y-axis direction. In addition, in the present embodiment, the X-axis direction corresponds to the "first direction" in the claims, and the Y-axis direction corresponds to the "second direction" in the claims. However, it is not limited to this correspondence.

[0023] The substrate 50 is a plate-shaped member extending in the XY plane. The substrate 50 has a main surface 50a on the positive side in the Z-axis direction and a main surface 50b on the negative side in the Z-axis direction. A rectangular through portion 51 is formed on the substrate 50. In addition, on the substrate 50, a rectangular through portion 52A is formed at a position spaced apart from the through portion 51 toward the negative side in the X-axis direction. On the substrate 50, a rectangular through portion 52B is formed at a position spaced apart from the through portion 51 toward the positive side in the X-axis direction. The substrate 50 has a coil conductor 53 on the main surface 50a. The coil conductor 53 constitutes a winding portion wound into a rectangular shape in a manner surrounding the through portion 51.

[0024] Specifically, if Figure 2As shown, the coil conductor 53 has side portions 53a, 53b, 53c, and 53d. The side portion 53a is arranged on the negative side of the X-axis direction relative to the through portion 51. The side portion 53b is arranged on the positive side of the X-axis direction relative to the through portion 51. The side portion 53c is arranged on the negative side of the Y-axis direction relative to the through portion 51. The side portion 53d is arranged on the positive side of the Y-axis direction relative to the through portion 51. In addition, a portion of the side portions 53c and 53d extends to a position corresponding to the through portions 52A and 52B in the X-axis direction.

[0025] The first magnetic core 1 is an E-shaped magnetic core. The first magnetic core 1 is arranged on the main surface 50a side of the substrate 50. The first magnetic core 1 includes a main body 6, a pair of first legs 7A, 7B, and a second leg 8. The first legs 7A, 7B penetrate the substrate 50 and extend toward the second magnetic core 2. The first legs 7A, 7B are inserted into the through-portions 52A, 52B of the substrate 50. The second leg 8 penetrates the substrate 50 and extends toward the second magnetic core 2. The second leg 8 is inserted into the through-portion 51 of the substrate 50.

[0026] The first leg portions 7A and 7B protrude from the main body 6 toward the negative side in the Z-axis direction. The first leg portion 7A is disposed at the end portion of the main body 6 on the negative side in the X-axis direction. The first leg portion 7B is disposed at the end portion of the main body 6 on the positive side in the X-axis direction. The first leg portion 7A and the first leg portion 7B are spaced apart from each other in the X-axis direction. The second leg portion 8 protrudes from the main body 6 toward the negative side in the Z-axis direction between the first leg portions 7A and 7B. The second leg portion 8 is disposed at a central position in the X-axis direction of the main body 6. The second leg portion 8 is disposed at a position spaced apart from the first leg portion 7A toward the positive side in the X-axis direction. The second leg portion 8 is disposed at a position spaced apart from the first leg portion 7B toward the negative side in the X-axis direction. The first magnetic core 1 will be described in more detail later.

[0027] The second magnetic core 2 is an I-shaped magnetic core. The second magnetic core 2 is arranged on the main surface 50b side of the substrate 50. The second magnetic core 2 is magnetically connected to the first magnetic core 1 via the legs 7A, 7B, and 8. The second magnetic core 2 has a rectangular plate-like shape extending parallel to the XY plane. The second magnetic core 2 has an upper surface 2a, a lower surface 2b, and side surfaces 2c, 2d, 2e, and 2f. The position of the upper surface 2a on the positive side in the Z-axis direction extends parallel to the XY plane. The position of the lower surface 2b on the negative side in the Z-axis direction extends parallel to the XY plane. The side surfaces 2c and 2d extend parallel to the XZ plane at the positive and negative sides in the Y-axis direction, respectively. The positions of the side surfaces 2e and 2f on the positive and negative sides in the X-axis direction extend parallel to the YZ plane.

[0028] The insulating component 3 is a component formed of an insulating material. The insulating material is a material constituting an insulator, such as a phenolic resin. The insulating component 3 is a component for ensuring insulation between the first magnetic core 1 and other components. In addition, the insulating component 3 is a component that forms a gap between the first leg 7A, 7B of the first magnetic core 1 and the second magnetic core 2 and is capable of positioning the first magnetic core 1. The insulating component 3 includes a pair of storage portions 11A, 11B and a storage portion 12 and a pair of connecting portions 13A, 13B. The first storage portions 11A, 11B are portions that store the first leg 7A, 7B of the first magnetic core 1. The second storage portion 12 is a portion that stores the second leg 8 of the first magnetic core 1. The connecting portion 13A is a portion that connects the first storage portion 11A and the second storage portion 12. The connecting portion 13B is a portion that connects the first storage portion 11B and the second storage portion 12. The insulating component 3 will be described in more detail later.

[0029] Next, refer to Figure 3 , describing the detailed structure of the first magnetic core 1. The main body 6 is a cube having a long side in the X-axis direction. The main body 6 has a lower surface 6a, an upper surface 6b, side surfaces 6c, 6d, and end surfaces 6e, 6f. The lower surface 6a extends parallel to the XY plane at the negative side in the Z-axis direction. The upper surface 6b extends parallel to the XY plane at the positive side in the Z-axis direction. The side surfaces 6c, 6d extend parallel to the XZ plane at the positive and negative sides in the Y-axis direction, respectively. The end surfaces 6e, 6f extend parallel to the YZ plane at the positive and negative sides in the X-axis direction.

[0030] When viewed from the Z-axis direction, the first leg portions 7A and 7B are rectangular in shape. The first leg portions 7A and 7B respectively have side surfaces 7a, 7b, 7c, 7d and a lower surface 7e. The positions of the side surfaces 7a and 7b on the positive and negative sides in the Y-axis direction are respectively extended in parallel with the XZ plane. The positions of the side surfaces 7c and 7d on the outer and inner sides in the X-axis direction are respectively extended in parallel with the YZ plane. The outer side in the X-axis direction refers to the end surfaces 6e and 6f sides based on the long side direction of the main body 6. The position of the lower surface 7e on the negative side in the Z-axis direction of the substrate 50 is extended in parallel with the XY plane. In the present embodiment, the side surfaces 7a and 7b of the first leg portions 7A and 7B are respectively in the same plane with the side surfaces 6c and 6d of the main body 6. The side surface 7c of the first leg portion 7A is in the same plane with the end surface 6e of the main body 6. The side surface 7c of the first leg portion 7B is in the same plane with the end surface 6f of the main body 6.

[0031] When viewed from the Z-axis direction, the second leg 8 is rectangular in shape. The second leg 8 has side surfaces 8a, 8b, 8c, 8d and a lower surface 8e, respectively. The side surfaces 8a, 8b extend parallel to the XZ plane at respective positions on the positive and negative sides in the Y-axis direction. The side surfaces 8c, 8d extend parallel to the YZ plane at respective positions on the positive and negative sides in the X-axis direction. The lower surface 8e extends parallel to the XY plane at a position on the negative side in the Z-axis direction of the substrate 50. In the present embodiment, the side surfaces 8a, 8b of the second leg 8 are respectively in the same plane as the side surfaces 6c, 6d of the main body 6. Among them, the shapes of the first leg 7A, 7B and the second leg 8 and their positional relationship with the main body 6 are not particularly limited.

[0032] The lower surface 7e of the first leg 7A, 7B of the first core portion 1 and the lower surface 8e of the second leg 8 are arranged close to each other in parallel with the upper surface 2a of the second core portion 2. In addition, the lower surface 7e of the first leg 7A, 7B and the lower surface 8e of the second leg 8 are located at the same position in the Z-axis direction, but may be slightly offset.

[0033] Next, refer to Figure 3 and Figure 4 , the detailed structure of the insulating component 3 is described. The insulating component 3, the first magnetic core 1 and the second magnetic core 2 have a linearly symmetrical structure with respect to the center line in the X-axis direction when viewed from the Y-axis direction. Therefore, although Figure 4 Only the structure on the negative side in the X-axis direction is shown, but the structure on the positive side in the X-axis direction also has the same structure. In the following description, the state where the insulating component 3 is assembled to the first magnetic core 1 is described ( Figure 1 and Figure 4 status shown).

[0034] like Figure 3 As shown, the storage portion 11A includes a side wall portion 21 (side wall portion, first side wall portion), a side wall portion 22 (fourth side wall portion), side walls 23 and 24 (side wall portions), and a bottom wall portion 25 .

[0035] The side wall portion 21 of the storage portion 11A extends along the side surface 7d on the inner side of the first leg portion 7A in the X-axis direction, and is interposed between the first leg portion 7A and the coil conductor 53. The side wall portion 21 extends parallel to the YZ plane at a position on the positive side of the side surface 7d in the X-axis direction so as to cover the side surface 7d. The side wall portion 21 of the storage portion 11A is interposed between the side surface 7d and the edge of the through portion 51 and the side portion 53a of the coil conductor 53 (see Figure 2 )between.

[0036] The side wall 22 of the storage portion 11A extends along the outer side surface 7c of the first leg portion 7A in the X-axis direction. The side wall 22 extends parallel to the YZ plane at the negative side of the side surface 7c in the X-axis direction to cover the side surface 7c.

[0037] The side wall portion 23 of the storage portion 11A extends along the side surface 7a on the positive side in the Y-axis direction of the first leg portion 7A. The side wall portion 23 extends parallel to the XZ plane in a manner that covers the side surface 7a at a position on the positive side in the Y-axis direction relative to the side surface 7a. Both ends of the side wall portion 23 in the X-axis direction are connected to the ends of the side walls 21 and 22 on the positive side in the Y-axis direction, respectively. The side wall portion 23 of the storage portion 11A is located between the side surface 7a and the edge of the through portion 52A and the extended portion of the side portion 53d of the coil conductor 53 (see Figure 2 Therefore, in the present embodiment, the side wall portion 23 of the storage portion 11A is interposed between the first leg portion 7A and the coil conductor 53.

[0038] The side wall portion 24 of the storage portion 11A extends along the side surface 7b on the negative side in the Y-axis direction of the first leg portion 7A. The side wall portion 24 extends parallel to the XZ plane in a manner that covers the side surface 7b at a position on the negative side in the Y-axis direction relative to the side surface 7b. Both ends of the side wall portion 24 in the X-axis direction are connected to the negative ends of the side walls 21 and 22 in the Y-axis direction, respectively. The side wall portion 24 of the storage portion 11A is located between the side surface 7b and the edge of the through portion 52A and the extended portion of the side portion 53c of the coil conductor 53 (see Figure 2 Therefore, in the present embodiment, the side wall portion 24 of the storage portion 11A is interposed between the first leg portion 7A and the coil conductor 53.

[0039] The bottom wall portion 25 of the storage portion 11A extends along the lower surface 7e of the first leg portion 7A. The bottom wall portion 25 is between the first leg portion 7A and the second magnetic core 2. The bottom wall portion 25 extends parallel to the XY plane in a manner covering the lower surface 7e at a position on the negative side in the Z-axis direction relative to the lower surface 7e. The bottom wall portion 25 contacts the lower surface 7e of the first leg portion 7A on the upper surface side, and contacts the upper surface 2a of the second magnetic core 2 on the lower surface side. The two ends of the bottom wall portion 25 in the X-axis direction are respectively connected to the ends of the side walls 21 and 22 on the negative side in the Z-axis direction. The two ends of the bottom wall portion 25 in the Y-axis direction are respectively connected to the ends of the side walls 23 and 24 on the negative side in the Z-axis direction.

[0040] The storage portion 11B includes a side wall portion 21 (side wall portion, first side wall portion), a side wall portion 22 (fourth side wall portion), side walls 23 and 24 (side wall portion, third side wall portion), and a bottom wall portion 25. The storage portion 11B has the same structure as the storage portion 11A, except that the side wall portion 21 is arranged on the negative side in the X-axis direction relative to the second leg portion 8, and the side wall portion 22 is arranged on the positive side in the X-axis direction relative to the second leg portion 8.

[0041] The storage portion 12 includes side wall portions 31 and 32 (side wall portions, second side wall portions) and side wall portions 33 and 34 (side wall portions, third side wall portions).

[0042] The side wall portion 31 of the storage portion 12 extends along the side surface 8c on the negative side in the X-axis direction of the second leg portion 8 and is interposed between the second leg portion 8 and the coil conductor 53. The side wall portion 31 extends parallel to the YZ plane at a position on the negative side in the X-axis direction relative to the side surface 8c so as to cover the side surface 8c. The side wall portion 31 of the storage portion 12 is interposed between the side surface 8c and the edge of the through portion 51 and the side portion 53a of the coil conductor 53 (see Figure 2 )between.

[0043] The side wall portion 32 of the storage portion 12 extends along the side surface 8d on the positive side of the second leg portion 8 in the X-axis direction, and is interposed between the second leg portion 8 and the coil conductor 53. The side wall portion 32 extends parallel to the YZ plane in a manner covering the side surface 8d at a position on the positive side of the side surface 8d in the X-axis direction. The side wall portion 32 of the storage portion 12 is interposed between the side surface 8d and the edge of the through portion 51 and the side portion 53b of the coil conductor 53 (see Figure 2 )between.

[0044] The side wall portion 33 of the storage portion 12 extends along the side surface 8a on the positive side in the Y-axis direction of the second leg portion 8, and is interposed between the second leg portion 8 and the coil conductor 53. The side wall portion 33 extends parallel to the XZ plane in a manner covering the side surface 8a at a position on the positive side in the Y-axis direction relative to the side surface 8a. Both ends of the side wall portion 33 in the X-axis direction are connected to the ends of the side walls 31 and 32 on the positive side in the Y-axis direction, respectively. The side wall 33 of the storage portion 12 is interposed between the side surface 8a and the edge of the through portion 51 and the side portion 53d of the coil conductor 53 (see Figure 2 )between.

[0045] The side wall portion 34 of the storage portion 12 extends along the side surface 8b on the negative side in the Y-axis direction of the second leg portion 8 and is interposed between the second leg portion 8 and the coil conductor 53. The side wall portion 34 extends parallel to the XZ plane in a manner covering the side surface 8b at a position on the negative side in the Y-axis direction relative to the side surface 8b. Both ends of the side wall portion 34 in the X-axis direction are connected to the ends of the side walls 31 and 32 on the negative side in the Y-axis direction, respectively. The side wall portion 34 of the storage portion 12 is interposed between the side surface 8b and the edge of the through portion 51 and the side portion 53c of the coil conductor 53 (see Figure 2 )between.

[0046] The ends of the negative side of the side walls 31, 32, 33, and 34 in the Z-axis direction are free ends without a bottom wall. Thus, an opening 35 is formed on the bottom side of the storage portion 12. The lower surface 8e of the second leg 8 and the upper surface 2a of the second core 2 are spaced apart from each other in the Z-axis direction via the opening 35. Thus, a gap GP is formed between the second leg 8 and the second core 2. Figure 4 As shown, a heat sink 60 is arranged in the gap GP. The heat sink 60 is in contact with the lower surface 8e of the second leg 8 and the upper surface 2a of the second magnetic core 2. The heat sink 60 is formed to thermally connect the lower surface 8e of the second leg 8 and the upper surface 2a of the second magnetic core 2. The heat sink 60 is formed by filling the gap GP in a fluid state and solidifying. The heat sink 60 is made of a material having a higher thermal conductivity than the insulating component 3 and a general gap sheet, such as a gap filler.

[0047] Each side wall portion 31, 32, 33, 34 extends to a position closer to the second magnetic core 2 side (i.e., the negative side in the Z-axis direction) than the substrate 50 and the lower surface 8e of the second leg portion 8. The lower end portions of the side wall portions 31, 32, 33, 34 are arranged at a position slightly separated from the upper surface 2a of the second magnetic core 2. Thus, each side wall portion 31, 32, 33, 34 protrudes from the edge portions of the four sides of the lower surface 8e in the Z-axis direction. Each side wall portion 31, 32, 33, 34 is arranged to surround and define a gap GP. Therefore, when the heat sink 60 is filled in the gap GP, the side wall portions 31, 32, 33, 34 can suppress the heat sink 60 from flowing out before solidification.

[0048] like Figure 3 As shown, the connection portion 13A includes an upper wall portion 41 and side wall portions 43, 44. The connection portion 13B includes an upper wall portion 41 and side wall portions 43, 44. Since the configuration of the connection portion 13B is the same as that of the connection portion 13A, the description thereof will be omitted.

[0049] The upper wall portion 41 extends in the X-axis direction along the main body 6 between the first leg portion 7A and the second leg portion 8. The upper wall portion 41 is interposed between the main body 6 and the coil conductor 53. The upper wall portion 41 extends parallel to the XY plane at a position on the negative side in the Z-axis direction relative to the lower surface 6a of the main body 6 so as to cover the lower surface 6a. Both ends of the upper wall portion 41 in the X-axis direction are connected to the ends of the side walls 21 and 31 on the positive side in the Z-axis direction, respectively. The upper wall portion 41 is interposed between the lower surface portion 6a and the side portion 53a of the coil conductor 53 (see Figure 2 ).

[0050] The side wall portion 43 rises from the end portion of the upper wall portion 41 on the positive side in the Y-axis direction toward the positive side in the Z-axis direction. The side wall portion 43 is opposite to the side surface 6c of the main body portion 6 in the Y-axis direction. The side wall portion 43 is connected to the side wall portions 23 and 33 in a manner that forms the same surface as the side wall portions 23 and 33. The side wall portion 44 rises from the end portion of the upper wall portion 41 on the negative side in the Y-axis direction toward the positive side in the Z-axis direction. The side wall portion 44 is opposite to the side surface 6d of the main body portion 6 in the Y-axis direction. The side wall portion 44 is connected to the side wall portions 24 and 34 in a manner that forms the same surface as the side wall portions 24 and 34.

[0051] Next, the operation and effects of the coil structure 100 of the present embodiment will be described.

[0052] In the coil structure 100 of the present disclosure, the insulating member 3 has the bottom wall portion 25 interposed between the pair of first leg portions 7A, 7B and the second magnetic core 2. Thus, the insulating member 3 can adjust the L value of the first leg portions 7A, 7B and the second magnetic core 2.

[0053] Here, in Figure 5 In the coil structure of the comparative example shown, a gap piece 130 is used to adjust the gap between the first leg portions 7A, 7B and the second magnetic core 2. However, when such a gap piece 130 is used, it is difficult to position and fix the first magnetic core 1 to the gap piece 130. Therefore, the position of the first magnetic core 1 relative to the second magnetic core 2 may be offset. In addition, it becomes difficult to confirm the positional offset.

[0054] In the present embodiment, the insulating component 3 has side walls 21, 23, 24, 31, 32, 33, 34 extending along a pair of first legs 7A, 7B and a second leg 8 and interposed between these legs 7A, 7B, 8 and the coil conductor 53. In this case, the side walls 21, 23, 24, 31, 32, 33, 34 can function as positioning portions relative to the first magnetic core 1. Therefore, when a gap is formed between the first legs 7A, 7B of the first magnetic core body 1 and the second magnetic core 2, the insulating component 3 can be easily fixed, positioned, and confirmed. As described above, since this process can be easily performed, it is possible to prevent deviation between components, etc., and improve the performance of the coil structure 100.

[0055] Here, for example, in the structure of a DCDC converter for an automobile, from the perspective of safety standards, the magnetic cores 1, 2 and the coil conductor 53 should all be set to the voltage of the primary side of the circuit (dangerous voltage). However, in order to dissipate heat from the magnetic cores 1, 2, they must be in contact with a heat dissipation component (disposed on the lower surface side of the second magnetic core 2). Therefore, a portion of the coil conductor 53 becomes the voltage of the primary side, and the magnetic core wires 1, 2 become the voltage of the secondary side (safe voltage). Here, the safety distance standard of the DCDC converter can be determined to, for example, 2.6 mm. Figure 5 In the coil structure of the comparative example shown, only a space is formed between the coil conductor 53 and the first magnetic core 1. Therefore, a standard safety distance needs to be ensured between the coil conductor 53 and each side surface of the leg portions 7A, 7B, and 8. Figure 5 The distances shown must be large enough to ensure that the distance between the side surface 7d of the first leg 7A and the coil conductor 53, the distance between the second leg 8 and the coil conductor 53, and the distance between the lower surface 6a of the body 6 and the coil conductor 53 are large. This causes a problem that the coil structure becomes larger.

[0056] In the present embodiment, the side walls 21, 23, 24, 31, 32, 33, 34 are interposed between the legs 7A, 7B, 8 and the coil conductor 53. In this case, the insulating member 3 is disposed between the legs 7A, 7B, 8 and the coil conductor 53, so that the distance between the legs 7A, 7B, 8 and the coil conductor 53 can be shortened. Thus, the coil structure 100 can be miniaturized.

[0057] The pair of first legs 7A and 7B extend from both ends of the body 6 in the X-axis direction, and the second leg 8 may be disposed between the pair of first legs 7A and 7B on the inner circumference of the coil conductor 53. In this case, the coil structure 100 of the present disclosure may be applied to an EI core.

[0058] The insulating member 3 has a side wall portion 21 extending along the inner side surface 7d of the first leg portions 7A, 7B in the X-axis direction and interposed between the first leg portions 7A, 7B and the coil conductor 53. Thus, the distance between the first leg portions 7A, 7B and the coil conductor 53 in the X-axis direction can be shortened.

[0059] The insulating member 3 has side walls 31 and 32 extending along the side surfaces 8c and 8d of the second leg 8 in the X-axis direction and interposed between the second leg 8 and the coil conductor 53. Thus, the distance between the second leg 8 and the coil conductor 53 in the X-axis direction can be shortened.

[0060] The insulating member 3 has side walls 33 and 34 extending along the side surfaces 8a and 8b of the second leg 8 in the Y-axis direction and interposed between the second leg 8 and the coil conductor 53. In this case, the distance between the second leg 8 and the coil conductor 53 in the Y-axis direction can be shortened.

[0061] The insulating member 3 has an upper wall portion 41 extending in the X-axis direction along the main body portion 6 between the first leg portions 7A, 7B and the second leg portion 8. In this case, the distance between the main body portion 6 and the coil conductor 53 can be shortened.

[0062] The insulating member 3 has a side wall portion 22 extending along the side surface 7c on the outside of the first leg portions 7A and 7B in the X-axis direction. In this case, when there is another conductor on the outside of the first leg portions 7A and 7B in the X-axis direction, the distance between the conductor and the first leg portions 7A and 7B in the X-axis direction can be shortened.

[0063] The heat sink 60 may be disposed in the gap GP between the second leg portion 8 and the second magnetic core 2. Thus, a heat dissipation path can be formed between the second leg portion 8 and the second magnetic core 2, where heat is easily accumulated.

[0064] The insulating member 3 has side walls 31 and 32 extending along the side surfaces 8c and 8d in the X-axis direction of the second leg portion 8 and interposed between the second leg portion 8 and the coil conductor 53. The side walls 31 and 32 extend to a position closer to the second magnetic core 2 than the lower surface 8e of the second leg portion 8. In this case, the heat sink 70 can be sealed near the end of the side walls 31 and 32 on the second magnetic core 2 side.

[0065] The present disclosure is not limited to the above-described embodiments.

[0066] The structure of the insulating member 3 is not limited to the above-described embodiment. For example, the side wall portions 22, 23, 24, 43, 44 may be omitted from the insulating member 3. In addition, the insulating member 3 only needs to have at least one side wall portion extending along at least any of the first leg portion and the second leg portion and interposed between any of the legs and the coil conductor 53.

[0067] In the above-mentioned embodiments, the EI core has been exemplified and described. However, the coil structure of the present disclosure is not particularly limited in the type of the core, and can be applied to a UI core, an EE core, a UU core, etc.

[0068] The coil structure in the case of the UI core is a structure in which the first leg portion 7B and the corresponding insulating member 3 are removed from the above-mentioned embodiment. Specifically, the first leg portion 7B and the portion of the main body portion 6 that is closer to the positive side of the X-axis direction than the second leg portion 8 are omitted from the first core portion 1, thereby forming a U-shaped first core. In addition, the first housing portion 11B and the connecting portion 13B can be omitted from the insulating member 3.

[0069] In the case of the EE core, in the above embodiment, as the second magnetic core, an E-shaped core having the same structure as the first core 1 is used instead of the I-shaped core. In this case, the second core is configured to turn the first core 1 upside down in the Z-axis direction. Thus, the legs 7A, 7B, 8 of the first core 1 are connected to the legs 7A, 7B, 8 of the second core. In addition, an insulating component 3 may also be provided for the second core. The coil structure in the case of the UU core is a structure in which the U-shaped core described in the UI core is used as the first coil and the second coil.

[0070] Description of Reference Numerals

[0071] 1…first magnetic core, 2…second magnetic core, 3…insulating component, 7A, 7B…first leg, 6…main body, 7A, 7B…first leg, 8…second leg, 21…side wall (side wall, first side wall), 22…side wall (fourth side wall), 23, 24…side wall (side wall), 25…bottom wall, 31, 32…side wall (side wall, second side wall), 33, 34…side wall (side wall, third side wall), 41…upper wall, 100…coil structure.

Claims

1. A coil structure, characterized in that: include: a substrate having a coil conductor; A first magnetic core disposed on one main surface side of the substrate; a second magnetic core disposed on the other main surface side of the substrate; and Insulating parts made of insulating materials, The first magnetic core has: a main body portion extending in a first direction along a main surface of the substrate; a first leg portion, which passes through the substrate from the main body and extends toward the second magnetic core; and a second leg portion extending from the main body portion through the substrate toward the second magnetic core at a position sandwiching the coil conductor between the first leg portion and the first leg portion in the first direction; The insulating component comprises: A bottom wall portion at least respectively disposed between the first leg portion and the second magnetic core; and a side wall portion extending along at least any one of the first leg portion and the second leg portion and interposed between the any one of the legs and the coil conductor, The second leg portion and the second magnetic core face each other across the opening portion and form a gap. A heat sink is disposed in the gap between the second leg portion and the second magnetic core.

2. The coil structure according to claim 1, characterized in that: A pair of the first legs extend from both ends of the main body in the first direction. The second leg portion is arranged on the inner peripheral side of the coil conductor between the pair of the first leg portions.

3. The coil structure according to claim 1, characterized in that: The insulating member includes a first side wall portion extending along an inner side surface of the first leg portion in the first direction and interposed between the first leg portion and the coil conductor.

4. The coil structure according to claim 2, characterized in that: The insulating member includes a first side wall portion extending along an inner side surface of the first leg portion in the first direction and interposed between the first leg portion and the coil conductor.

5. The coil structure according to claim 1, characterized in that: The insulating member has a second side wall portion extending along a side surface of the second leg portion in the first direction and interposed between the second leg portion and the coil conductor.

6. The coil structure according to claim 2, characterized in that: The insulating member has a second side wall portion extending along a side surface of the second leg portion in the first direction and interposed between the second leg portion and the coil conductor.

7. The coil structure according to claim 3, characterized in that: The insulating member has a second side wall portion extending along a side surface of the second leg portion in the first direction and interposed between the second leg portion and the coil conductor.

8. The coil structure according to claim 4, characterized in that: The insulating member has a second side wall portion extending along a side surface of the second leg portion in the first direction and interposed between the second leg portion and the coil conductor.

9. The coil structure according to any one of claims 1 to 8, characterized in that: Let a direction along the main surface of the substrate and intersecting the first direction be a second direction, The insulating member has a third side wall portion extending along a side surface of the second leg portion in the second direction and interposed between the second leg portion and the coil conductor.

10. The coil structure according to any one of claims 1 to 8, characterized in that: The insulating member has an upper wall portion extending in the first direction along the main body portion between the first leg portion and the second leg portion.

11. The coil structure according to claim 9, characterized in that: The insulating member has an upper wall portion extending in the first direction along the main body portion between the first leg portion and the second leg portion.

12. The coil structure according to any one of claims 1 to 8, characterized in that: The insulating member includes a fourth side wall portion extending along a side surface of the first leg portion on the outer side in the first direction.

13. The coil structure according to claim 9, characterized in that: The insulating member includes a fourth side wall portion extending along a side surface of the first leg portion on the outer side in the first direction.

14. The coil structure according to claim 10, characterized in that: The insulating member includes a fourth side wall portion extending along a side surface of the first leg portion on the outer side in the first direction.

15. The coil structure according to claim 11, characterized in that: The insulating member includes a fourth side wall portion extending along a side surface of the first leg portion on the outer side in the first direction.

16. The coil structure according to claim 1, characterized in that: The insulating member includes a second side wall portion extending along a side surface of the second leg portion in the first direction and interposed between the second leg portion and the coil conductor. The second side wall portion extends to a position closer to the second core than a lower surface of the second leg portion.

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