Inductor components
By improving the columnar core and flange structure of the inductor components and designing the protruding side and end face to be coplanar, the problems of large protrusion configuration space and difficulty in miniaturizing inductors are solved, thus achieving the stability and miniaturization of inductors.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- MURATA MFG CO LTD
- Filing Date
- 2022-09-01
- Publication Date
- 2026-07-31
AI Technical Summary
The protrusions in existing coil components are pointed and thin, which makes it difficult to miniaturize the top plate and inductor components, and the space required for protrusion configuration is large.
The inductor structure employs a columnar core and flange portion, with the protruding side and end face being perpendicular to each other, reducing the space required for protrusion placement and securing the connection with resin filling.
This approach enables miniaturization of inductor components, reduces the space required for protrusions, strengthens the connection between the top plate and the flange, suppresses individual differences in inductance characteristics and variations in magnetic flux density, and improves the stability of the inductor.
Smart Images
Figure CN115810462B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to inductor components. Background Technology
[0002] Patent Document 1 describes a coil component comprising a drum-shaped core, a top plate, and a coil. The drum-shaped core comprises a core portion, a first flange portion, and a second flange portion. The core portion is cylindrical, extending from a central axis. The first flange portion is connected to a first end of the core portion and extends outward from the circumference of the core portion. The second flange portion is connected to a second end of the core portion and extends outward from the circumference of the core portion. The top plate is a flat plate extending elongated along the central axis of the core portion. The top plate has multiple protrusions protruding from its main surface towards the first flange portion at a position opposite to the first flange portion. Additionally, the top plate has multiple protrusions protruding from its main surface towards the second flange portion at a position opposite to the second flange portion. The front end of each protrusion contacts either the first or second flange portion. Each protrusion is tapered. In other words, the sides of each protrusion are inclined. Specifically, the diameter of each protrusion decreases concentrically from the main surface of the top plate towards the flange portion. The front end of each protrusion is flat.
[0003] Patent Document 1: Japanese Patent Application Publication No. 2018-107248
[0004] In the coil component described in Patent Document 1, the protrusions are pointed. Therefore, the space on the main surface of the top plate for arranging the protrusions needs to be larger than the contact area between the front end of the protrusion and each flange. Consequently, it is difficult to miniaturize the top plate and thus the inductor component. Summary of the Invention
[0005] To address the aforementioned issues, the present invention provides an inductor component comprising: a drum-shaped core having a columnar core portion, a first flange portion, and a second flange portion, wherein the columnar core portion extends about a central axis, the first flange portion is connected to a first end of the core portion in the extending direction of the central axis and extends radially outward from the circumferential surface of the core portion centered on the central axis, and the second flange portion is connected to a second end of the core portion in the extending direction of the central axis and extends radially outward from the circumferential surface of the core portion centered on the central axis. A radially outwardly extending portion extends from the center; an electrical wire is wound around the core portion; and a top plate is connected to the first flange portion and the second flange portion. The top plate has a main surface opposite to the first flange portion, an end surface perpendicular to the main surface, and a protrusion protruding from the main surface at a position opposite to the first flange portion toward the first flange portion. The protrusion has a front end surface parallel to the main surface and a side surface extending from the front end surface toward the main surface. The side surface includes an inclined surface that is inclined relative to the end surface and a vertical surface that is connected to and coplanar with the end surface.
[0006] In the above structure, the portion of the side of the protrusion that is coplanar with the end face is perpendicular to the main surface. That is, the portion of the side of the protrusion that is coplanar with the end face does not expand as it faces the main surface. Therefore, compared to a shape where the side of the protrusion is generally inclined, the configuration space for the protrusions on the main surface of the top plate can be reduced.
[0007] To address the aforementioned issues, the present invention provides an inductor component comprising: a drum-shaped core having a columnar core portion, a first flange portion, and a second flange portion, wherein the columnar core portion extends about a central axis, the first flange portion is connected to a first end of the core portion in the extending direction of the central axis and extends radially outward from the circumferential surface of the core portion centered on the central axis, and the second flange portion is connected to a second end of the core portion in the extending direction of the central axis and extends radially outward from the circumferential surface of the core portion centered on the central axis; A thread is wound around the core portion; and a top plate is connected to the first flange portion and the second flange portion. The top plate has a main surface opposite to the first flange portion. The first flange portion has a first plane opposite to the main surface, an end face perpendicular to the first plane, and a protrusion protruding from the first plane relative to the top plate. The protrusion has a front end face parallel to the first plane and a side face extending from the front end face toward the first plane. The side face includes an inclined surface inclined relative to the end face and a vertical surface connected to and coplanar with the end face.
[0008] In the above structure, the portion of the side of the protrusion that is coplanar with the end face is perpendicular to the first plane. That is, the portion of the side of the protrusion that is coplanar with the end face does not expand as it moves toward the first plane. Therefore, compared to a shape where the side of the protrusion is generally inclined, the arrangement space of the protrusion on the first plane of the first flange portion can be reduced.
[0009] According to the present invention, the space required for setting the protrusion can be reduced. Attached Figure Description
[0010] Figure 1 This is a perspective view of the inductor component according to the first embodiment.
[0011] Figure 2 This is an exploded perspective view of the inductor component according to the first embodiment.
[0012] Figure 3 This is a perspective top view of the inductor component according to the first embodiment.
[0013] Figure 4 This is a perspective view of the inductor component according to the second embodiment. Detailed Implementation
[0014] Hereinafter, one embodiment of the inductor component will be described with reference to the accompanying drawings. Furthermore, for ease of understanding, the drawings may show enlarged versions of the constituent elements. The dimensional proportions of the constituent elements may differ from the actual dimensional proportions or those shown in other drawings.
[0015] <First Implementation>
[0016] like Figure 1 As shown, the inductor component 10 includes a drum-shaped core 20, wires 50, a top plate 60, and two external electrodes 80.
[0017] The drum-shaped core 20 has a core portion 30 and a pair of flange portions 40. The core portion 30 extends about the central axis CA.
[0018] In the following description, a specific axis orthogonal to the central axis CA is designated as the first axis X, and an axis orthogonal to both the central axis CA and the first axis X is designated as the second axis Y. Furthermore, one direction along the central axis CA is designated as the positive direction C1, and the direction opposite to the positive direction C1 is designated as the negative direction C2. Similarly, one direction along the first axis X is designated as the first positive direction X1, and the direction opposite to the first positive direction X1 is designated as the first negative direction X2. Additionally, one direction along the second axis Y is designated as the second positive direction Y1, and the direction opposite to the second positive direction Y1 is designated as the second negative direction Y2.
[0019] The core portion 30 is approximately quadrangular in shape. That is, in a cross-section orthogonal to the central axis CA, the core portion 30 is approximately quadrilateral. In the cross-section orthogonal to the central axis CA, two opposite sides of the core portion 30 are parallel to the first axis X. Furthermore, in the cross-section orthogonal to the central axis CA, the remaining two sides of the core portion 30 are parallel to the second axis Y.
[0020] The first flange portion 40A, as one of a pair of flange portions 40, is connected to the first end, which is the end of the core portion 30 in the positive direction C1.
[0021] The first flange portion 40A is generally a flat, roughly rectangular parallelepiped with a small dimension along the central axis CA. Viewed from the circumferential surface of the core portion 30, the first flange portion 40A extends radially outward with respect to the central axis CA. That is, the dimension of the first flange portion 40A along the first axis X becomes larger than the dimension of the core portion 30 along the first axis X. Furthermore, the dimension of the first flange portion 40A along the second axis Y becomes larger than the dimension of the core portion 30 along the second axis Y.
[0022] The end face of the outer surface of the first flange portion 40A facing the first positive direction X1 is orthogonal to the first axis X. Additionally, the end face of the outer surface of the first flange portion 40A facing the first negative direction X2 is orthogonal to the first axis X.
[0023] The second flange portion 40B, one of a pair of flange portions 40, is connected to the second end, which is the end of the core portion 30 in the negative direction C2. The second flange portion 40B has a shape that is symmetrical to the first flange portion 40A in the direction along the central axis CA. That is, when viewed from the circumferential surface of the core portion 30, the second flange portion 40B extends radially outward with the central axis CA as the center.
[0024] The drum-shaped core 20 is made of a magnetic material. For example, the drum-shaped core 20 can be made of magnetic ceramics, such as nickel-zinc ferrite, metallic magnetic powder, ceramic powder, synthetic resin materials, and mixtures of these materials.
[0025] The first external electrode 80A, which is one of the two external electrodes 80, is located at the end of the first flange portion 40A in the first negative direction X2. Specifically, the first external electrode 80A is disposed on the portion of the outer surface of the first flange portion 40A on the first negative direction X2 side when viewed from the central axis CA, particularly the portion extending from the circumference of the core portion 30 towards the first negative direction X2 side. The first external electrode 80A is located on the end face of the first flange portion 40A on the first negative direction X2 side and a portion of each of the four faces adjacent to this end face.
[0026] The second external electrode 80B, which is the other of the two external electrodes 80, is located at the end of the second flange portion 40B in the first negative direction X2. Specifically, the second external electrode 80B is disposed on the portion of the outer surface of the second flange portion 40B on the first negative direction X2 side when viewed from the central axis CA, particularly the portion extending from the circumference of the core portion 30 towards the first negative direction X2 side. The second external electrode 80B is located on the end face of the second flange portion 40B on the first negative direction X2 side and a portion of each of the four faces adjacent to this end face.
[0027] Each external electrode 80 is, for example, composed of a metal layer such as silver or copper and a plating layer such as nickel or tin applied to the surface of that metal layer. Furthermore, the end face on the first negative direction X2 side of the outer surface of the first flange portion 40A and the second flange portion 40B, i.e., the surface where the external electrode 80 is disposed, is a mounting surface 90. Moreover, each mounting surface 90 is orthogonal to the first axis X. In addition, the layer structure of the external electrode 80 is omitted in the accompanying drawings.
[0028] The wire 50 is wound around the core portion 30. The wire 50 is wound into a spiral shape with the central axis CA as the winding center axis. The wire 50 has a wiring structure in which an insulating film is used to cover the wire from the radial outward side, and the wire is made of copper or the like. The first end of the wire 50 is connected to the first external electrode 80A. The second end of the wire 50 is connected to the second external electrode 80B.
[0029] The top plate 60 is generally a flat, roughly rectangular parallelepiped with small dimensions along the first axis X. The top plate 60 is made of the same magnetic material as the drum-shaped core 20.
[0030] like Figure 2 As shown, the top plate 60 has a main surface 60A, two first end surfaces 60B, and two second end surfaces 60C. The main surface 60A is the surface of the top plate 60 that is opposite to the first flange portion 40A and the second flange portion 40B. Furthermore, when the main surface 60A is viewed in a direction orthogonal to the main surface 60A, the main surface 60A is rectangular.
[0031] like Figure 3 As shown, the dimension of the top plate 60 along the central axis CA is longer than the dimension of the drum-shaped core 20 along the central axis CA. Furthermore, the dimension of the drum-shaped core 20 along the central axis CA is the distance from the end of the first flange portion 40A in the positive direction C1 to the end of the second flange portion 40B in the negative direction C2. Here, the dimension in the direction orthogonal to the central axis CA and parallel to the main surface 60A and the mounting surface 90, i.e., the dimension along the second axis Y, is taken as the width dimension. The width dimension of the top plate 60 is longer than the width dimensions of the first flange portion 40A and the second flange portion 40B. Furthermore, the dimension of the drum-shaped core 20 along the central axis CA, its width dimension, and its dimension along the first axis X are, for example, 1.6 mm, 0.8 mm, and 1.1 mm, respectively.
[0032] like Figure 1 As shown, the top plate 60 is connected to the end face of the first flange portion 40A in the first positive direction X1 via resin 55. Additionally, the top plate 60 is connected to the end face of the second flange portion 40B in the first positive direction X1 via resin 55. That is, the top plate 60 is connected to each flange portion 40 to support the first flange portion 40A and the second flange portion 40B. The resin 55 has adhesive force. That is, the resin 55 bonds the top plate 60 and the flange portions 40. Furthermore, in Figure 2 and Figure 3 The illustration of resin 55 is omitted in the text.
[0033] Each first end face 60B is a face perpendicular to the main face 60A. In this embodiment, the first end faces 60B are the end faces in the positive direction C1 and the negative direction C2 of the outer surface of the top plate 60.
[0034] Each second end face 60C is perpendicular to the main end face 60A and the first end face 60B. That is, the first end face 60B and the second end face 60C are perpendicular to each other. In this embodiment, the second end faces 60C are the end faces in the second positive direction Y1 and the second negative direction Y2 of the top plate 60, respectively.
[0035] The top plate 60 has four protrusions 61. The four protrusions 61 are located at each corner of the main surface 60A. Two of the four protrusions 61 are first protrusions 71 that protrude from the main surface 60A toward the first flange 40A. The remaining two protrusions 61 are second protrusions 72 that protrude from the main surface 60A toward the second flange 40B.
[0036] like Figure 2 As shown, when viewing the top plate 60 in the first positive direction X1, each of the first protrusions 71 and each of the second protrusions 72 is generally quadrilateral in shape. Furthermore, each of the first protrusions 71 and each of the second protrusions 72 is a pointed shape, decreasing in size towards the first negative direction X2 along the central axis CA and in size along the second axis Y. In other words, each of the first protrusions 71 and each of the second protrusions 72 is approximately a frustum-shaped quadrangular pyramid.
[0037] Each first protrusion 71 has a front face 62 and four side faces 63. The front face 62 is the outer surface of the first protrusion 71 that is closest to the first flange portion 40A. The front face 62 is parallel to the main face 60A. A portion of the front face 62 contacts the first flange portion 40A. When viewed in the first positive direction X1, the front face 62 is approximately quadrilateral in shape. The outer edges of the front face 62 are parallel to the outer edges of the top plate 60.
[0038] The four side faces 63 are surfaces on the outer surface of the first protrusion 71 that extend from the front end face 62 toward the main face 60A. Each side face 63 extends from each edge of the front end face 62. The side faces 63 are continuous with each other.
[0039] The four sides 63 can be roughly divided into two vertical surfaces 63A and two inclined surfaces 63B. Each vertical surface 63A is a surface parallel to the first axis X. That is, each vertical surface 63A is a surface perpendicular to the central axis CA or the second axis Y.
[0040] One of the two vertical surfaces 63A is connected to and coplanar with the first end face 60B. In other words, there is no step difference between the vertical surface 63A and the first end face 60B; they are connected to each other on the same plane. In other words, at the connection between the vertical surface 63A and the first end face 60B, there is no surface parallel to the main surface 60A. Furthermore, this vertical surface 63A is the surface on the outer surface of the first protrusion 71 facing the positive direction C1. This vertical surface 63A corresponds to the first vertical surface connected to and coplanar with the first end face 60B.
[0041] Furthermore, the other of the two vertical surfaces 63A is connected to and coplanar with the second end face 60C. In other words, there is no step difference between the vertical surface 63A and the second end face 60C; they are connected to each other on the same plane. In other words, at the connection between the vertical surface 63A and the second end face 60C, there is no surface parallel to the main surface 60A. Additionally, this vertical surface 63A is the outward-facing surface of the outer surface of the first protrusion 71 along the second axis Y. This vertical surface 63A corresponds to the second vertical surface connected to and coplanar with the second end face 60C.
[0042] Each inclined surface 63B is inclined relative to the first axis X. That is, each inclined surface 63B is inclined relative to the first end face 60B and the second end face 60C. The inclined surface 63B reflects the approximate square pyramid shape of the first protrusion 71 and is inclined further away from the center of the front end face 62 as it moves towards the first positive direction X1.
[0043] Each second protrusion 72, like the first protrusion 71 described above, has a front end face 62 and four side faces 63. Furthermore, the four side faces 63 can be roughly divided into two vertical faces 63A and two inclined faces 63B. One of the two vertical faces 63A is connected to and coplanar with the first end face 60B. The remaining vertical face 63A is connected to and coplanar with the second end face 60C. That is, the vertical face 63A of the second protrusion 72 facing the negative direction C2 corresponds to the first vertical face connected to and coplanar with the first end face 60B. Moreover, the vertical face 63A of the second protrusion 72 facing outwards along the second axis Y corresponds to the second vertical face connected to and coplanar with the second end face 60C.
[0044] Furthermore, the two first protrusions 71 are of the same size and are symmetrical in shape. Additionally, the two second protrusions 72 are of the same size and are symmetrical in shape. Moreover, the two first protrusions 71 on the positive direction C1 side and the two second protrusions 72 on the negative direction C2 side are symmetrically structured and symmetrically arranged along the central axis CA.
[0045] Here, as Figure 3 As shown, when viewing the inductor component 10 in the first negative direction X2, the area where the front end face 62 of the first protrusion 71 overlaps with the first flange portion 40A is defined as the overlap range R. More specifically, the overlap range R is the area where the front end face 62 contacts the first flange portion 40A. Furthermore, the term "contact" also includes the case where they contact each other via adhesive. In this embodiment, since there are two first protrusions 71 opposite to the first flange portion 40A, there are also two overlap ranges R.
[0046] Furthermore, the total area of these two overlapping regions R is less than 1 / 3 of the area A of the first flange portion 40A facing the top plate 60. Additionally, the surface of the first flange portion 40A facing the top plate 60 is included in the surface of the first flange portion 40A parallel to the main surface 60A and facing the main surface 60A. Moreover, when viewing the inductor component 10 towards the first negative direction X2, the area overlapping with the main surface 60A in this surface is considered the surface of the first flange portion 40A facing the top plate 60. Therefore, in this embodiment, the area A is equal to the area of the end face of the first flange portion 40A on the first positive direction X1 side.
[0047] Furthermore, as described above, the second flange portion 40B has a shape that is symmetrical to the first flange portion 40A along the direction of the central axis CA. Therefore, when the overlap range of the front end face 62 of the second protrusion 72 opposite to the second flange portion 40B and the second flange portion 40B is defined as the overlap range R, the total area of these two overlap ranges R is less than 1 / 3 of the area A of the second flange portion 40B opposite to the top plate 60.
[0048] Furthermore, as described above, the dimensions of the top plate 60 along the central axis CA and along the second axis Y are both larger than the dimensions of the drum-shaped core 20. Therefore, when the inductor component 10 is viewed toward the first negative direction X2, a portion of the front end face 62 of the first protrusion 71 and the second protrusion 72 protrudes from the drum-shaped core 20.
[0049] like Figure 1As shown, since the top plate 60 has a first protrusion 71, a space P is created between the main surface 60A of the top plate 60 and the end face of the first flange portion 40A on the first positive direction X1 side. This space P is filled with the aforementioned resin 55. Here, a plurality of first protrusions 71 are arranged along the second axis Y of the first flange portion 40A. That is, in this embodiment, the area enclosed by the two first protrusions 71, the top plate 60, and the surface of the first flange portion 40A opposite to the main surface 60A is filled with resin 55. In this embodiment, the resin 55 covers the entire surface of each flange portion 40 on the first positive direction X1 side. The thickness of the resin 55 between the first flange portion 40A and the front end face 62 is negligible compared to the thickness of the resin 55 between the flange portion 40 and the main surface 60A. The resin 55 may, for example, contain magnetic powder such as ferrite powder. When the resin 55 contains magnetic powder, the saturation magnetic flux density when a current is applied to the inductor component 10 can be adjusted. That is, it is possible to adjust the DC overlap characteristics. In addition, on the second flange portion 40B side, the space P is also filled with resin 55.
[0050] Here, the manufacturing method of the inductor component 10 will be described.
[0051] First, to create the drum-shaped core 20, ferrite powder is placed in a mold and pressed into shape. Then, the molded body obtained through pressing is sintered. Next, the sintered body is roller-processed to remove burrs and other imperfections, thus creating the drum-shaped core 20. The top plate 60 is also manufactured using the same process. Therefore, each protrusion 61 has a generally pointed shape, allowing for rapid demolding after pressing.
[0052] Next, an outer electrode 80 is stacked at the end of the drum-shaped core 20 in the first negative direction X2. Then, a wire 50 is wound around the core portion 30 of the drum-shaped core 20. Each end of the wire 50 is heated and pressure-welded, and connected to the first outer electrode 80A and the second outer electrode 80B, respectively. The wire 50 protruding from the outer electrode 80 is cut off. Furthermore, in Figure 2 The exploded view shows the wire 50 and the external electrode 80, but in the inductor component 10, the ends of the wire 50 are located inside the first external electrode 80A and the second external electrode 80B, respectively.
[0053] Similarly, the top plate 60 is pressed and molded, and then rolled to remove burrs and other imperfections. Then, resin 55 is applied to the end face of the flange portion 40 of the drum-shaped core 20 on the first positive direction X1 side, and the top plate 60 is bonded together.
[0054] <Simulation of the inductor component in the first embodiment>
[0055] The resulting inductance was simulated by changing the shapes of the first protrusion 71 and the second protrusion 72, and by changing the area of the overlap range R. Specifically, the inductance was simulated by changing the overlap range R so that the total value of the overlap range R / area A was in the range of 1 to 1 / 6. Furthermore, in the simulation, the parameters of the overlap range R on the first flange portion 40A side and the overlap range R on the second flange portion 40B side were consistent. Here, the state where the total value of the overlap range R / area A is 1 is the state where the two first protrusions 71 are integrated, and the entire end face of the first positive direction X1 side of the first flange portion 40A is in contact with the first protrusion 71. This is also true for the second protrusion 72.
[0056] When the inductance generated by applying a sufficiently small current to the inductor component without causing magnetic flux saturation is set as the initial value L, the initial value L gradually decreases as the total value of the overlapping range R / area A decreases from 1.
[0057] Here, the initial L value decreases sharply when the total value of the overlapping range R / area A decreases from 1 to 1 / 3. For example, the initial L value when the total value of the overlapping range R / area A is 1 / 3 is approximately 40% of the initial L value when the total value of the overlapping range R / area A is 1.
[0058] On the other hand, when the sum of the overlapping range R / area A is less than 1 / 3, the initial L value does not decrease much even if the sum of the overlapping range R / area A decreases. For example, the initial L value when the sum of the overlapping range R / area A is 1 / 6 is about 85% of the initial L value when the sum of the overlapping range R / area A is 1 / 3.
[0059] Based on these results, it can be seen that if the total value of the overlap range R / area A is less than 1 / 3, even if the dimensions of the flange 40 and the top plate 60 change due to manufacturing errors, the influence on the initial L value of the inductor component can be suppressed.
[0060] Furthermore, when the inductance generated by applying a relatively large current to the inductor component to produce magnetic flux saturation is taken as the saturation L value, the saturation L value gradually increases as the total value of the overlapping range R / area A decreases from 1. In addition, a large saturation L value means that even when a large current is applied, the inductance is difficult to decrease from the initial L value.
[0061] Here, when the sum of overlapping ranges R / area A decreases from 1 to 1 / 3, the saturation L value increases sharply. For example, the saturation L value when the sum of overlapping ranges R / area A is 1 / 3 is approximately 4.5 times the saturation L value when the sum of overlapping ranges R / area A is 1. On the other hand, when the sum of overlapping ranges R / area A is less than 1 / 3, even if the sum of overlapping ranges R / area A decreases, the saturation L value does not increase much and remains roughly constant.
[0062] These results show that if the total value of the overlap range R / area A is less than 1 / 3, then even if the dimensions of the flange 40 and the top plate 60 change due to manufacturing errors, the influence on the saturation L value of the inductor component, i.e., the DC overlap characteristic, can be suppressed. Furthermore, with such an inductor component structure, the influence on the DC overlap characteristic can be suppressed, thus obtaining a stable DC overlap characteristic.
[0063] <Effects of the First Implementation>
[0064] (1-1) In the above embodiment, one of the vertical surfaces 63A of the first protrusion 71 is connected to and coplanar with the first end face 60B. The vertical surface 63A is not a shape that expands towards the top plate 60 like the inclined surface 63B. Therefore, compared to the case where the entire side surface 63 of the first protrusion 71 is an inclined surface 63B, the placement space for the first protrusion 71 on the main surface 60A of the top plate 60 can be reduced. Furthermore, since the vertical surface 63A is coplanar with the first end face 60B, even when the top plate 60 is formed by stamping using a mold, it is less likely to become an obstacle when demolding. The same effect is achieved for the second protrusion 72 on the second flange portion 40B side.
[0065] (1-2) In the above embodiment, one of the vertical surfaces 63A of the first protrusion 71 is connected to and coplanar with the second end face 60C. Compared to the case where the entire side surface 63 of the first protrusion 71 is an inclined surface 63B, the proportion occupied by the inclined surface 63B in the first protrusion 71 is smaller. That is, the placement space of the first protrusion 71 on the main surface 60A of the top plate 60 can be further reduced. The same effect can be obtained for the second protrusion 72 on the side of the second flange portion 40B.
[0066] (1-3) In the above embodiments, the total value of the overlap range R / area A is less than 1 / 3 on both the first flange portion 40A and the second flange portion 40B. Therefore, even if the total value of the overlap range R / area A changes due to manufacturing errors, the initial L value and DC overlap characteristics will not change significantly. In other words, in the above embodiments, individual differences in the characteristics of each inductor component 10 can be suppressed.
[0067] (1-4) In the above embodiments, the end of the wire 50 is connected to the external electrode 80 on the side opposite to the top plate 60. Therefore, the end of the wire 50 does not interfere with the top plate 60. In addition, considering the need to avoid interference between the wire 50 and the top plate 60, it is not necessary to set the height dimensions of the first protrusion 71 and the second protrusion 72.
[0068] (1-5) In the above embodiments, resin 55 is filled between the main surface 60A and the surface of the first flange portion 40A opposite to the main surface 60A. This structure makes the connection between the top plate 60 and the first flange portion 40A more stable. The same effect can be achieved on the side of the second flange portion 40B.
[0069] (1-6) In the above embodiments, the dimension of the top plate 60 along the central axis CA is longer than the dimension of the drum-shaped core 20 along the central axis CA. When manufacturing the inductor component 10, it is assumed that there is an offset in the relative positional relationship between the top plate 60 and the first flange portion 40A and the second flange portion 40B along the central axis CA. In this case, according to the above structure, the contact area between the front end face 62 and the first flange portion 40A and the second flange portion 40B is easily kept constant. Therefore, the electrical characteristics of the inductor component 10 are less prone to individual variations.
[0070] (1-7) In the above embodiments, the width of the top plate 60 is longer than the width of the drum-shaped core 20. Similar to the effect in (1-6), it is assumed that during the manufacturing of the inductor component 10, the relative positional relationship between the top plate 60 and the first flange 40A and the second flange 40B is offset in the direction along the second axis Y. In this case, the contact area between the front end face 62 and the first flange 40A and the second flange 40B is easily kept constant. Therefore, the electrical characteristics of the inductor component 10 are less prone to individual variations.
[0071] (1-8) When a current is applied to the inductor component 10, magnetic flux passes from the flange 40 to the top plate 60. The magnetic flux density increases in the portion near the central axis CA of the flange 40. In this embodiment, the first protrusion 71 and the second protrusion 72 are located at the corners of the top plate 60. According to this structure, it is not easily affected by changes in magnetic flux. Therefore, the characteristics of the inductor component 10 are easily stabilized.
[0072] <Second Implementation>
[0073] Next, a second embodiment of the inductor component 10 will be described. The inductor component 10 of the second embodiment differs from that of the inductor component 10 of the first embodiment in the structures related to the first protrusion 71 and the second protrusion 72. Other structures are the same as in the first embodiment. Hereinafter, the positions related to the first protrusion 71 and the second protrusion 72 will be described. Furthermore, descriptions of structures identical to those in the first embodiment will be simplified or omitted.
[0074] like Figure 4 As shown, the inductor component 10 includes a drum-shaped core 20, wires 50, a top plate 60, and two external electrodes 80. Furthermore, in Figure 4 In the figure, the resin used to bond the top plate 60 and the flange 40 is omitted.
[0075] The top plate 60 is a flat, rectangular parallelepiped with a small dimension along the direction of the first axis X. The top plate 60 has a main surface 60A opposite to a pair of flanges 40 in the top plate 60. Furthermore, in the second embodiment, the top plate 60 may not have protrusions.
[0076] The first flange portion 40A of the drum-shaped core 20 includes a first plane 42, a first end face 43A, and two second end faces 43B. The first plane 42 is the surface of the first flange portion 40A opposite to the main surface 60A. That is, the first plane 42 is the end face of the first flange portion 40A in the first positive direction X1.
[0077] The first end face 43A is a face perpendicular to the first plane 42. In this embodiment, the first end face 43A is the face on the outer surface of the flange portion 40 facing the side opposite to the core portion 30. In other words, the first end face 43A of the first flange portion 40A is the end face in the positive direction C1 on the outer surface of the first flange portion 40A. Furthermore, the first end face 43A of the second flange portion 40B is the end face in the negative direction C2 on the outer surface of the second flange portion 40B.
[0078] Each second end face 43B is a surface perpendicular to the first plane 42 and the first end face 43A. That is, the first end face 43A and the second end face 43B are perpendicular to each other. In this embodiment, the second end face 43B is the end face in the second positive direction Y1 and the end face in the second negative direction Y2 on the outer surface of the first flange portion 40A.
[0079] The first flange portion 40A has two first protrusions 71. Each first protrusion 71 protrudes from a position on the first plane 42 opposite to the top plate 60 toward the top plate 60. The first protrusions 71 are respectively located at the end of the first flange portion 40A in the second positive direction Y1 and the end in the second negative direction Y2.
[0080] When viewed in the first negative direction X2, each first protrusion 71 is generally quadrilateral in shape. Furthermore, each first protrusion 71 is a pointed shape that decreases in size towards the first positive direction X1 along the central axis CA and in size along the second axis Y. In other words, each first protrusion 71 is approximately a truncated pyramid shape.
[0081] Each first protrusion 71 has a front face 62 and four side faces 63. The front face 62 is the outer surface of the first protrusion 71 that is closest to the top plate 60. The front face 62 is parallel to the first plane 42. The front face 62 is in contact with the top plate 60. When viewed in the first negative direction X2, the front face 62 is approximately quadrilateral in shape. The outer edges of the front face 62 are parallel to the outer edges of the flange portion 40.
[0082] The four side faces 63 are surfaces on the outer surface of the first protrusion 71 that extend from the front end face 62 toward the first plane 42. Each side face 63 extends from each side of the front end face 62. The side faces 63 are continuous with each other.
[0083] The four sides 63 can be roughly divided into two vertical surfaces 63A and two inclined surfaces 63B. Each vertical surface 63A is parallel to the first axis X. That is, each vertical surface 63A is perpendicular to the central axis CA or the second axis Y. One of the two vertical surfaces 63A is connected to and coplanar with the first end surface 43A. In other words, there is no step difference between the vertical surface 63A and the first end surface 43A; they are connected to each other in the same plane. In other words, at the connection between the vertical surface 63A and the first end surface 43A, there is no surface parallel to the main surface 60A. In addition, the vertical surface 63A is the surface on the outer surface of the first protrusion 71 facing the positive direction C1. This first vertical surface 63A corresponds to the first vertical surface connected to and coplanar with the first end surface 43A.
[0084] Furthermore, the other of the two vertical surfaces 63A is connected to and coplanar with the second end surface 43B. In other words, there is no step difference between the vertical surface 63A and the second end surface 43B; they are connected to each other on the same plane. In other words, at the connection between the vertical surface 63A and the second end surface 43B, there is no surface parallel to the main surface 60A. Additionally, the vertical surface 63A is the outward-facing surface of the outer surface of the first protrusion 71 along the second axis Y. This second vertical surface 63A corresponds to the second vertical surface connected to and coplanar with the second end surface 43B.
[0085] Each inclined surface 63B is inclined relative to the first axis X. That is, each inclined surface 63B is inclined relative to the first end face 43A and the second end face 43B. The inclined surface 63B reflects the approximate square pyramid shape of the first protrusion 71, and the inclination is such that the closer it is to the first negative direction X2, the further away it is from the center of the front end face 62.
[0086] The second flange portion 40B has two second protrusions 72. Each second protrusion 72 protrudes from a position on the first plane 42 opposite to the top plate 60 toward the top plate 60. The second protrusions 72 are respectively located at the end of the second flange portion 40B in the second positive direction Y1 and the end in the second negative direction Y2.
[0087] When viewed in the first negative direction X2, each second protrusion 72 is generally quadrilateral in shape. Furthermore, each second protrusion 72 is a pointed shape that decreases in size towards the first positive direction X1 along the central axis CA and in size along the second axis Y. In other words, each second protrusion 72 is approximately a truncated pyramid shape.
[0088] Each second protrusion 72, like the first protrusion 71 described above, has a front end face 62 and four side faces 63. Furthermore, the four side faces 63 can be roughly divided into two vertical faces 63A and two inclined faces 63B. One of the two vertical faces 63A is connected to and coplanar with the first end face 43A. The remaining one of the two vertical faces 63A is connected to and coplanar with the second end face 43B. That is, the vertical face 63A of the second protrusion 72 facing the negative direction C2 corresponds to the first vertical face 43A, which is connected to and coplanar with the first end face 43A. Moreover, the vertical face 63A of the second protrusion 72 facing outwards along the second axis Y corresponds to the second vertical face 43B, which is connected to and coplanar with the second end face 43B.
[0089] Furthermore, the two first protrusions 71 are of the same size and are symmetrical in shape. Additionally, the two second protrusions 72 are of the same size and are symmetrical in shape. Moreover, the two first protrusions 71 on the positive direction C1 side and the two second protrusions 72 on the negative direction C2 side are symmetrically structured and symmetrically arranged along the central axis CA.
[0090] Here, when viewing the inductor component 10 in the first negative direction X2, the area where the front end face 62 of the first protrusion 71 overlaps with the top plate 60 is defined as the overlap range R. More specifically, the overlap range R is the area where the front end face 62 contacts the top plate 60. Furthermore, the term "contact" also includes the case where they contact each other via adhesive. In this embodiment, since there are two first protrusions 71 on the first flange portion 40A side, there are also two overlap ranges R. Furthermore, in this embodiment, the area of each overlap range R is equal to the area of each front end face 62. Moreover, the total area of these two overlap ranges R is less than 1 / 3 of the area A of the first flange portion 40A facing the top plate 60. Furthermore, the surface of the first flange portion 40A facing the top plate 60 includes the surface of the first flange portion 40A that is parallel to the main surface 60A and faces the main surface 60A. When observing the inductor component 10 in the first negative direction X2, the area of this surface that overlaps with the main surface 60A is taken as the surface of the first flange portion 40A opposite to the top plate 60.
[0091] Furthermore, on the second flange portion 40B side, the structure of the overlapping range R is the same as that on the first flange portion 40A side. That is, when the overlapping range of the front end face 62 of the second protrusion 72 opposite to the second flange portion 40B and the second flange portion 40B is taken as the overlapping range R, the total area of these two overlapping ranges R is less than 1 / 3 of the area A of the second flange portion 40B opposite to the top plate 60.
[0092] <Effects of the Second Implementation>
[0093] Next, the effects of the second embodiment will be explained. In addition to the effects of (1-3) to (1-7) of the first embodiment, the inductor component 10 of the second embodiment also has the following effects.
[0094] (2-1) In the above embodiment, one of the vertical surfaces 63A of each first protrusion 71 is connected to and coplanar with the first end face 43A. In other words, the vertical surface 63A is not a shape that expands towards the top plate 60 like the inclined surface 63B. Therefore, compared to the case where the entire side surface 63 of the first protrusion 71 is an inclined surface 63B, the arrangement space of the first protrusions 71 on the first plane 42 of the first flange portion 40A can be reduced. Furthermore, since the vertical surface 63A is coplanar with the first end face 43A, even when the drum-shaped core 20 is formed by stamping using a mold, it is difficult for it to become an obstacle when demolding the mold. The same effect can be obtained for the second protrusion 72.
[0095] (2-2) In the above embodiment, one surface of the vertical surface 63A of each first protrusion 71 is connected to and coplanar with the second end surface 43B. In the above embodiment, compared to the case where the entire side surface 63 of the first protrusion 71 is an inclined surface 63B, the proportion occupied by the inclined surface 63B in the first protrusion 71 is smaller. That is, the arrangement space of the first protrusions 71 on the first plane 42 of the first flange portion 40A can be further reduced. The same effect can be obtained for the second protrusion 72.
[0096] <Example of Change>
[0097] This embodiment can be modified and implemented as follows. This embodiment and the following modifications can be combined and implemented with each other within the scope of technical inconsistency.
[0098] In each embodiment, the core portion 30 can be cylindrical, regardless of its shape. For example, the core portion 30 can also be cylindrical. Furthermore, the shapes of the first flange portion 40A and the second flange portion 40B are not limited to flat cuboids. Viewed from the circumferential surface of the core portion 30, the first flange portion 40A and the second flange portion 40B can extend radially outward about the central axis CA.
[0099] In various embodiments, the top plate 60 may have the same or shorter dimensions as the drum-shaped core 20 along the central axis CA. Similarly, the width of the top plate 60 may have the same or shorter dimensions as the flange portion 40. The top plate 60 can be connected to support the first flange portion 40A and the second flange portion 40B.
[0100] In various embodiments, the position of the external electrode 80 is not limited to the end of the outer surface of the first flange portion 40A and the second flange portion 40B on the side of the first negative direction X2 when viewed from the central axis CA. For example, the external electrode 80 may also be disposed on the end face of the first flange portion 40A and the second flange portion 40B on the side of the first positive direction X1.
[0101] In various embodiments, a first protrusion 71 may be provided on the top plate 60 at a position opposite to the first flange portion 40A, and a second protrusion 72 may not be provided on the top plate 60 at a position opposite to the second flange portion 40B. In this case, the entire surface of the end face on the first positive direction X1 side of the second flange portion 40B side is connected to the top plate 60.
[0102] • In various embodiments, the edges and corners of the top plate 60 may also have rounded corners. For example, the main surface 60A and the first end surface 60B, the first end surface 60B and the second end surface 60C, and the second end surface 60C and the main surface 60A may also be connected to each other with rounded corners. Similarly, the front end surface 62 and the side surface 63 of the first protrusion 71 may also be connected to each other with rounded corners. The same applies to the second protrusion 72.
[0103] • In various embodiments, a portion of the first protrusion 71 may also be frustum-shaped. That is, the first protrusion 71 only needs to have a vertical surface 63A, and the inclined surface 63B in the first protrusion 71 may also be the side surface shape of a frustum. The same applies to the second protrusion 72.
[0104] • In various embodiments, the shape of each protrusion 61 may also be different. That is, the four protrusions 61 may not be symmetrical. In addition, the protrusions 61 may not be arranged in symmetrical positions.
[0105] In various embodiments, the total area of the overlapping range R can be greater than 1 / 3 of the area A opposite to the top plate 60 of the first flange 40A. However, if the total area of the overlapping range R divided by the area A is less than 1 / 30, the initial value of L becomes quite small. That is, it approaches the characteristics of the inductor component 10 when it does not have the top plate 60. In addition, if the total area of the overlapping range R divided by the area A is less than 1 / 30, it is difficult to accurately control the size of the first protrusion 71.
[0106] Therefore, from the viewpoint of balancing inductance and DC overlap characteristics, and the ease of manufacturing the first protrusion 71, this ratio is preferably 1 / 3 or less and 1 / 30 or more; from the viewpoint of the ease of manufacturing the first protrusion 71, this ratio is preferably 1 / 10 or more. This also applies to the overlap range R on the second flange portion 40B side.
[0107] In various embodiments, resin 55 may be filled only in a portion of the space P between the top plate 60 and the end face on the first positive direction X1 side of the first flange portion 40A. Alternatively, as long as the top plate 60 and the first flange portion 40A can be connected, resin 55 may not be filled into the space P. The same applies to the space P on the side of the second flange portion 40B.
[0108] In the first embodiment, the top plate 60 may not be a flat, approximately rectangular parallelepiped. For example, when viewed from the first positive direction X1, the top plate 60 may be a hexagon or other polygonal shape. Furthermore, for example, if the top plate 60 is hexagonal, the surfaces of the top plate 60 that are orthogonal to the main surface 60A and adjacent to the first protrusion 71 and the second protrusion 72 are respectively designated as the first end face 60B and the second end face 60C. In this case, although the second end face 60C intersects with the first end face 60B, it is not limited to being perpendicular. This is also true in the second embodiment.
[0109] In the first embodiment, the entire front end face 62 of the first protrusion 71 may contact the drum-shaped core 20. For example, if the dimensions of the top plate 60 along the central axis CA and along the second axis Y are equal to the dimensions of the drum-shaped core 20, then the entire front end face 62 of the first protrusion 71 contacts the first flange portion 40A. The same applies to the second protrusion 72 on the second flange portion 40B side.
[0110] In the first embodiment, the first protrusion 71 may have only one vertical surface 63A. In this case, the vertical surface 63A may be coplanar with either the first end surface 60B or the second end surface 60C of the top plate 60. Alternatively, the first protrusion 71 may have three or more vertical surfaces 63A. In this case, one side surface 63 of the first protrusion 71 is coplanar with the first end surface 60B, and the other two side surfaces 63 are coplanar with a pair of second end surfaces 60C respectively. The same applies to the second protrusion 72. Furthermore, this also applies in the second embodiment.
[0111] Explanation of reference numerals in the attached figures
[0112] CA…Central axis; 10…Inductor component; 20…Drum-shaped core; 30…Core section; 40…Flange section; 40A…First flange section; 40B…Second flange section; 50…Wire; 60…Top plate; 60A…Main surface; 60B…First end face; 60C…Second end face; 61…Protrusion; 62…Front end face; 63…Side surface; 63A…Vertical surface; 63B…Inclined surface; 71…First protrusion; 72…Second protrusion.
Claims
1. An inductor component comprising: The drum-shaped core has a columnar core portion, a first flange portion, and a second flange portion, wherein, The columnar core extends around the central axis. The first flange is connected to the first end of the core in the direction of extension of the central axis and extends radially outward from the circumferential surface of the core. The second flange is connected to the second end of the core in the direction of extension of the central axis and extends radially outward from the circumferential surface of the core. The wire is wound around the aforementioned core portion; and Top plate, connected to the first flange portion and the second flange portion. The top plate includes: a main surface opposite to the first flange portion, an end surface perpendicular to the main surface, and a protrusion on the main surface that protrudes toward the first flange portion from a position opposite to the first flange portion. The aforementioned protrusion has a front face parallel to the aforementioned main surface and a side face extending from the aforementioned front face to the aforementioned main surface. The aforementioned side surface includes an inclined surface that is inclined relative to the aforementioned end face and a vertical surface that is connected to and coplanar with the aforementioned end face. The top plate has four protrusions, which are located at the corners of the main surface of the top plate. The surfaces of the first flange and the second flange that face the main surface of the top plate are flat. The aforementioned inclined surface includes a first inclined surface and a second inclined surface that intersects with the first inclined surface.
2. The inductor component according to claim 1, wherein, When viewed from a direction orthogonal to the aforementioned main surface, the main surface appears to be quadrilateral in shape. The aforementioned top plate includes a first end face and a second end face that are perpendicular to each other. As the aforementioned end faces... The protrusion has a first vertical surface that is connected to and coplanar with the first end face and a second vertical surface that is connected to and coplanar with the second end face, serving as the vertical surface.
3. The inductor component according to claim 1 or 2, wherein, When viewing the inductor component in a direction orthogonal to the aforementioned main surface, the overlap range between the aforementioned front end surface and the aforementioned first flange portion is taken as the overlap range. The total area of the aforementioned overlapping range is less than 1 / 3 of the area of the first flange portion opposite to the top plate.
4. The inductor component according to claim 1 or 2, wherein, It also has external electrodes. When the direction from the central axis toward the top plate, which is orthogonal to the central axis, is taken as the first direction, and the direction opposite to the first direction is taken as the second direction, The aforementioned external electrode is disposed on the portion of the outer surface of the first flange portion in the second direction when viewed from the central axis. The end of the aforementioned wire is connected to the aforementioned external electrode.
5. The inductor component according to claim 1 or 2, wherein, Resin is filled between the main surface and the surface of the first flange that faces the main surface.
6. The inductor component according to claim 1 or 2, wherein, The dimension of the top plate along the central axis is longer than the dimension of the drum-shaped core along the central axis.
7. The inductor component according to claim 1 or 2, wherein, When the dimension in the direction orthogonal to the aforementioned central axis and parallel to the aforementioned main surface is taken as the width dimension, The width of the top plate is greater than the width of the first flange.
8. An inductor component comprising: The drum-shaped core has a columnar core portion, a first flange portion, and a second flange portion, wherein, The columnar core extends around the central axis. The first flange is connected to the first end of the core in the direction of extension of the central axis and extends radially outward from the circumferential surface of the core. The second flange is connected to the second end of the core in the direction of extension of the central axis and extends radially outward from the circumferential surface of the core. The wire is wound around the aforementioned core portion; and Top plate, connected to the first flange portion and the second flange portion. The aforementioned top plate has a main surface opposite to the aforementioned first flange portion. The first flange portion has a first plane opposite to the main surface, an end face perpendicular to the first plane, and a first protrusion protruding from the first plane toward the top plate at a position opposite to the top plate. The first protrusion has a front end face parallel to the first plane and a side end extending from the front end face toward the first plane. The aforementioned side surface includes an inclined surface that is inclined relative to the aforementioned end face and a vertical surface that is connected to and coplanar with the aforementioned end face. The first flange portion has two first protrusions, the second flange portion has two second protrusions, and the main surface of the top plate is a plane. When viewing the inductor component in a direction orthogonal to the main surface, and taking the area where the front end surface overlaps with the top plate as the overlap area, The total area of the aforementioned overlapping range is less than 1 / 3 of the area of the first flange portion opposite to the top plate.
9. The inductor component according to claim 8, wherein, When viewed from a direction orthogonal to the aforementioned main surface, the first flange portion is quadrilateral in shape. The aforementioned first flange portion includes a first end face and a second end face that are perpendicular to each other, serving as the aforementioned end face. The first protrusion has a first vertical surface that is connected to and coplanar with the first end face and a second vertical surface that is connected to and coplanar with the second end face, serving as the vertical surface.
10. The inductor component according to claim 8 or 9, wherein, It also has external electrodes. When the direction from the central axis toward the top plate, which is orthogonal to the central axis, is taken as the first direction, and the direction opposite to the first direction is taken as the second direction, The aforementioned external electrode is disposed on the portion of the outer surface of the first flange portion in the second direction when viewed from the central axis. The end of the aforementioned wire is connected to the aforementioned external electrode.
11. The inductor component according to claim 8 or 9, wherein, Resin is filled between the main surface and the surface of the first flange that faces the main surface.
12. The inductor component according to claim 8 or 9, wherein, The dimension of the top plate along the central axis is longer than the dimension of the drum-shaped core along the central axis.
13. The inductor component according to claim 8 or 9, wherein a dimension in a direction orthogonal to the central axis and parallel to the main surface is taken as a width dimension, the width dimension of the top plate is larger than the width dimension of the first flange portion.