Magnetic component and electronic device

Abstract

The magnetic component is configured to be used with a coil wound around a central axis along an axial direction. The magnetic component includes first to third magnetic elements. The first magnetic element is configured to pass magnetic flux generated by the coil therethrough, extends in the axial direction to have a first end portion and a second end portion in the axial direction, and has a portion overlapping the coil when viewed from a direction perpendicular to the axial direction. The second magnetic element is disposed on an opposite side of the coil from the first end portion of the first magnetic element in the axial direction. The third magnetic element is disposed on an opposite side of the coil from the second magnetic element in the axial direction. The third magnetic element has a magnetic anisotropy greater than a magnetic anisotropy of each of the first and second magnetic elements, and has an easy magnetization direction along which the third magnetic element is more easily magnetized than in other directions. The easy magnetization direction of the third magnetic element is perpendicular to the axial direction. The magnetic component can help reduce magnetic loss.

Description

Technical Field

[0001] This disclosure relates to magnetic components used with coils, and electronic devices including such magnetic components. Background Technology

[0002] Patent document 1 discloses a coil element. The coil element is, for example, a multilayer inductor. The coil element includes a coil conductor, an isotropic magnetic material layer, an anisotropic magnetic material layer, and a magnetic core.

[0003] An isotropic magnetic material layer is disposed on at least one of the upper and lower surfaces of the coil conductor. An anisotropic magnetic material layer is disposed on the surface of the isotropic magnetic material layer opposite to the coil conductor. The anisotropic magnetic material layer is made of a first anisotropic magnetic material having an easy magnetization direction perpendicular to the stacking direction of the isotropic and anisotropic magnetic material layers. A magnetic core is disposed inside the coil conductor. The magnetic core is made of a second anisotropic magnetic material having an easy magnetization direction parallel to the stacking direction of the isotropic and anisotropic magnetic material layers.

[0004] Reference List

[0005] Patent documents

[0006] Patent Document 1: JP 2018-125527 A Summary of the Invention

[0007] A magnetic component is configured for use with a coil wound around a central axis along an axial direction. The magnetic component includes a first magnetic element to a third magnetic element. The first magnetic element is configured such that magnetic flux generated by the coil passes through it. The first magnetic element extends axially to have a first end and a second end in the axial direction. When viewed from a direction perpendicular to the axial direction, the first magnetic element has a portion overlapping the coil. A second magnetic element is disposed axially on the opposite side of the coil relative to the first end of the first magnetic element. A third magnetic element is disposed axially on the opposite side of the coil relative to the second magnetic element. The magnetic anisotropy of the third magnetic element is greater than that of each of the first and second magnetic elements. The third magnetic element has an easy magnetization direction along which it is more easily magnetized compared to other directions. The easy magnetization direction of the third magnetic element is perpendicular to the axial direction.

[0008] This magnetic component helps reduce magnetic loss. Attached Figure Description

[0009] Figure 1A This is a perspective view of an electronic device according to an embodiment;

[0010] Figure 1B It is along Figure 1A Cross-sectional view of electronic devices using the IB-IB line;

[0011] Figure 2 The magnetic flux generated in the electronic device according to the embodiment is shown;

[0012] Figure 3 A method for manufacturing an electronic device according to an embodiment is shown;

[0013] Figure 4 The materials used in a method of manufacturing an electronic device according to an embodiment are shown;

[0014] Figure 5 The materials used in a method of manufacturing an electronic device according to an embodiment are shown;

[0015] Figure 6A Simulation results of the intensity distribution of magnetic flux density inside the magnetic components of a comparative example electronic device are shown;

[0016] Figure 6B Simulation results of the intensity distribution of magnetic flux density inside the magnetic components of a comparative example electronic device are shown;

[0017] Figure 7 A flowchart illustrating a method for manufacturing an electronic device according to an embodiment is shown;

[0018] Figure 8 A flowchart illustrating another method of manufacturing an electronic device according to an embodiment is shown;

[0019] Figure 9 Simulation results of the intensity distribution of magnetic flux density inside the magnetic component of an electronic device according to an embodiment are shown;

[0020] Figure 10 Simulation results of the intensity distribution of magnetic flux density inside the magnetic component of an electronic device according to an embodiment are shown;

[0021] Figure 11 Simulation results of the intensity distribution of magnetic flux density inside the magnetic component of an electronic device according to an embodiment are shown;

[0022] Figure 12 Simulation results of the intensity distribution of magnetic flux density inside the magnetic component of an electronic device according to an embodiment are shown;

[0023] Figure 13 Simulation results of the intensity distribution of magnetic flux density inside the magnetic component of an electronic device according to an embodiment are shown;

[0024] Figure 14Simulation results of the intensity distribution of magnetic flux density inside the magnetic component of an electronic device according to an embodiment are shown;

[0025] Figure 15 Simulation results of the intensity distribution of magnetic flux density inside the magnetic component of an electronic device according to an embodiment are shown;

[0026] Figure 16 Simulation results of the intensity distribution of magnetic flux density inside the magnetic component of an electronic device according to an embodiment are shown;

[0027] Figure 17 A flowchart of yet another manufacturing method of an electronic device according to an embodiment is shown. Detailed Implementation

[0028] The accompanying drawings describe magnetic components and electronic devices according to embodiments. Note that the embodiments described below are merely examples of various embodiments of this disclosure. Various modifications can be made to the following embodiments based on design, etc., to achieve the objectives of this disclosure. The drawings referenced in the following description of the embodiments are schematic diagrams. The proportions (including thickness) of the various constituent elements shown in the drawings do not necessarily reflect their actual size proportions.

[0029] (1) Overview

[0030] Figure 1A This is a perspective view of the electronic device 100 according to an embodiment. Figure 1B It is along Figure 1A A cross-sectional view of an electronic device 100 with an IB-IB line. The electronic device 100 includes a magnetic component 1 and a coil 2.

[0031] Figure 2 The magnetic flux generated in the electronic device 100 is shown. Figure 3 A method of manufacturing an electronic device 100 is illustrated. The coil 2 includes a winding 20 wound around a virtual central axis A1 along the axial direction X1. The coil 2 is wound around an internal space 21 through which the central axis A1 passes.

[0032] The magnetic component 1 includes magnetic element 11, magnetic element 12 (121, 122) and magnetic element 13 (131, 132). Each of the magnetic elements 11 to 13 is made of magnetic material.

[0033] The magnetic element 11 is disposed on the same layer as the coil 2 along the axial direction X1. That is, when viewed from a direction perpendicular to the axial direction X1, the magnetic element 11 has a portion that overlaps with the coil 2. The magnetic element 11 includes a portion 111 that passes through the internal space 21 surrounded by the coil 2 and a portion 112 that is located outside the coil 2. When viewed from a direction perpendicular to the axial direction X1, each of portions 111 and 112 has a portion that overlaps with the coil 2.

[0034] Along the axial direction X1, the magnetic element 12 is located outside the coil 2 and outside the magnetic element 11. The magnetic element 12 covers the outer surface of the coil 2 along the axial direction X1, that is, the surface of the coil 2 that intersects the axial direction X1.

[0035] In the axial direction X1, magnetic element 13 is located outside magnetic element 12. Magnetic element 13 covers the outer surface of magnetic element 12 in the axial direction X1, that is, the surface of magnetic element 12 away from coil 2. In the axial direction X1, magnetic element 12 is located between coil 2 and magnetic element 13. In the axial direction X1, magnetic element 12 is located between magnetic element 11 and magnetic element 13.

[0036] The magnetic anisotropy of magnetic element 13 is greater than that of each of magnetic elements 11 and 12. The permeability of a magnetic element with magnetic anisotropy varies depending on the direction of the magnetic flux passing through it. For example, the magnitude of the magnetic anisotropy is represented by the ratio of the maximum to the minimum permeability of the magnetic element among the permeability values ​​considered for magnetic flux passing through it in each direction. A larger ratio indicates a greater magnitude of magnetic anisotropy. Magnetic element 13 has an easy magnetization direction along which it is more easily magnetized compared to other directions. One or both of magnetic elements 11 and 12 may have an easy magnetization direction along which they are more easily magnetized compared to other directions. The directionality of the easy magnetization direction of magnetic element 13 is more pronounced than that of magnetic elements 11 and 12.

[0037] In the magnetic component 1, the easy magnetization direction of the magnetic element 13 is perpendicular to the axial direction X1.

[0038] like Figure 2As shown, in the magnetic component 1 and electronic device 100 according to this embodiment, the current flowing through the coil 2 generates a magnetic flux B1. This magnetic flux B1 originates from a portion 111 of the central magnetic element 11, passes through the upper magnetic element 12 (121), the upper magnetic element 13 (131), the upper magnetic element 12, the outer portion 112 of the outer magnetic element 11, the lower magnetic element 12 (122), the lower magnetic element 13 (132), and the lower magnetic element 12 (122), and reaches the portion 111 of the central magnetic element 11. In the magnetic element 13, the magnetic flux B1 is oriented in a direction substantially perpendicular to the axial direction X1. As described above, the easy magnetization direction of the magnetic element 13 is perpendicular to the axial direction X1. Therefore, in the magnetic element 13, the direction of the magnetic flux B1 generated by the current flowing through the coil 2 is consistent with its easy magnetization direction. This helps to increase the effective permeability of the magnetic element 13, thereby increasing the inductance of the magnetic component 1.

[0039] The magnetic anisotropy of magnetic element 11 is less than that of magnetic element 13, and the magnetic anisotropy of magnetic element 12 is less than that of magnetic element 13. Therefore, in both magnetic elements 11 and 12, the magnetic flux B1 generated by the current flowing through coil 2 is less likely to be affected by the easy magnetization direction of the magnetic element. Thus, in magnetic component 1, near the boundary between magnetic elements 11 and 12, it is less likely that the direction of magnetic flux B1 will change significantly due to the easy magnetization direction of the magnetic element. This helps to homogenize the magnetic flux density in magnetic element 11 of magnetic component 1. Therefore, magnetic component 1 helps to reduce magnetic losses.

[0040] (2) Details

[0041] The magnetic component 1 and the electronic device 100 according to this embodiment are described in detail with reference to the accompanying drawings. The electronic device 100 of this embodiment is a so-called inductor 200, which includes: a magnetic core 10 as the magnetic component 1; and a coil 2.

[0042] (2.1) Structure of electronic device 100

[0043] The inductor 200, as an electronic device 100, includes a coil 2 and a magnetic core 10. In this embodiment, the inductor 200 is a metal composite inductor, wherein the coil 2 and the magnetic core 10, which contains magnetic metal powder, are integrally formed. That is, the magnetic core 10 (magnetic component 1) is integrally formed with the coil 2 so that the coil 2 is housed therein. Therefore, the inductor 200 includes a magnetic core 10 as a gapless magnetic core. Figure 1B As shown, there is no gap between the inductor 200 and the magnetic core 10.

[0044] like Figure 3As shown, coil 2 is formed by winding 20, which has a rectangular cross-section and is wound around a virtual central axis A1. Winding 20 is, for example, a flat conductor with an insulating coating. Coil 2 includes an electrode 201 and another electrode 202 configured to be electrically connected to an external power source. Electrode 201 and electrode 202 are respectively disposed at one end and the other end of winding 20. For example, the conductor material can be copper. Winding 20 is wound from electrode 201 around the central axis A1 in a plane such that its diameter gradually decreases in a spiral shape, thus forming a first layer. Then, at the minimum diameter portion of the first layer, winding 20 rises (or falls) in an axial direction X1, which is its thickness direction, to form a step. Then, winding 20 is wound in another plane such that its diameter gradually increases in a spiral shape, thus forming a second layer and connecting to electrode 202. That is, coil 2 includes a spiral winding 20. Having a spiral winding 20 can help reduce the height of the electronic device 100 (inductor 200) including coil 2.

[0045] Coil 2 has a space 21 at its center, in which there is no winding 20 but the central shaft A1 passes through the space 21.

[0046] When electrodes 201 and 202 are connected to an external power source, the power source applies a voltage between electrodes 201 and 202, causing current to flow through coil 2. The current flowing through coil 2 generates a magnetic field around coil 2.

[0047] like Figure 1B As shown, the magnetic core 10 includes magnetic element 11, magnetic element 12 (121, 122) and magnetic element 13 (131, 132).

[0048] As described above, the magnetic element 11 is located in the same layer as the coil 2 in the axial direction X1. In this disclosure, "the same layer as the coil 2" means that it is located in the same plane as the coil 2 when viewed from a direction perpendicular to the axial direction X1. The magnetic element 11 includes a portion 111 disposed inside the coil in a direction perpendicular to the axial direction X1. The portion 111 is part of the magnetic element 11, and the winding 20 of the coil 2 is wound around the portion 111. The magnetic element 11 also includes a portion 112 disposed outside the coil 2 in a direction perpendicular to the axial direction X1. The portion 112 is part of the magnetic element 11 and is disposed outside the winding 20 of the coil 2 when viewed from the axial direction X1. For example, the portion 112 has a rectangular column shape. The magnetic element 11 extends in the axial direction X1 and has a first end 11A and a second end 11B at its opposite ends in the axial direction X1. The portion 111 of the magnetic element 11 extends in the axial direction X1 and has a first end 111A and a second end 111B at its opposite ends in the axial direction X1. A portion 112 of the magnetic element 11 extends along an axial direction X1 and has a first end 112A and a second end 112B at opposite ends along the axial direction X1. The ends 111A and 112A of the portions 111 and 112 of the magnetic element 11 constitute the end 11A of the magnetic element 11. The ends 111B and 112B of the portions 111 and 112 of the magnetic element 11 constitute the end 11B of the magnetic element 11.

[0049] The magnetic element 11 has a thickness D1 along the axial direction X1.

[0050] As described above, magnetic elements 12 (121, 122) are disposed on the outer side of coil 2 and the outer side of magnetic element 11 in the axial direction X1. Magnetic element 12 is located on a different layer than magnetic element 11 in the axial direction X1. Magnetic element 121 is disposed on one side in the axial direction X1. Figure 1B (the upper side of the middle), and covering the outer surface of coil 2 ( Figure 1B The upper surface of the magnetic element 11 and the outer surface of the magnetic element 122 are disposed on the other side along the axial direction X1. Figure 1B (the lower side of the middle), and covering the outer surface of coil 2 ( Figure 1B The lower surface of the coil 12 and the outer surface of the magnetic element 11 are connected. Therefore, the magnetic element 12 covers the two outer surfaces of the coil 2 in the axial direction X1. The magnetic element 121 is directly connected to the end 11A of the magnetic element 11, and in this embodiment, it is directly connected to the ends 111A and 112A of the portions 111 and 112 of the magnetic element 11. The magnetic element 122 is directly connected to the end 11B of the magnetic element 11, and in this embodiment, it is directly connected to the ends 111B and 112B of the portions 111 and 112 of the magnetic element 11.

[0051] Magnetic element 12 has a thickness D2 along the axial direction X1. Magnetic elements 121 and 122 of magnetic element 12 have the same thickness D2.

[0052] As described above, magnetic elements 13 (131, 132) are disposed outside magnetic element 12 along the axial direction X1. Magnetic element 13 is disposed on a different layer from magnetic elements 11 and 12 along the axial direction X1. Magnetic element 131 is disposed on one side along the axial direction X1. Figure 1B The upper side of the magnetic element 12 (part 121) is covered, and the outer surface of the magnetic element 12 (part 121) is also covered. Figure 1B The upper surface of the middle). Magnetic element 132 is disposed on the other side along the axial direction X1 ( Figure 1B (the lower side of the middle), and covers the outer surface of the magnetic element 12 (122) ( Figure 1B (Lower surface of the middle). Magnetic element 13 forms the outermost layer of magnetic component 1 in the axial direction X1. Magnetic element 131 is directly connected to magnetic element 121. Magnetic element 132 is directly connected to magnetic element 122.

[0053] Magnetic element 13 has a thickness D3 along the axial direction X1. Magnetic elements 131 and 132 have the same thickness D3.

[0054] When viewed from the axial direction X1, magnetic elements 11 to 13 have approximately the same outer peripheral shape.

[0055] Magnetic element 11 is made of isotropic magnetic material. Magnetic element 12 is made of isotropic magnetic material. In this embodiment, magnetic elements 11 and 12 are made of the same material (isotropic magnetic material).

[0056] Figure 4 This is a schematic cross-sectional view of the isotropic magnetic material forming magnetic elements 11 and 12. The isotropic magnetic material is a composite material comprising spherical magnetic metal powder 31 and resin 32. For example, the composite material comprising magnetic metal powder 31 and resin 32 is formed into a sheet, such that the magnetic metal powder 31 is substantially uniformly distributed in the resin 32, thereby forming an isotropic magnetic sheet 30. Figure 4 In the isotropic magnetic sheet 30 shown, spherical magnetic metal powder 31 is uniformly distributed, which provides isotropic magnetic permeability.

[0057] On the other hand, the magnetic element 13 is made of anisotropic magnetic material.

[0058] Figure 5This is a schematic cross-sectional view of the anisotropic magnetic material forming the magnetic element 13. The anisotropic magnetic material is a composite material comprising flat magnetic metal powder 41 and resin 42. The particles of magnetic metal powder 41 have a metal foil shape, which has surfaces 41A and 41B at opposite ends in the direction DX, and end faces 41C connecting the outer peripheries of surfaces 41A and 41B. For example, the particles of magnetic metal powder 41 have a thickness of approximately 1 μm along the direction DX. The particles of magnetic metal powder 41 have an aspect ratio greater than or equal to 20, which indicates the ratio of the width along the direction DM perpendicular to the direction DX to the thickness along the direction DX. The composite material comprising magnetic metal powder 41 and resin 42 is formed into a sheet, wherein the particles of magnetic metal powder 41 are oriented such that the surfaces 41A and 41B of the particles of magnetic metal powder 41 face each other in the direction DX, thereby forming an anisotropic magnetic sheet 40. The anisotropic magnetic sheet 40 has a large magnetic anisotropy. The anisotropic magnetic sheet 40 has an easy magnetization direction that extends along a direction contained in a plane including the direction DM and is perpendicular to the direction DX.

[0059] The inductor 200 can be manufactured by stacking and pressing the aforementioned coil 2, isotropic magnetic sheet 30, and anisotropic magnetic sheet 40. An example of the manufacturing method of the inductor 200 will be described later.

[0060] The inductor 200 may also include a housing in which the magnetic core 10 and the coil 2 are housed. For example, electrodes 201 and 202 may be held by the housing, such that they are exposed outside the housing.

[0061] The advantages of magnetic component 1 (magnetic core 10), which includes magnetic elements 11 to 13, are explained.

[0062] Figure 6A The simulation results of the intensity distribution of magnetic flux density inside the magnetic core 10 of the inductor 200 according to this embodiment are shown. Figure 6B Simulation results of the intensity distribution of magnetic flux density inside the magnetic core 310 of the inductor 300 according to the comparative example are shown. Figure 6A and Figure 6B Each is represented by a grayscale value, where the color approaches white as the magnetic flux density increases. Figure 6A and Figure 6B In the diagram, the darkest area represents coil 2.

[0063] As described above, in the inductor 200 according to this embodiment, magnetic elements 11 and 12 are made of isotropic magnetic materials, while magnetic element 13 is made of anisotropic magnetic materials.

[0064] about Figure 6AThe simulation parameters were set as follows: the relative permeability of magnetic elements 11 and 12 was set to 30; the relative permeability of magnetic element 13 along the axial direction X1 (corresponding to the thickness direction of magnetic element 13) was set to 2; and the relative permeability of magnetic element 13 along the direction perpendicular to the axial direction X1 (corresponding to the length direction of magnetic element 13) was set to 200. Figure 6A In the simulation, the ratio of the thickness D2 of magnetic element 12 to the sum of the thickness D2 of magnetic element 12 and the thickness D3 of magnetic element 13 is set to 0.4.

[0065] The comparative example inductor 300 includes a coil 302 and magnetic elements 311, 312, and 313, which have the same geometry as the coil 2 and magnetic elements 11, 12, and 13 of the inductor 200 of the embodiment. The coil 302 and magnetic elements 312 and 313 of the comparative example inductor 300 are also the same as the coil 2 and magnetic elements 12 and 13 of the inductor 200 of the embodiment in terms of materials, etc. However, the magnetic element 311 of the comparative example inductor 300 is formed of anisotropic magnetic material and has an easy magnetization direction along the axial direction X1.

[0066] about Figure 6B The simulation parameters were set as follows: the relative permeability of magnetic element 312 was set to 30; the relative permeability of magnetic element 313 along the axial direction X1 (corresponding to the thickness direction of magnetic element 313) was set to 2; and the relative permeability of magnetic element 313 along the direction perpendicular to the axial direction X1 (corresponding to the length direction of magnetic element 313) was set to 200. Figure 6B In the simulation, the relative permeability of magnetic element 311 along the axial direction X1 (corresponding to the thickness direction of magnetic element 311) was set to 200. The relative permeability of magnetic element 311 along the direction perpendicular to the axial direction X1 (corresponding to the length direction of magnetic element 311) was set to 2. Figure 6B In the simulation, with Figure 6A Similarly, the ratio of the thickness D2 of magnetic element 312 to the sum of the thickness D2 of magnetic element 312 and the thickness D3 of magnetic element 313 is set to 0.4.

[0067] like Figure 6BAs shown, the inductor 300 of the comparative example has a boundary in the central region R10 of the magnetic element 311, which is the boundary between a portion with a relatively large magnetic flux density and a portion with a relatively small magnetic flux density, and this boundary extends approximately along the axial direction X1. On the other hand, the inductor 200 of this embodiment has a portion in region R1 of the portion 111 of the magnetic element 11, which is a portion with a relatively large magnetic flux density, and this portion extends approximately towards the center of region R1. Furthermore, the magnetic element 13 of the inductor 200 of this embodiment has a portion in region R2 near the boundary with the magnetic element 12, which is the portion with the largest magnetic flux density (the brightest part), but the area of ​​this portion is smaller than the area of ​​this portion of the inductor 300 of the comparative example.

[0068] from Figure 6A and Figure 6B As can be seen, in the comparative example inductor 300, compared to the inductor 200 of this embodiment, the portion with a relatively large magnetic flux density is concentrated in the region of the magnetic core 10 close to the coil 2. In other words, in the inductor 200 of this embodiment, compared to the inductor 300 of the comparative example, the intensity of the magnetic flux density in the magnetic core is homogenized. It is known that the magnetic loss of an inductor tends to increase depending on the intensity of the magnetic flux density in the magnetic core. This means that homogenizing the magnetic flux density will reduce magnetic loss. Therefore, the inductor 200 of this embodiment can reduce magnetic loss compared to the inductor 300 of the comparative example.

[0069] Furthermore, the inductor 200 of this embodiment satisfies the following first and second conditions.

[0070] The first condition includes: in the axial direction X1, the size D2 of the magnetic element 12 falls within the range of 30% to 65% of the sum of the size D2 of the magnetic element 12 and the size D3 of the magnetic element 13.

[0071] The first condition is represented by the following formula 1.

[0072] 0.3≤D2 / (D2+D3)≤0.65 (Formula 1)

[0073] The second condition includes: in the axial direction X1, the size D1 of the magnetic element 11 falls within 50% to 100% of the sum of the size D2 of the magnetic element 12 (e.g., magnetic element 121) and the size D3 of the magnetic element 13 (e.g., magnetic element 131) located on one side of the coil 2 in the axial direction X1.

[0074] The second condition is represented by the following formula 2.

[0075] 0.5≤D1 / (D2+D3)≤1 (Formula 2)

[0076] Satisfying Formulas 1 and 2 can increase the inductance of inductor 200 while reducing magnetic losses, as described later.

[0077] (2.2) Manufacturing method

[0078] refer to Figure 3 and Figure 7 The manufacturing method of the inductor 200 in this embodiment will be described. In this example, the inductor 200 can be manufactured according to a sheet forming method.

[0079] Figure 7 This is a flowchart illustrating the steps of a sheet forming method, which is an example of a method for manufacturing the inductor 200 according to this embodiment. The sheet forming method includes a granulation step ST11, a forming step ST12, and a curing step ST13.

[0080] The granulation step ST11 includes preparing isotropic magnetic materials as the basis for magnetic elements 11 and 12, and preparing anisotropic magnetic materials as the basis for magnetic element 13, which will form magnetic core 10.

[0081] As described above, the raw materials for isotropic and anisotropic magnetic materials include magnetic metal powders 31 and 41 and resins 32 and 42. The materials of the magnetic metal powders 31 and 41 are not particularly limited, but can be magnetic metals selected from, for example, the group consisting of Fe-Si-Al based alloys, Fe-Si based alloys, Fe-Si-Cr based alloys, Fe-Ni based alloys, amorphous alloys, and nanocrystalline alloys. For example, the resins 32 and 42 can be thermosetting resins. The materials of the resins 32 and 42 are not particularly limited, but can be selected from, for example, the group consisting of epoxy resins, phenolic resins, and silicone resins.

[0082] The raw materials for isotropic and anisotropic magnetic materials may optionally include at least one of inorganic insulating materials or additives. The inorganic insulating material may be a powder, for example, which helps reduce the likelihood of contact between particles of magnetic metal powder 31 or 41, thereby suppressing an increase in eddy current losses. The presence of inorganic insulating material between the particles of magnetic metal powder 31 or 41 provides electrical insulation between them. This can reduce the size of the conductor in which eddy currents are induced. The material of the inorganic insulating material is not particularly limited, but may be selected from, for example, the group consisting of boron nitride, talc, mica, zinc oxide, titanium oxide, silicon oxide, aluminum oxide, iron oxide, and barium sulfate. For example, additives help increase the dispersibility of magnetic metal powder 31 or 41 and modify the particle surface of magnetic metal powder 31 or 41. The additive is not particularly limited, but may be selected from, for example, the group consisting of silane coupling agents, titanium-based coupling agents, titanium alkoxides, and titanium chelates.

[0083] Granulation step ST11 includes mixing and dispersing magnetic metal powder 31 and inorganic insulating material to prepare a mixed powder (mixing and dispersion). This step includes mixing resin 32 and additives with the thus obtained mixed powder and kneading them to prepare a paste-like granular powder (gelatinization). This step includes mixing and dispersing magnetic metal powder 41 and inorganic insulating material to prepare a mixed powder. This step includes mixing resin 42 and additives with the thus obtained mixed powder and kneading them to prepare a paste-like granular powder.

[0084] There are no particular limitations on the apparatus and / or method used for the granulation step ST11. For example, various ball mills such as rotary ball mills and planetary ball mills, as well as various apparatuses such as V-type mixers and planetary mixers, can be used. In the granulation step ST11, organic solvents such as toluene and ethanol can be mixed as needed. Resin 32 and additives can be added simultaneously with the mixing and dispersion of magnetic metal powder 31 and inorganic insulating material. Additionally, resin 42 and additives can be added simultaneously with the mixing and dispersion of magnetic metal powder 41 and inorganic insulating material.

[0085] The forming step ST12 includes forming the obtained granular powder into sheets to form isotropic magnetic sheets 30 and anisotropic magnetic sheets 40 (sheet forming). There are no particular limitations on the apparatus and / or method used for the forming step ST12. For example, a doctor blade sheet forming machine, an extrusion molding machine, etc., can be used. The isotropic magnetic sheets 30 and / or anisotropic magnetic sheets 40 can be formed by forming the granular powder into sheet-like molded bodies, and, if necessary, by cutting off unwanted portions, for example, with a click cutter, to achieve the desired shape and size.

[0086] As described above, the isotropic magnetic sheet 30 has isotropic permeability. On the other hand, the anisotropic magnetic sheet 40 has an easy magnetization direction, which is along the surface of the anisotropic magnetic sheet 40, i.e., along the direction DM perpendicular to the thickness direction DX (see...). Figure 5 ).

[0087] like Figure 3 As shown, molding step ST12 includes stacking anisotropic magnetic sheet 40, isotropic magnetic sheet 30, coil 2, another isotropic magnetic sheet 30, and another anisotropic magnetic sheet 40 sequentially from bottom to top, and pressing the stacked body to form a coil-embedded molded body. There are no particular limitations on the apparatus and / or method used for the pressing process, but commonly used pressing methods can be used.

[0088] In the pressing process, isotropic magnetic sheets 30 are disposed on the upper and lower sides of the coil 2. The central portions of the two isotropic magnetic sheets 30 enter the central internal space 21 of the coil 2, and the peripheral portions of the two isotropic magnetic sheets 30 enter the space outside the coil 2. The portions of the isotropic magnetic sheets 30 entering the internal space 21 form portions 111 of the magnetic element 11. Furthermore, the portions of the isotropic magnetic sheets 30 entering the space outside the coil 2 form portions 112 of the magnetic element 11. When the isotropic magnetic sheets 30 are prepared, they can be manufactured to have a shape with protrusions in areas corresponding to at least a portion of portions 111 and / or portions 112 of the magnetic element 11.

[0089] The portion of the isotropic magnetic sheet 30 located on the outer side (upper and lower side) of the coil 2 along the axial direction X1 forms the magnetic element 12 of the magnetic component 1.

[0090] Anisotropic magnetic sheet 40 forms magnetic element 13 of magnetic component 1.

[0091] The curing step ST13 includes heating the molded body obtained by the compression molding process at a temperature in the range of 150°C to 250°C to cure the resins 32, 42 (thermosetting resins) contained in the isotropic magnetic sheet 30 and the anisotropic magnetic sheet 40 (resin curing).

[0092] Figure 1A and Figure 1B The inductor 200 shown can be formed according to the sheet forming method described above.

[0093] The manufacturing method of inductor 200 is not limited to sheet forming method. Figure 8 This is a flowchart illustrating the steps of a particle molding method, which is another example of a method for manufacturing the inductor 200 in this embodiment.

[0094] like Figure 8 As shown, the granulation method includes a granulation step ST21, a molding step ST22, and a curing step ST23.

[0095] The granulation step ST21 includes preparing isotropic magnetic materials as the basis for magnetic elements 11 and 12, and preparing anisotropic magnetic materials as the basis for magnetic element 13, which will form magnetic core 10. The raw materials for the isotropic and anisotropic magnetic materials can be the same as those described in the sheet forming method.

[0096] Granulation step ST21 includes mixing and dispersing magnetic metal powder 31 and inorganic insulating material to prepare a mixed powder (mixing and dispersion). This step includes mixing resin 32 and additives with the thus obtained mixed powder to prepare particulate powder (hereinafter referred to as "isotropic magnetic powder") (granulation). This step includes mixing and dispersing magnetic metal powder 41 and inorganic insulating material to prepare a mixed powder. This step includes mixing resin 42 and additives with the thus obtained mixed powder to prepare particulate powder (hereinafter referred to as "anisotropic magnetic powder"). The particulate powder thus obtained can be sorted according to their particle size to increase the flowability of the particulate powder (sorting). This allows the particulate powder to reliably fill the mold, thus improving moldability. It should be noted that, unlike granulation step ST11, in granulation step ST21, the particulate powder does not form a paste.

[0097] The molding step ST22 includes placing the particulate powder and coil 2 into a mold, such that isotropic magnetic powder is present inside and around coil 2, and pressing them into shape. This step includes arranging anisotropic magnets made of anisotropic magnetic powder on both sides (upper and lower sides) of the isotropic magnets made of isotropic magnetic powder along the axial direction X1 of coil 2. This step includes pressing them into shape to form a molded body (coil embedded integrally molded). There are no particular limitations on the apparatus and / or method used for the pressing process, but commonly used pressing methods can be employed.

[0098] The curing step ST23 includes heating the molded body obtained by the pressing process to cure the resins 32 and 42 (thermosetting resins) contained in the isotropic magnetic powder and the anisotropic magnetic powder (resin curing).

[0099] Figure 1A and Figure 1B The inductor 200 shown can also be formed according to the particle molding method described above.

[0100] The magnetic core 10 of the inductor 200, manufactured according to a sheet molding method or a particle molding method, includes magnetic elements 11 and 12 made of isotropic magnetic material and magnetic element 13 made of anisotropic magnetic material. This helps to reduce the magnetic loss of the magnetic component 1. The magnetic core 10 of the inductor 200, manufactured according to a sheet molding method or a particle molding method, can provide a gapless structure, wherein there are no gaps inside the magnetic core 10 or in the region between the magnetic core 10 and the coil 2.

[0101] (2.3) Thickness of magnetic components

[0102] Through careful research and exploration, the inventors of this application discovered a specific relationship between the thickness D1 of magnetic element 11, the thickness D2 of magnetic element 12, and the thickness D3 of magnetic element 13. This specific relationship can increase the inductance of magnetic component 1 and reduce magnetic loss. The relationship between the thickness D1 of magnetic element 11, the thickness D2 of magnetic element 12, and the thickness D3 of magnetic element 13 is explained below.

[0103] The inventors of this application first studied the ratio P1 (=D2 / (D2+D3)) of the thickness of the isotropic magnetic material (magnetic element 12) to the total thickness of the magnetic elements (magnetic element 12 and magnetic element 13) located outside the coil 2 (the upper and lower sides of the coil 2).

[0104] Therefore, the inventors of this application simulate the intensity distribution of magnetic flux density inside the magnetic core 10 using various ratios of P1. Regarding the parameters used for simulation, ... Figure 6A Similarly, the relative permeability of magnetic elements 11 and 12 is set to 30, the relative permeability of magnetic element 13 along the axial direction X1 (corresponding to the thickness direction of magnetic element 13) is set to 2, and the relative permeability of magnetic element 13 along the direction perpendicular to the axial direction X1 (corresponding to the length direction of magnetic element 13) is set to 200. In the simulation, the ratio of the thickness D1 of magnetic element 11 to the sum of the thicknesses D2 of magnetic element 12 and D3 of magnetic element 13 is set to 0.9 (D1 / (D2+D3)=0.9).

[0105] Figure 9 and Figure 10 The simulation results are shown. Similar to... Figure 6A , Figure 9 and Figure 10 Each is represented by a grayscale value, where the color approaches white as the magnetic flux density increases. Figure 9 and Figure 10 In the diagram, the darkest area represents coil 2.

[0106] Figure 9 (a) shows the simulation results when the ratio P1 = 0. Figure 9 (b) shows the simulation results when the ratio P1 = 0.2. Figure 9 (c) shows the simulation results for the ratio P1 = 0.3, and Figure 9 (d) shows the simulation results for the ratio P1 = 0.6. Figure 10 (a) shows the simulated result when the ratio P1 = 0.65. Figure 10 (b) shows the simulation results for the ratio P1 = 0.7. Figure 10(c) shows the simulation results for the ratio P1 = 0.75, and Figure 10 (d) shows the simulation results for the ratio P1 = 0.8. Figure 6A This corresponds to the case where the ratio P1 = 0.4.

[0107] from Figure 9 (a) to Figure 9 As can be seen from (c), the intensity distribution of magnetic flux density inside part 111 of magnetic element 11 gradually becomes more uniform as the ratio P1 increases from 0 to 0.3. Figure 9 (c) Figure 6A , Figure 9 (d) and Figure 10 As can be seen from (a), the magnetic flux density distribution within part 111 of magnetic element 11 remains uniform in the range of 0.3 to 0.65, with a ratio P1 between 0.3 and 0.65. Figure 10 It can be seen that when the ratio P1 increases from 0.65 to 0.8, the uniformity of the magnetic flux density intensity distribution inside part 111 of the magnetic element 11 gradually decreases.

[0108] When the ratio P1 is 0 (i.e., the inductor does not include the magnetic element 12) and when the ratio P1 is 0.7 or greater, the magnetic element 13 has a portion with a very high magnetic flux density near the boundary (especially near the center) relative to the magnetic element 12.

[0109] Table 1 shows the inductance of inductor 200 at different ratios P1. In Table 1, the inductance values ​​are standardized such that the inductance value of an inductor with a ratio P1 of 0 is set to 100. Therefore, each of these values ​​can be said to indicate the ratio of the inductance of the corresponding inductor to the inductance of an inductor with a ratio P1 of 0, expressed as a percentage. Table 1 also shows the evaluation results of the inductance. The inductance is evaluated based on the comparison with an inductor without magnetic element 12 (ratio P1 = 0). Inductors with an inductance value of 100 or less are classified as “bad” and marked “NG”. Inductors with an inductance value greater than 100 are classified as “good” and marked “G”. Table 1 also shows the evaluation results of magnetic flux uniformity relative to the value of ratio P1. To evaluate the uniformity of magnetic flux, the intensity distribution is checked visually. Inductors with high uniformity are classified as “good” and marked “G”. Inductors with low uniformity are classified as "bad" and marked "NG".

[0110] Table 1

[0111]

[0112]

[0113] As shown in Table 1, the inductor 200 including a magnetic element 12 with a thickness satisfying the relationship P1 < 0.7 has a larger inductance than the inductor 200 without the magnetic element 12 (i.e., P1 = 0). This is believed to be because, since the magnetic element 12 exists between magnetic elements 11 and 13, and magnetic element 11 does not directly contact magnetic element 13, the magnetic flux from magnetic element 13 to magnetic element 11 can change its direction within the magnetic element 12. Therefore, the cross-section of a larger area of ​​the magnetic element 11 can serve as an effective magnetic circuit.

[0114] Considering the inductance values ​​and magnetic flux uniformity in Table 1, it can be said that the ratio P1 is preferably in the range of 0.3 to 0.65 (30% to 65%), in other words, the first condition mentioned above is preferably satisfied.

[0115] The inventors of this application also studied the value of P2 (=D1 / (D2+D3)) of the ratio of the thickness of the magnetic element 11 (corresponding to the thickness of the coil 2) to the total thickness of the magnetic elements 12 and 13 located outside the coil 2 (on the upper and lower sides of the coil 2).

[0116] Therefore, the inventors of this application simulate the intensity distribution of magnetic flux density inside the magnetic core 10 for each of the various values ​​of ratio P1, using various values ​​of ratio P2. Regarding the parameters used for simulation, ... Figure 6A Similarly, the relative permeability of magnetic element 11 and magnetic element 12 is set to 30, the relative permeability of magnetic element 13 along the axial direction X1 is set to 2, and the relative permeability of magnetic element 13 along the direction perpendicular to the axial direction X1 (which corresponds to the length direction of magnetic element 13) is set to 200. Figure 6A , Figure 9 and Figure 10 This corresponds to the case where the ratio P2 = 0.9.

[0117] Figures 11 to 16 The simulation results are shown. Similar to... Figure 6A , Figures 11 to 16 Each is represented by a grayscale value, where the color approaches white as the magnetic flux density increases. Figures 11 to 16 In the diagram, the darkest area represents coil 2.

[0118] Figure 11 The simulation results are shown when the ratio P2 = 0.5. Figure 11 (a) shows the simulation results for the ratios P2 = 0.5 and P1 = 0. Figure 11 (b) shows the simulation results for ratios P2 = 0.5 and P1 = 0.3. Figure 11 (c) shows the simulation results for the ratios P2 = 0.5 and P1 = 0.4. Figure 11 Figure (d) shows the simulation results for the ratios P2 = 0.5 and P1 = 0.65.

[0119] Figure 12 The simulation results are shown when the ratio P2 = 0.7. Figure 12 (a) shows the simulation results for the ratios P2 = 0.7 and P1 = 0. Figure 12 (b) shows the simulation results for the ratios P2 = 0.7 and P1 = 0.3. Figure 12 (c) shows the simulation results for the ratios P2 = 0.7 and P1 = 0.4. Figure 12 Figure (d) shows the simulation results for the ratios P2 = 0.7 and P1 = 0.65.

[0120] Figure 13 The simulation results are shown when the ratio P2 = 0.9. Figure 13 (a) shows the simulation results for the ratios P2 = 0.9 and P1 = 0. Figure 13 (b) shows the simulation results for the ratios P2 = 0.9 and P1 = 0.3. Figure 13 (c) shows the simulation results for the ratios P2 = 0.9 and P1 = 0.4. Figure 13 Figure (d) shows the simulation results for the ratios P2 = 0.9 and P1 = 0.65.

[0121] Figure 14 and Figure 15 The simulation results are shown when the ratio P2 = 1. Figure 14 (a) shows the simulation results for the ratios P2 = 1 and P1 = 0. Figure 14 (b) shows the simulation results for the ratios P2 = 1 and P1 = 0.3. Figure 14 (c) shows the simulation results for the ratios P2 = 1 and P1 = 0.4. Figure 15 (a) shows the simulation results for the ratios P2 = 1 and P1 = 0.6. Figure 15 (b) shows the simulation results for the ratios P2 = 1 and P1 = 0.65.

[0122] Figure 16 The simulation results are shown when the ratio P2 = 1.1. Figure 16 (a) shows the simulation results for the ratios P2 = 1.1 and P1 = 0. Figure 16 (b) shows the simulation results for the ratios P2 = 1.1 and P1 = 0.3. Figure 16(c) shows the simulation results for the ratios P2 = 1.1 and P1 = 0.65.

[0123] Table 2 shows the inductance of inductor 200 under different ratios P2 and P1. The inductance values ​​were standardized such that for each ratio P1, the inductance value of the inductor with a ratio P1 of 0 was set to 100. The evaluation criteria for flux uniformity in Table 2 are the same as those in Table 1.

[0124] Table 2

[0125]

[0126]

[0127] As can be seen from Table 2, an excessively thick magnetic element 11 (D1) in inductor 200 (i.e., P2 = 1.1) reduces the inductance increase provided by magnetic element 12. This is believed to be because when magnetic element 11 has an excessive thickness, the inductance increase provided by magnetic element 12 (i.e., increasing the cross-section of the effective magnetic circuit in magnetic element 11) is suppressed.

[0128] As shown in Table 2, from the viewpoint of inductance value and magnetic flux uniformity, the ratio P2 is preferably less than or equal to 1 (i.e., 100%). Furthermore, when the thickness D1 of the magnetic element 11, corresponding to the thickness of the coil 2, is small, it is difficult to increase the number of turns in the winding 20. Therefore, the ratio P2 is preferably greater than or equal to 0.5.

[0129] In summary, it is preferable to satisfy the second condition described above. The second condition includes that, in the axial direction X1, the size D1 of the magnetic element 11 falls within 50% to 100% of the sum of the size D2 of the magnetic element 12 (e.g., magnetic element 121) and the size D3 of the magnetic element 13 (e.g., magnetic element 131) located on one side of the coil 2 in the axial direction X1.

[0130] Considering the results when the ratio P2 = 1, it can be said that the ratio P1 is preferably in the range of 0.3 to 0.6 (30% to 60%).

[0131] By adjusting the thicknesses of magnetic elements 11, 12 (121, 122) and 13 (131, 132), the inductance of inductor 200 can be increased while magnetic losses are reduced, thus satisfying the first and second conditions.

[0132] (3) Variation

[0133] The above embodiments are merely examples of various embodiments of the present invention. Various modifications can be made to the above embodiments based on design, etc., as long as the objectives of this disclosure are achieved. Some variations of the above embodiments are described below. Features of the variations described below can be combined with features of the above embodiments.

[0134] The inductor 200 is not limited to an integrally molded product with the coil 2 embedded therein. The magnetic core 10 of the inductor 200 can be manufactured separately from the coil 2 and assembled onto the coil 2. The magnetic core 10 can be a pressed powder core manufactured by molding magnetic powder.

[0135] The method of manufacturing the inductor 200 of this variant is described. Figure 17 This is a flowchart illustrating the manufacturing method of the inductor 200 as an electronic device of this variant.

[0136] like Figure 17 As shown, the manufacturing method of this variant includes a granulation step ST31, a core-making step ST32, and an assembly step ST33.

[0137] The granulation step ST31 includes preparing isotropic magnetic materials as the basis for magnetic elements 11 and 12, and preparing anisotropic magnetic materials as the basis for magnetic element 13, which will form magnetic core 10. The raw materials for the isotropic and anisotropic magnetic materials can be the same as those described in the sheet forming method of the above embodiments.

[0138] Granulation step ST31 includes kneading a mixture of resin 32 containing an organic solvent and magnetic metal powder 31 to obtain a clay-like mixture in which magnetic metal powder 31 is dispersed (mixing and dispersion). Granulation step ST31 includes kneading a mixture of resin 42 containing an organic solvent and magnetic metal powder 41 to obtain a clay-like mixture in which magnetic metal powder 41 is dispersed (mixing and dispersion). In this step, inorganic insulating materials and / or additives may be further mixed.

[0139] The granulation step ST31 includes forming the mixture into a block (e.g., column) and drying it to remove solvent from the mixture. This step includes breaking the mixture block to obtain thus broken solid flakes (granulation). These solid flakes include multiple particles of various sizes, including magnetic metal powder 31 or 41 with a resin coating of substantially constant thickness on its surface. This step includes sorting these solid flakes according to their size to obtain particulate powder with particle sizes falling within a desired range (sorting).

[0140] Core-making step ST32 includes pressing the particulate powder into a molded body with the desired shape using a molding die (high-pressure pressing). Pressing includes forming, for example, two segmented magnetic cores with an E-shaped cross-section and two plate-shaped magnetic cores with a flat plate shape.

[0141] Each segmented magnetic core has been achieved by... Figure 1B The magnetic core 10 shown is shaped by dividing the entire area of ​​magnetic elements 11 and 12 into upper and lower portions along the axial direction X1. Each segmented magnetic core is made of particulate powder containing magnetic metal powder 31. Each segmented magnetic core includes: a base portion including magnetic element 12; and three legs including magnetic element 11 and protruding from the base portion.

[0142] Each plate-shaped magnetic core has a shape corresponding to the shape of the magnetic element 13. Each plate-shaped magnetic core is made of particulate powder containing magnetic metal powder 41.

[0143] The core-making step ST32 includes heating the obtained molded body under an inert gas atmosphere or in air to remove the resin, which serves as a binder, from the molded body (resin removal).

[0144] The core-making step ST32 includes heat treatment (high-temperature annealing) of the molded body after resin removal. Heat treatment helps reduce the strain of the magnetic metal powders 31, 41 caused by the stress applied during the pressing process. This reduces hysteresis losses.

[0145] The core-making step ST32 includes injecting impregnating resin into the heat-treated molded body (segmented core) (impregnation). The resin is removed from the molded body through heat treatment, thus reducing the bonding strength of the molded body. The impregnating resin is impregnated into the space surrounding the particles of the magnetic metal powders 31, 41 and injected into the molded body. This increases the mechanical strength of the molded body.

[0146] Assembly step ST33 includes grinding the obtained molded bodies (segmented cores and / or plate cores) as needed. Assembly step ST33 includes, for example, joining each pair of segmented cores and plate cores with adhesive to form two joined bodies, each having an E-shaped cross-section. The two joined bodies and coil 2 are then assembled into inductor 200.

[0147] The magnetic core 10 (magnetic component 1) made according to this method also includes magnetic elements 11, 12 and 13, thus helping to reduce magnetic loss.

[0148] (3.2) Other variations

[0149] In one variation, the electronic device 100 is not limited to the inductor 200, but can be a transformer or other device.

[0150] In one variation, at least one of magnetic elements 11 or 12 may be made of anisotropic magnetic material instead of isotropic magnetic material. At least one of magnetic elements 11 or 12 may be made of anisotropic magnetic material, provided that the magnetic anisotropy of magnetic element 13 is greater than either the magnetic anisotropy of magnetic element 11 or any one of the magnetic anisotropy of the magnetic element itself. The magnetic anisotropy of magnetic element 12 may be greater than that of magnetic element 11. In other words, the magnetic anisotropy may increase in the order of magnetic element 11, magnetic element 12, and magnetic element 13, meaning that the easy magnetization direction may become more pronounced in this order.

[0151] In a variation of the sheet forming method, the magnetic element 11 may be made of a different element from the magnetic sheet that forms the magnetic element 12.

[0152] In one variation, the boundary between magnetic element 12 and magnetic element 13 is not limited to having a planar shape. When the inductor 200 is manufactured according to a sheet forming method, a step can be formed in the magnetic element 12 and / or magnetic element 13 in the region near the boundary between the central space 21 of the coil 2 and the winding 20. Variations of the magnetic component 1 according to this disclosure include magnetic components having such steps.

[0153] In one variation, the easy magnetization direction of the magnetic element 13 may not be parallel to the plane perpendicular to the axis X1. Slight deviations and / or bends are possible.

[0154] In a variant of the inductor 200, which is a metal composite inductor, the coil 2 can be made into a monolithic product integrally formed with at least a portion of the magnetic core 10 (e.g., magnetic element 11).

[0155] In one variation, the magnetic element 11 is not limited to including part 112.

[0156] In one variation, the winding 20 is not limited to having a two-layer structure with a portion on the same layer as the electrode 201 and a portion on the same layer as the electrode 202, but may have a single-layer structure, a three-layer structure, or a multi-layer structure.

[0157] (4) aspects

[0158] As can be seen from the above embodiments and variations, the following aspects are disclosed.

[0159] The magnetic component (1) of the first aspect includes a magnetic element (11), a magnetic element (12), and a magnetic element (13). The magnetic element (11) is disposed in the same layer as the coil (2) in the axial direction (X1). The magnetic element (12) is disposed outside the coil (2) in the axial direction (X1). The magnetic element (13) is disposed outside the magnetic element (12) in the axial direction (X1). The magnetic anisotropy of the magnetic element (13) is greater than that of each of the magnetic elements (11) and (12). The magnetic element (13) has an easy magnetization direction perpendicular to the axial direction (X1).

[0160] This can help reduce magnetic loss.

[0161] In the magnetic component (1) of the second aspect of the first aspect, the magnetic element (11) is made of an isotropic magnetic material. The magnetic element (13) is made of anisotropic magnetic material.

[0162] This can help reduce magnetic loss.

[0163] In the magnetic component (1) of the third aspect referring to the first or second aspect, the magnetic element (11) and the magnetic element (12) are made of the same material as each other.

[0164] This can help reduce magnetic loss.

[0165] In the magnetic component (1) of the fourth aspect referring to any one of the first to third aspects, in the axial direction (X1), the size (D2) of the magnetic element (12) falls within the range of 30% to 65% of the sum of the size (D2) of the magnetic element (12) and the size (D3) of the magnetic element (13).

[0166] This can help increase inductance while reducing magnetic loss.

[0167] In the magnetic component (1) of the fifth aspect referring to any one of the first to fourth aspects, the size (D1) of the magnetic element (11) in the axial direction (X1) falls within 50% to 100% of the sum of the size (D2) of the magnetic element (12) and the size (D3) of the magnetic element (13) located on one side of the coil (2) in the axial direction (X1).

[0168] This can help increase inductance while reducing magnetic loss.

[0169] The magnetic component (1) of the sixth aspect, referring to any one of the first to fifth aspects, is a molded article integrally formed with the coil (2) so that the coil (2) is embedded therein.

[0170] This aspect can help reduce the magnetic loss of the magnetic component (1) integrally formed with the coil (2).

[0171] The electronic device (100) of the seventh aspect includes a magnetic component (1) and a coil (2) of any one of the first to sixth aspects.

[0172] This can help reduce magnetic loss.

[0173] List of reference numerals

[0174] 1. Magnetic components

[0175] 100 Electronic devices

[0176] 2 coils

[0177] 11 Magnetic Components (First Magnetic Component)

[0178] 12 Magnetic components (second magnetic component, fourth magnetic component)

[0179] 13 Magnetic components (third magnetic component, fifth magnetic component)

[0180] 121 Magnetic Component (Second Magnetic Component)

[0181] 122 Magnetic Components (Fourth Magnetic Component)

[0182] 131 Magnetic Components (Third Magnetic Component)

[0183] 132 Magnetic Components (Fifth Magnetic Component)

[0184] A1 Central Axis

[0185] X1 Axial axis.

Claims

1. A magnetic component configured for use with a coil wound around a central axis along an axial direction, the magnetic component comprising: A first magnetic element, through which a magnetic flux generated by the coil passes, the first magnetic element extending in the axial direction to have a first end and a second end in the axial direction, and having a portion overlapping the coil when viewed from a direction perpendicular to the axial direction; A second magnetic element is disposed on the opposite side of the coil in the axial direction relative to the first end of the first magnetic element; A third magnetic element is disposed on the opposite side of the coil in the axial direction relative to the second magnetic element; A fourth magnetic element is disposed on the opposite side of the coil in the axial direction relative to the second end of the first magnetic element; and The fifth magnetic element is disposed on the opposite side of the coil in the axial direction relative to the fourth magnetic element. The coil is wound around the internal space through which the central axis passes. The first magnetic element has: The first portion extends axially and passes through the internal space of the coil, the first portion being connected to the second magnetic element and the fourth magnetic element, and The second part extends axially and passes through the space outside the coil; the second part is connected to the second magnetic element and the fourth magnetic element. The magnetic anisotropy of the third magnetic element is greater than that of each of the first and second magnetic elements. The third magnetic element has an easy magnetization direction, and it is easier to magnetize along this direction compared to other directions. The easy magnetization direction of the third magnetic element is perpendicular to the axial direction. The magnetic anisotropy of the fifth magnetic element is greater than that of each of the first, second, and fourth magnetic elements. The fifth magnetic element has an easy magnetization direction, and it is easier to magnetize along this direction compared to other directions. The easy magnetization direction of the fifth magnetic element is perpendicular to the axial direction. The dimension of the second magnetic element along the axial direction falls within 30% to 60% of the sum of the dimensions of the second magnetic element along the axial direction and the dimensions of the third magnetic element along the axial direction. The dimension of the first magnetic element along the axial direction falls within 50% to 100% of the sum of the dimensions of the second magnetic element along the axial direction and the dimensions of the third magnetic element along the axial direction.

2. The magnetic component according to claim 1, wherein... The first magnetic element is made of an isotropic magnetic material, and The third magnetic element is made of anisotropic magnetic material.

3. The magnetic component according to claim 1 or 2, wherein The first magnetic element and the second magnetic element are made of the same material.

4. The magnetic component according to claim 1 or 2, wherein The second magnetic element is directly connected to the first end of the first magnetic element, and The third magnetic element is directly connected to the second magnetic element.

5. The magnetic component according to claim 1 or 2, wherein... The second magnetic element is directly connected to the first end of the first magnetic element. The third magnetic element is directly connected to the second magnetic element. The fourth magnetic element is directly connected to the second end of the first magnetic element, and The fifth magnetic element is directly connected to the fourth magnetic element.

6. The magnetic component according to claim 1 or 2, wherein The magnetic component is a molded article integrally formed with the coil so that the coil is embedded in the magnetic component.

7. An electronic device, comprising: The magnetic component according to any one of claims 1 to 6; and The coil.

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