inductor

Abstract

An inductor (100) includes a magnetic core (10) including a magnetic material, a coil element (20) having a coil portion (21) and a lead-out portion (22), an electrode member (30) disposed on a side surface (13c) and a bottom surface (11), and a connection portion (40) connecting the lead-out portion (22) and the electrode member (30). The electrode member (30) has a bottom plate portion (31) disposed along the bottom surface (11), a side plate portion (35) disposed along the side surface (13c), and a first protruding plate portion (36) connected to the side plate portion (35) and protruding in a direction away from the side surface (13c). The lead-out portion (22) extends along the side plate portion (35) or the side surface (13c) outside the magnetic core (10). The first protruding plate portion (36) has an edge portion (E1) in contact with the lead-out portion (22) along an extension direction of the lead-out portion (22). The connection portion (40) has a first connection portion (41) after the lead-out portion (22) and the edge portion (E1) of the first protruding plate portion (36) are welded.

Description

Technical Field

[0001] This disclosure relates to inductors. Background Technology

[0002] Inductors, as passive components that store electrical energy as magnetic energy, are used, for example, in DC-DC converters to smooth the voltage rise / fall and direct current. Inductors are mounted on the surface of circuit boards, for example. For instance, Patent Document 1 discloses an inductor comprising a main body containing magnetic material, a coil element disposed inside the main body, and terminal metal pieces connected to the coil element. In the inductor described in Patent Document 1, the front end of the coil element protrudes from the main body, and terminal metal pieces are soldered to the exposed front end of the coil element.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2011-243685 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] In conventional inductors, the low reliability of the connection between the electrode components (which are terminal metal parts) and the coil element leads to low inductor reliability. This disclosure addresses this issue by aiming to improve the reliability of inductors.

[0008] Methods used to solve problems

[0009] An inductor according to a technical solution of this disclosure comprises: a magnetic core, comprising a magnetic material, having a bottom surface, a top surface, and a side surface connected to the bottom surface and the top surface; a coil element having a coil portion and a lead-out portion, the coil portion being embedded in the magnetic core, the lead-out portion being connected to an end of the coil portion and extending from the side surface to the outside of the magnetic core; an electrode component disposed on the side surface and the bottom surface; and a connecting portion connecting the lead-out portion and the electrode component; the electrode component having a base plate portion disposed along the bottom surface, a side plate portion connected to the base plate portion and disposed along the side surface, and a first protruding plate portion connected to the side plate portion and protruding in a direction away from the side surface; the lead-out portion extending outside the magnetic core along the side plate portion or the side surface; the first protruding plate portion having at least a portion of an edge portion contacting the lead-out portion along the extending direction of the lead-out portion; and the connecting portion having a first connecting portion after welding the lead-out portion to the edge portion of the first protruding plate portion.

[0010] Invention Effects

[0011] According to this disclosure, the reliability of inductors can be improved. Attached Figure Description

[0012] Figure 1 This is a perspective view of an inductor according to an implementation method.

[0013] Figure 2 It means from Figure 1 The diagram shows the inductor with the connection removed and the electrode components separated.

[0014] Figure 3 This is a front view of the inductor according to the implementation method.

[0015] Figure 4 This is a side view of an inductor according to an embodiment.

[0016] Figure 5 This is a top view of the inductor according to the implementation method.

[0017] Figure 6 This is a perspective view of the coil element included in the inductor according to the embodiment.

[0018] Figure 7 This refers to the lead-out portion and electrode components of the inductor in the relevant implementation method from... Figure 4 A cross-sectional view observed along line VII-VII.

[0019] Figure 8 This is a flowchart illustrating a method for manufacturing an inductor according to an embodiment.

[0020] Figure 9 This is a side view of an inductor according to a variation of the embodiment 1.

[0021] Figure 10 The lead-out portion and electrode components of the inductor in the modified embodiment 1 are from... Figure 9 Cross-sectional view of X-ray observation.

[0022] Figure 11 This is a perspective view of the inductor in a modified embodiment 2.

[0023] Figure 12 This is a side view of the inductor in a variation of the embodiment 2.

[0024] Figure 13 The lead-out portion and electrode components of the inductor in the modified embodiment 2 are from... Figure 12 A cross-sectional view observed along line XIII-XIII.

[0025] Figure 14 This is a perspective view of the inductor in variation 3 of the embodiment.

[0026] Figure 15This is a perspective view of the inductor in variation 4 of the implementation method. Detailed Implementation

[0027] (The process of reaching this agreement is made public)

[0028] In a structure where an electrode component is welded to the front end of the coil element, as described in Patent Document 1 above, the cross-sectional area of ​​the connection portion connecting the coil element and the electrode component decreases, leading to a decrease in the reliability of the connection between the coil element and the electrode component. Furthermore, in a structure where an electrode component is welded to the front end of the coil element, the cross-sectional area of ​​the current path at the welding point cannot be increased, resulting in increased DC resistance and a decrease in the reliability of the inductor. Additionally, if the cross-sectional area of ​​the current path at the welding point cannot be increased, a temperature rise occurs when the inductor is energized, further reducing the inductor's reliability.

[0029] This disclosure provides a structure as shown below to improve the reliability of the inductor. The embodiments will now be described in more detail with reference to the accompanying drawings.

[0030] Furthermore, the embodiments described below represent specific examples of this disclosure. The numerical values, shapes, materials, constituent elements, arrangement positions of constituent elements, connection methods, steps, and order of steps shown in the following embodiments are examples and are not intended to limit this disclosure. Moreover, any constituent elements in the following embodiments that are not described in the independent claims are treated as arbitrary constituent elements.

[0031] Furthermore, in this specification, terms indicating the relationship between elements such as parallelism, terms indicating the shape of elements such as cuboids, and numerical ranges are not merely expressions of a strict meaning, but rather imply substantially equal ranges, for example, including differences of a few percentage points.

[0032] Furthermore, the figures are schematic diagrams that have been appropriately emphasized, omitted, or proportionally adjusted to illustrate this disclosure, and are not necessarily exact representations; there are instances where the shapes, positional relationships, and proportions differ from the actual figures. In the figures, substantially identical structures are given the same labels, and repeated descriptions are sometimes omitted or simplified.

[0033] In addition, the X, Y, and Z axes, representing three mutually orthogonal directions, are shown in each figure for illustration purposes. These axes and their directions are used to explain the process. Furthermore, the axes are assigned for ease of explanation and do not restrict the direction or orientation of the inductor.

[0034] Furthermore, in this specification, the terms "top surface" and "bottom surface" in the structure of the inductor do not refer to the absolute spatial top surface (the surface on the vertically upward side) and bottom surface (the surface on the vertically downward side), but are used as terms defined by the relative positional relationship of the constituent elements of the inductor.

[0035] (Implementation Method)

[0036] [structure]

[0037] The structure of the inductor according to the relevant embodiments will be described. An inductor is a passive element that stores electrical energy flowing through a coil element as magnetic energy.

[0038] Figure 1 This is a perspective view of the inductor 100 according to the embodiment. Figure 2 It means from Figure 1 The diagram shows the inductor 100 with the connection portion 40 removed and the electrode component 30 separated. Figure 3 This is a front view of inductor 100. Figure 4 This is a side view of inductor 100. Figure 5 This is a top view of inductor 100. Additionally, in Figures 3 to 5 In this diagram, the front view is a view taken from the positive side of the X-axis towards the negative side, the side view is a view taken from the negative side of the Y-axis towards the positive side, and the top view is a view taken from the positive side of the Z-axis towards the negative side. The same applies to the other figures in the following description. Furthermore, in... Figure 5 Part of it also indicates Figure 4 A cross-sectional view of the inductor 100 along the V-V line is shown. Furthermore, in Figure 5 In the diagram, the top view shape of the coil element 20 is represented by solid or dashed lines.

[0039] like Figures 1 to 5 As shown, the inductor 100 includes a magnetic core 10, a coil element 20 having a coil portion 21 and a lead portion 22, an electrode component 30 serving as an external terminal, and a connecting portion 40 connecting the lead portion 22 and the electrode component 30.

[0040] In the following description, the positive half of the X-axis of the inductor 100 will be described in detail. The negative half of the X-axis of the inductor 100 has the same structure as the positive half of the X-axis of the inductor 100 and is subject to the same description.

[0041] The general shape of the inductor 100 is determined, for example, by the shape of the magnetic core 10, which is a cuboid-shaped pressed powder core. Furthermore, the magnetic core 10 can be molded into any shape. That is, by the shape of the magnetic core 10 during molding, an inductor 100 of any shape can be realized. In the magnetic core 10 of this embodiment, for example, the dimension in the X-axis direction is 17 mm or more, the dimension in the Y-axis direction is 17 mm or more, and the dimension in the Z-axis direction is 7 mm or more.

[0042] The magnetic core 10 is the outer casing of the inductor 100, covering a portion of the coil element 20. The magnetic core 10 contains a magnetic material, such as a pressed powder core composed of metallic magnetic powder and resin material. Furthermore, the magnetic core 10 can be formed using any magnetic material. Ferrite or other magnetic materials can be used. The metallic magnetic powder is a particulate material with a specified elemental composition, such as Fe-Si-Al, Fe-Si, Fe-Si-Cr, or Fe-Si-Cr-B. Furthermore, the resin material is a silicone resin or similar material that can maintain a certain shape by bonding the metallic magnetic powder particles together while insulating them from each other.

[0043] The magnetic core 10 is, for example, rectangular. The magnetic core 10 has a bottom surface 11, a top surface 12 facing away from the bottom surface 11, and four side surfaces 13a, 13b, 13c, and 13d connected to the bottom surface 11 and the top surface 12. Side surfaces 13a and 13b are arranged in the X-axis direction and face away from each other. Side surfaces 13c and 13d are arranged in the Y-axis direction and face away from each other. The bottom surface 11, the top surface 12, and the side surfaces 13a, 13b, 13c, and 13d are all flat planes. The group of bottom surfaces 11 and 12, the group of side surfaces 13a and 13b, and the group of side surfaces 13c and 13d are groups of surfaces in a parallel position. The bottom surface 11 and 12, and the side surfaces 13a, 13b, 13c, and 13d extend in intersecting directions, specifically in orthogonal directions. Furthermore, sides 13a and 13b extend in the direction of intersection with sides 13c and 13d, specifically in the direction of orthogonality.

[0044] The coil element 20 has a coil portion 21 embedded in the magnetic core 10 and a plurality of leads 22 exposed to the outside of the magnetic core 10.

[0045] Figure 6 This is a three-dimensional view of the coil element 20 of the inductor 100.

[0046] like Figure 6 As shown, the coil element 20 consists of one coil section 21 and two lead-out sections 22. Figure 6In the middle, the coil part 21 is the part on the positive side of the Y-axis that corresponds to the single-dot dashed line on the coil element 20, and the lead-out part 22 is the part on the negative side of the Y-axis that corresponds to the single-dot dashed line.

[0047] The coil element 20 is, for example, made of a wire. The wire is, for example, made of a metal wire and an insulating film covering the metal wire, said metal wire being made of a metallic material selected from metals such as aluminum, copper, silver, and gold, alloys containing one or more of these metals, and materials composed of metals or alloys and other substances. Specifically, the wire is, for example, copper wire covered with an insulating film. The coil section 21 and the lead-out section 22 are, for example, names given to various parts formed by machining a single component made of the same material.

[0048] The coil portion 21 is the part covered by the magnetic core 10. The coil portion 21 is composed of wound wire and functions as a coil. There is no particular limitation on the number of turns in the coil portion 21; for example, it can be from 0.5 turns to 10 turns, and is appropriately selected to match the performance requirements of the inductor 100 and the size of the magnetic core 10. The cross-section of the wire constituting the coil portion 21 is, for example, a circle with a diameter of 2 mm or more, and the aspect ratio of the cross-section is 1:1. The coil portion 21 is embedded in the magnetic core 10 with its winding axis a1 along the direction connecting the bottom surface 11 and the top surface 12 (Z-axis direction).

[0049] The coil portion 21 has two ends 21a and 21b that connect the wound portion to the side surface 13c of the magnetic core 10 (see reference). Figure 5 When viewed from a direction perpendicular to the side surface 13c, one end 21a of the coil portion 21 is positioned to the right and outer side of the winding axis a1, i.e., on the positive side of the X-axis, while the other end 21b is positioned to the left and outer side of the winding axis a1, i.e., on the negative side of the X-axis. Furthermore, when viewed from a direction perpendicular to the side surface 13c, the height of both ends 21a and 21b of the coil portion 21 relative to the bottom surface 11 is the same as the height relative to the top surface 11, compared to the center c1 of the side surface 13c.

[0050] like Figure 4 As shown, the lead-out portion 22 is connected to the end portion 21a or 21b of the coil portion 21, and extends outward from the side surface 13c of the magnetic core 10, along the side plate portion 35 or the side surface 13c. Specifically, the lead-out portion 22 is led out at a height higher than the center c1 of the side surface 13c and closer to the top surface 12, bends to cover the side plate portion 35 of the electrode member 30, extends in the direction (Z-axis direction) connecting the bottom surface 11 and the top surface 12, and is interrupted before reaching the end on the bottom surface 11 side. In this embodiment, the lead-out portion 22 is led out from one of the four side surfaces 13c.

[0051] like Figures 1 to 5As shown, the electrode component 30 is disposed on the outside of the magnetic core 10 (e.g., on the bottom surface 11 side and the side surface 13c side), and is electrically connected to the lead-out portion 22 via the connecting portion 40. The electrode component 30 is provided corresponding to each of the two lead-out portions 22. The electrode component 30 comprises a conductive material, such as a metal plate. The metal plate is made of a metal material selected from metals such as aluminum, copper, silver, and gold, alloys containing one or more of these metals, and materials composed of metals or alloys and other substances.

[0052] The electrode component 30 has a base plate portion 31 disposed on the bottom surface 11 side of the magnetic core 10, a side plate portion 35 connected to the base plate portion 31, and a first protruding plate portion 36 connected to the side plate portion 35. The base plate portion 31, the side plate portion 35, and the first protruding plate portion 36 are, for example, names given to various parts formed by processing a single component made of the same material.

[0053] The base plate portion 31 is disposed on the bottom surface 11 side of the magnetic core 10 such that it extends along the bottom surface 11. The base plate portion 31 is fixed to the magnetic core 10 by adhesive. The base plate portion 31 is bonded to the circuit board by solder when the inductor 100 is mounted to the circuit board.

[0054] The side plate portion 35 is connected to the bottom plate portion 31 and is disposed along the side surface 13c of the magnetic core 10. In this embodiment, the side plate portion 35 extends from the bottom plate portion 31 toward the top surface 12 and is disposed between the side surface 13c and the lead-out portion 22 of the magnetic core 10. When viewed from a direction perpendicular to the side surface 13c, the side plate portion 35 has an outer end portion 35h located outside the lead-out portion 22 and an inner end portion 35i located inside the lead-out portion 22, i.e., on the winding shaft a1 side (see reference). Figure 2 Additionally, the side plate portion 35 is configured corresponding to one of the four side surfaces 13c. The side plate portion 35 can also be fixed to the magnetic core 10 by adhesive.

[0055] The first protruding plate portion 36 is connected to the outer end portion 35h of the side plate portion 35 and protrudes in a direction away from the side surface 13c of the magnetic core 10. The first protruding plate portion 36 protrudes perpendicularly relative to the side plate portion 35. Furthermore, the first protruding plate portion 36 has an edge portion E1 located on the opposite side to the side surface 13c and the outer end portion 35h. At least a portion of the edge portion E1 contacts the lead-out portion 22 along the extending direction of the lead-out portion 22.

[0056] Figure 7 The lead-out portion 22 and electrode component 30 of the inductor 100 are connected from... Figure 4 A cross-sectional view observed along line VII-VII.

[0057] like Figure 7As shown, the lead-out portion 22 has a covered area 23a with an insulating film 24 on its outer peripheral surface 23, and an exposed area 23b where the wire is exposed without the insulating film 24. The exposed area 23b, when viewed from a direction perpendicular to the side surface 13c, is formed at least in a region outside the axis a2 of the lead-out portion 22. That is, all or most of the exposed area 23b is located on the side where the first protruding plate portion 36 is disposed. For example, the length of the exposed area 23b in the outer periphery of the lead-out portion 22 is more than 30% and less than 70% of the length of the outer periphery of the lead-out portion 22. Furthermore, the length of the exposed area 23b is preferably longer than the length of the covered area 23a.

[0058] The edge E1 of the first protruding plate portion 36 contacts the exposed area 23b. A connecting portion 40 is formed at the location where the exposed area 23b contacts the edge E1 of the first protruding plate portion 36.

[0059] like Figure 1 and Figure 3 As shown, the connecting portion 40 has a first connecting portion 41 after the lead-out portion 22 is welded to the edge portion E1 of the first protruding plate portion 36. The first connecting portion 41 is formed along the extending direction of the lead-out portion 22. For example, the first connecting portion 41 is composed of a plurality of weld marks ws formed by laser seam welding, and the plurality of weld marks ws are connected along the extending direction of the lead-out portion 22. The plurality of weld marks ws can be either all of the weld marks ws connected continuously, or a portion of the weld marks ws connected continuously.

[0060] The length of the first connecting portion 41 in the extending direction of the lead-out portion 22 is, for example, more than 1.5 times and less than 5 times the diameter of the lead-out portion 22. Furthermore, when the length of the first connecting portion 41 in the extending direction is L1, the thickness of the first protruding plate portion 36 is t1, and the area of ​​the cross-section of the lead-out portion 22 is S (the area shaded to the right), the relationship L1 ≥ (S × 0.2) / t1 exists. In the above formula, L1 × t1 corresponds to the cross-sectional area of ​​the welded part. Therefore, the longer the length L1 of the first connecting portion 41, the larger the cross-sectional area of ​​the welded part.

[0061] In this embodiment, the edge portion E1 of the first protruding plate portion 36 contacts along the extending direction of the lead-out portion 22. Therefore, the length of the connection portion 40 formed by welding the edge portion E1 to the lead-out portion 22 can be increased. This increases the cross-sectional area of ​​the connection portion 40 connecting the coil element 20 and the electrode component 30, improving reliability related to the connection. Furthermore, since the cross-sectional area of ​​the current path in the connection portion 40 can be increased, the DC resistance can be reduced, improving the reliability of the inductor. Additionally, since the cross-sectional area of ​​the current path in the connection portion 40 can be increased, temperature rise when the inductor is energized can be suppressed, further improving the reliability of the inductor.

[0062] [Manufacturing Method]

[0063] Next, the manufacturing method of the inductor 100 described above will be explained. Figure 8 This is a flowchart illustrating a method for manufacturing the inductor 100 according to an embodiment. Furthermore, the manufacturing method described below is an example, and the manufacturing method of the inductor 100 is not limited to this example. In addition, the following description mainly focuses on the positive half of the inductor 100 along the X-axis; the negative half of the inductor 100 along the X-axis can also be manufactured using the same method, and the same description applies.

[0064] In the manufacturing method of inductor 100, the first step is to press-form the magnetic core 10 together with the coil element 20 (step S11). Step S11 is performed by placing the coil element 20, which has a coil portion 21, into a molding die and pressing the powder-coated magnetic core. The pressure applied during pressing is, for example, 5 tons / cm². 2 The heat curing temperature is, for example, 185°C. After pressure molding, the lead-out portion 22, which is not covered by the magnetic core 10, protrudes vertically relative to the side 13c of the magnetic core 10.

[0065] Next, a process is performed to form an exposed area 23b on the outer peripheral surface 23 of the lead-out portion 22 (step S12). The exposed area 23b is formed by removing a portion of the insulating film 24 by laser irradiation or the like after step S11.

[0066] Next, the electrode component 30, which has been pre-formed by cutting and bending a metal sheet, is bonded to the magnetic core 10 using an adhesive (step S13). At this time, the electrode component 30 and the magnetic core 10 are configured as follows: Figure 1 As shown in the positional relationship, the base plate 31 and the bottom surface 11 are bonded together. Furthermore, in step S13, the adhesive is hardened by heating or other methods as needed.

[0067] Next, a process is performed in which the lead-out portion 22 exposed from the magnetic core 10 is bent along the side surface 13c (step S14). Specifically, the lead-out portion 22 is bent from the root located on the side surface 13c to cover the side plate portion 35 of the electrode member 30, forming a shape that extends in the direction connecting the bottom surface 11 and the top surface 12. As a result, the lead-out portion 22 contacts the edge portion E1 of the first protruding plate portion 36.

[0068] Next, a process is performed to weld the edge portion E1 of the first protruding plate portion 36 and the lead-out portion 22 by means of laser seam welding or the like (step S15). As a result, a first connecting portion 41 is formed along the extending direction of the lead-out portion 22. The weld mark ws formed on the first connecting portion 41 is circular in shape, for example, formed by rotating the spot of the laser beam around a predetermined radius.

[0069] After steps S11 to S15 as described above, an inductor 100 is manufactured that connects the coil element 20 and the electrode component 30 via the connecting part 40.

[0070] [Effects, etc.]

[0071] As described above, the inductor 100 of this embodiment includes: a magnetic core 10 containing magnetic material, having a bottom surface 11, a top surface 12, and a side surface 13c connected to the bottom surface 11 and the top surface 12; a coil element 20 having a coil portion 21 embedded in the magnetic core 10 and a lead-out portion 22 connected to an end (e.g., 21a) of the coil portion 21 and extending from the side surface 13c to the outside of the magnetic core 10; an electrode component 30 disposed on the side surface 13c and the bottom surface 11; and a connecting portion 40 connecting the lead-out portion 22 and the electrode component 30. The electrode component 30 has a base plate portion 31 disposed along the bottom surface 11, a side plate portion 35 connected to the base plate portion 31 and disposed along the side surface 13c, and a first protruding plate portion 36 connected to the side plate portion 35 and protruding in a direction away from the side surface 13c. The lead-out portion 22 extends outside the magnetic core 10 along the side plate portion 35 or the side surface 13c. The first protruding plate portion 36 has an edge portion E1 that contacts the lead-out portion 22 along the extending direction of the lead-out portion 22. The connecting portion 40 has a first connecting portion 41 after the lead-out portion 22 is welded to the edge portion E1 of the first protruding plate portion 36.

[0072] In the inductor 100 of this embodiment, the edge portion E1 of the first protruding plate portion 36 contacts along the extending direction of the lead portion 22. Therefore, the length of the first connection portion 41 formed by welding the edge portion E1 to the lead portion 22 can be increased. This increases the cross-sectional area of ​​the connection portion 40 that connects the coil element 20 and the electrode member 30, improving reliability related to the connection. Furthermore, according to this structure, since the cross-sectional area of ​​the current path of the connection portion 40 can be increased, the DC resistance can be reduced, improving the reliability of the inductor. Moreover, since the cross-sectional area of ​​the current path of the connection portion 40 can be increased, temperature rise when the inductor is energized can be suppressed, further improving the reliability of the inductor.

[0073] Alternatively, the first connecting portion 41 may be formed along the extending direction of the lead-out portion 22.

[0074] According to this structure, the length of the first connecting portion 41 formed along the extending direction of the lead-out portion 22 can be increased. This increases the cross-sectional area of ​​the connecting portion 40 that connects the coil element 20 and the electrode component 30, improving reliability related to the connection. Furthermore, according to this structure, since the cross-sectional area of ​​the current path in the connecting portion 40 can be increased, the DC resistance can be reduced, improving the reliability of the inductor. Moreover, since the cross-sectional area of ​​the current path in the connecting portion 40 can be increased, temperature rise when the inductor is energized can be suppressed, further improving the reliability of the inductor.

[0075] Alternatively, the first connecting portion 41 may be formed by connecting multiple weld marks ws.

[0076] This structure allows for an increase in the length of the first connecting portion 41, thereby increasing the cross-sectional area of ​​the connecting portion 40. This, in turn, improves the reliability of the inductor 100.

[0077] Alternatively, the lead-out portion 22 may have a covered area 23a with an insulating film 24 on its outer peripheral surface 23 and an exposed area 23b without the insulating film 24; the connecting portion 40 is formed in the exposed area 23b.

[0078] This structure improves the reliability of the connection between the lead-out portion 22 in the connection portion 40 and the electrode component 30. Consequently, the reliability of the inductor 100 is enhanced.

[0079] Alternatively, when the lead-out portion 22 is viewed in cross-section, the length of the exposed area 23b of the outer periphery of the lead-out portion 22 may be more than 30% and less than 70% of the length of the outer periphery of the lead-out portion 22.

[0080] According to this structure, compared to the case where the entire outer periphery of the lead-out portion 22 is made into an exposed area 23b, the exposed area 23b can be formed more easily. For example, when the insulating film 24 of the lead-out portion 22 is removed by laser irradiation, the insulating film 24 can be removed by irradiating the laser from one direction, and the exposed area 23b can be formed easily.

[0081] Alternatively, when the length of the first connecting portion 41 in the extension direction of the lead-out portion 22 is L1, the thickness of the first protruding plate portion 36 is t1, and the area of ​​the cross-section of the lead-out portion 22 is S, the relationship L1≥(S×0.2) / t1 can be established.

[0082] By having the above-described relationship, the length of the first connection portion 41 can be adequately ensured. As a result, the reliability of the inductor 100 can be improved.

[0083] Alternatively, the lead-out portion 22 may extend in the direction that connects the bottom surface 11 and the top surface 12.

[0084] This ensures the length of the first connection portion 41 is adequately guaranteed. Consequently, the reliability of the inductor 100 is improved.

[0085] (Modifications of the implementation method)

[0086] The following describes an inductor with variations of the embodiments. In the following descriptions of the variations, the focus is on the differences from the embodiments, and the descriptions of the commonalities are omitted or simplified.

[0087] [Variation Example 1]

[0088] The inductor 100A of the modified embodiment 1 will be described. In the modified embodiment 1, an example in which the inductor 100A has a second connection portion 42 in addition to the first connection portion 41 will be described.

[0089] Figure 9 This is a side view of the inductor of a variation of the embodiment 1. Figure 10 The lead-out portion 22 and electrode component 30A of the inductor 100A in the modified example 1 are connected from... Figure 9 Cross-sectional view of X-ray observation.

[0090] The inductor 100A in Modified Example 1 includes a magnetic core 10, a coil element 20 having a coil portion 21 and a lead portion 22, an electrode component 30A as an external terminal, and a connecting portion 40 connecting the lead portion 22 and the electrode component 30A. The structure of the magnetic core 10 and the coil element 20 is substantially the same as in the embodiment. In addition, in Modified Example 1, the outer peripheral surface 23 of the lead portion 22 is not covered by the insulating film 24 and becomes an exposed area 23b.

[0091] The electrode component 30A has a base plate portion 31, a side plate portion 35A, and a first protruding plate portion 36, and also has a second protruding plate portion 37. The base plate portion 31 and the first protruding plate portion 36 are the same as in the embodiment, but the side plate portion 35A is shorter in length in the X-axis direction compared to the embodiment.

[0092] The second protruding plate portion 37 is connected to the inner end portion 35i of the side plate portion 35A and protrudes in a direction away from the side surface 13c of the magnetic core 10. The second protruding plate portion 37 protrudes perpendicularly relative to the side plate portion 35A, clamping the lead-out portion 22 and facing the first protruding plate portion 36. That is, when viewed from a direction perpendicular to the side surface 13c, the first protruding plate portion 36 and the second protruding plate portion 37 protrude from both ends of the side plate portion 35A and face each other. The lead-out portion 22 is located between the first protruding plate portion 36 and the second protruding plate portion 37 and is clamped by the first protruding plate portion 36 and the second protruding plate portion 37.

[0093] Furthermore, the second protruding plate portion 37 has an edge portion E2 located on the side opposite to the side surface 13c and the inner end portion 35i. At least a portion of the edge portion E2 contacts the lead-out portion 22 along the extending direction of the lead-out portion 22. In addition, when viewed from the lead-out portion 22, the edge portion E2 contacts the lead-out portion 22 in the region opposite to the edge portion E1.

[0094] The connecting portion 40 has a first connecting portion 41 after welding the lead-out portion 22 and the edge portion E1, and a second connecting portion 42 after welding the lead-out portion 22 and the edge portion E2.

[0095] In Modification 1, the second connecting portion 42 is also composed of multiple weld marks ws formed by laser seam welding, and the multiple weld marks ws are connected along the extending direction of the lead-out portion 22. That is, the second connecting portion 42 is formed along the extending direction of the lead-out portion 22. The length of the second connecting portion 42 is, for example, more than 1.5 times and less than 5 times the diameter of the lead-out portion 22.

[0096] In Modification 1, the connecting portion 40 is composed of two connecting portions, a first connecting portion 41 and a second connecting portion 42. Therefore, the length of the connecting portion 40, which is the sum of the lengths of the first connecting portion 41 and the second connecting portion 42, can be increased.

[0097] On the other hand, in Modification 1, since there are two connecting parts, the lengths of the first connecting part 41 and the second connecting part 42 in the extending direction can be shortened compared to the embodiment. Therefore, in Modification 1, when the length of the first connecting part 41 in the extending direction is L1, the thickness of the first protruding plate 36 is t1, and the cross-sectional area of ​​the lead-out part 22 is S, the relationship L1 ≥ (S × 0.1) / t1 exists; and when the length of the second connecting part 42 in the extending direction is L2, and the thickness of the second protruding plate 37 is t2, the relationship L2 ≥ (S × 0.1) / t2 exists. In the above formulas, the sum of L1 × t1 and L2 × t2 corresponds to the cross-sectional area of ​​the welded part.

[0098] In the inductor 100A of Modified Example 1, the edge portion E1 of the first protruding plate portion 36 also contacts along the extending direction of the lead portion 22. Therefore, the length of the connection portion 40 formed by welding the edge portion E1 to the lead portion 22 can be increased.

[0099] Furthermore, in the inductor 100A of Modified Example 1, the electrode component 30A also has a second protruding plate portion 37, which sandwiches the lead-out portion 22 and faces the first protruding plate portion 36, and is connected to the side plate portion 35A and protrudes in a direction away from the side surface 13c. The second protruding plate portion 37 has an edge portion E2 that contacts the lead-out portion 22 along the extending direction of the lead-out portion 22.

[0100] In the inductor 100A of Modified Example 1, the edge portion E2 of the second protruding plate portion 37 contacts along the extending direction of the lead portion 22. Therefore, the length of the connection portion formed by welding the edge portion E2 to the lead portion 22 can be increased. As a result, the reliability of the inductor 100A can be improved.

[0101] Alternatively, the connecting portion 40 may also have a second connecting portion 42 after the lead-out portion 22 is welded to the edge portion E2 of the second protruding plate portion 37.

[0102] Therefore, since the connecting portion 40 is composed of two connecting portions, namely the first connecting portion 41 and the second connecting portion 42, the total length of the connecting portion 40, which includes the lengths of the first connecting portion 41 and the second connecting portion 42, can be increased. This allows for a larger cross-sectional area of ​​the connecting portion 40. Consequently, the reliability of the inductor 100A can be improved.

[0103] Alternatively, when the length of the first connecting portion 41 in the extension direction of the lead-out portion 22 is L1, the thickness of the first protruding plate portion 36 is t1, and the area of ​​the cross-section of the lead-out portion 22 is S, the relationship L1≥(S×0.1) / t1 is given. When the length of the second connecting portion 42 in the extension direction of the lead-out portion 22 is L2, and the thickness of the second protruding plate portion 37 is t2, the relationship L2≥(S×0.1) / t2 is given.

[0104] In this way, by having two connection points, the lengths of the first connection portion 41 and the second connection portion 42 in the extension direction of the lead-out portion 22 can be prevented from exceeding the required length. As a result, the inductor 100A can be miniaturized or reduced in height.

[0105] Alternatively, the side plate portion 35A may be located between the side surface 13c and the lead-out portion 22; the first protruding plate portion 36 and the second protruding plate portion 37 may protrude from both ends of the side plate portion 35A when viewed from a direction perpendicular to the side surface 13c.

[0106] According to this structure, the lead-out portion 22 can be clamped in by the first protruding plate portion 36 and the second protruding plate portion 37, which can improve the mechanical strength of the inductor 100A. As a result, the reliability of the inductor 100A can be improved.

[0107] [Variation Example 2]

[0108] The inductor 100B of Modification 2 of the relevant embodiment will be described. In Modification 2, an example of the inductor 100B having a second connection portion 42 in addition to the first connection portion 41 will also be described.

[0109] Figure 11This is a perspective view of the inductor 100B of Modified Example 2 of the embodiment. Figure 12 This is a side view of the inductor 100B in modified example 2. Figure 13 The lead-out portion 22B and electrode component 30B of the inductor 100B in the relevant modified example 2 are from... Figure 12 A cross-sectional view observed along line XIII-XIII.

[0110] The inductor 100B in Modified Example 2 includes a magnetic core 10, a coil element 20 having a coil portion 21 and a lead portion 22B, an electrode component 30B as an external terminal, and a connecting portion 40 connecting the lead portion 22B and the electrode component 30B. The structure of the magnetic core 10 is substantially the same as in the embodiment.

[0111] In Modification 2, the coil portion 21 has two ends that connect the wound portion to the side surface 13c of the magnetic core 10. When viewed from a direction perpendicular to the side surface 13c, the two ends of the coil portion 21 are located at a height higher than the center c1 of the side surface 13c and closer to the bottom surface 11.

[0112] Lead-out portion 22B is connected to the end of coil portion 21, extending outward from side surface 13c of magnetic core 10 and along side surface 13c. Specifically, when viewed from a direction perpendicular to side surface 13c, lead-out portion 22B is drawn out at a height higher than the center c1 of side surface 13c towards the bottom surface 11, bent along side surface 13c, and extends in the direction connecting bottom surface 11 and top surface 12, interrupting before reaching the end on the top surface 12 side. The outer peripheral surface 23 of lead-out portion 22B is not covered by insulating film 24 and becomes exposed area 23b (not shown).

[0113] The electrode component 30B of Modified Example 2 has a base plate portion 31, a side plate portion 35B, a first protruding plate portion 36, and a second protruding plate portion 37.

[0114] The side plate portion 35B has an opening 35j along the extending direction of the lead-out portion 22B. The length of the opening 35j in the extending direction is longer than the length of the lead-out portion 22B, and the width of the opening 35j is the same as the diameter of the lead-out portion 22B. The opening 35j can be either a rectangular through hole or a slit.

[0115] The first protruding plate portion 36 and the second protruding plate portion 37, when viewed from a direction perpendicular to the side surface 13c, are connected to the regions on both outer sides of the opening 35j of the side plate portion 35B, and protrude in a direction away from the side surface 13c of the magnetic core 10. The first protruding plate portion 36 and the second protruding plate portion 37 protrude perpendicularly relative to the side plate portion 35B, sandwiching the lead-out portion 22B and facing each other. That is, the lead-out portion 22B is located between the first protruding plate portion 36 and the second protruding plate portion 37, and is sandwiched between the first protruding plate portion 36 and the second protruding plate portion 37.

[0116] The first protruding plate portion 36 has an edge portion E1 located on the side opposite to the side surface 13c. At least a portion of the edge portion E1 contacts the lead-out portion 22B along the extending direction of the lead-out portion 22B. The second protruding plate portion 37 has an edge portion E2 located on the side opposite to the side surface 13c. At least a portion of the edge portion E2 contacts the lead-out portion 22B along the extending direction of the lead-out portion 22B. When viewed from the lead-out portion 22B, the edge portions E1 and E2 contact the lead-out portion 22B at positions opposite to each other.

[0117] The connecting portion 40 has a first connecting portion 41 after the lead-out portion 22B is welded to the edge portion E1, and a second connecting portion 42 after the lead-out portion 22B is welded to the edge portion E2. The length of each of the first connecting portion 41 and the second connecting portion 42 is, for example, more than 1.5 times and less than 5 times the diameter of the lead-out portion 22B.

[0118] In Modification 2, the connecting portion 40 is also composed of two connecting portions, a first connecting portion 41 and a second connecting portion 42. Therefore, the length of the connecting portion 40, which is the sum of the lengths of the first connecting portion 41 and the second connecting portion 42, can be increased.

[0119] On the other hand, in Modification 2, since there are two connecting parts, the lengths of the first connecting part 41 and the second connecting part 42 in the extending direction of the lead-out part 22B can be shortened compared to the embodiment. In Modification 2, when the length of the first connecting part 41 in the extending direction is L1, the thickness of the first protruding plate 36 is t1, and the cross-sectional area of ​​the lead-out part 22B is S, the relationship L1≥(S×0.1) / t1 exists. When the length of the second connecting part 42 in the extending direction is L2, and the thickness of the second protruding plate 37 is t2, the relationship L2≥(S×0.1) / t2 exists. In the above formulas, the value obtained by adding L1×t1 and L2×t2 corresponds to the cross-sectional area of ​​the welded part.

[0120] The inductor 100B of Modified Example 2 can also achieve the same effect as the inductor 100A of Modified Example 1.

[0121] In the inductor 100B of Modified Example 2, the side plate portion 35B has an opening 35j along the extending direction of the lead-out portion 22B, and the first protruding plate portion 36 and the second protruding plate portion 37 protrude from the regions of the side plate portion 35B located on both outer sides of the opening 35j when viewed from a direction perpendicular to the side surface 13c.

[0122] According to this structure, the lead-out portion 22B can be clamped in by the first protruding plate portion 36 and the second protruding plate portion 37, which can improve the mechanical strength of the inductor 100B. As a result, the reliability of the inductor 100B can be improved.

[0123] [Variation Example 3]

[0124] The inductor 100C of Modification 3 of the relevant embodiment will be described. In Modification 3, an example will be described in which the lead-out portion 22C extends in a direction intersecting the direction that connects the bottom surface 11 and the top surface 12 of the magnetic core 10, and the connecting portion 40C is formed in the direction of extension.

[0125] Figure 14 This is a perspective view of the inductor 100C of Modified Example 3 of the embodiment.

[0126] The inductor 100C in Modified Example 3 includes a magnetic core 10, a coil element 20 having a coil portion 21 and a lead portion 22C, an electrode component 30C as an external terminal, and a connecting portion 40C connecting the lead portion 22C and the electrode component 30C. The magnetic core 10 is the same as in the embodiment.

[0127] The coil portion 21 of Modified Example 3 has two ends that connect the wound portion to the side surface 13c of the magnetic core 10. When viewed from a direction perpendicular to the side surface 13c, one end of the coil portion 21 is located closer to the side surface 13a than the winding axis a1, and the other end is located closer to the side surface 13b than the winding axis a1.

[0128] In the following description, we will mainly describe the positive half of the X-axis of inductor 100C. The negative half of the X-axis of inductor 100C has the same structure as the positive half of the X-axis and is subject to the same description.

[0129] Lead-out portion 22C is connected to the end of coil portion 21, extends outward from side surface 13c of magnetic core 10, and extends along side plate portion 35C. Specifically, lead-out portion 22C is led out from side surface 13c, bent to cover side plate portion 35C of electrode member 30C, extends in a direction (X-axis direction) intersecting the direction connecting bottom surface 11 and top surface 12, and is interrupted before reaching the center of side surface 13c. In addition, in modified example 3, lead-out portion 22C is also led out from one of the four side surfaces 13c.

[0130] Electrode component 30C is disposed outside the magnetic core 10 and electrically connected to lead-out portion 22C via connecting portion 40C. Electrode component 30C has a base plate portion 31 disposed on the bottom surface 11 side of the magnetic core 10, a side plate portion 35C connected to the base plate portion 31, and a first protruding plate portion 36C connected to the side plate portion 35C. The base plate portion 31 is the same as in the embodiment.

[0131] The side plate portion 35C is connected to the bottom plate portion 31 and is arranged along the side surface 13c of the magnetic core 10. The side plate portion 35C is located between the side surface 13c and the lead-out portion 22C of the magnetic core 10. The side plate portion 35C has a top surface end portion 35k that is located on the top surface 12 side of the lead-out portion 22C when viewed from a direction perpendicular to the side surface 13c. In this modified example, the side plate portion 35C is arranged to correspond to only one of the four side surfaces 13c.

[0132] The first protruding plate portion 36C is connected to the top surface end portion 35k of the side plate portion 35C and protrudes in a direction away from the side surface 13c of the magnetic core 10. The first protruding plate portion 36C protrudes perpendicularly relative to the side plate portion 35C. Furthermore, the first protruding plate portion 36C has an edge portion E3 located on the side opposite to the side surface 13c and the top surface end portion 35k. At least a portion of the edge portion E3 contacts the lead-out portion 22C along the extending direction (X-axis direction) of the lead-out portion 22C.

[0133] The lead-out portion 22C has a covered area 23a with an insulating film 24 on its outer peripheral surface 23 and an exposed area 23b without the insulating film 24. When viewed from a direction perpendicular to the side surface 13c, the exposed area 23b is formed at least in the region closer to the top surface 12 than the axis a2 of the lead-out portion 22C. That is, the exposed area 23b is located on the side where the first protruding plate portion 36C is disposed.

[0134] The edge E3 of the first protruding plate portion 36C contacts the exposed area 23b. A connecting portion 40C is formed at the location where the exposed area 23b contacts the edge E3 of the first protruding plate portion 36C.

[0135] The connecting portion 40C has a first connecting portion 41C after the lead-out portion 22C is welded to the edge portion E3 of the first protruding plate portion 36C. The first connecting portion 41C is formed along the extending direction of the lead-out portion 22C. For example, the first connecting portion 41C is composed of a plurality of weld marks ws formed by laser seam welding, and the plurality of weld marks ws are connected along the extending direction of the lead-out portion 22C. The length of the first connecting portion 41C in the extending direction of the lead-out portion 22C is, for example, more than 1.5 times and less than 5 times the diameter of the lead-out portion 22C.

[0136] In the inductor 100C of Modified Example 3, the same effect as that of the inductor 100 in the Embodiment 1 can also be obtained.

[0137] In the inductor 100C of Modified Example 3, the lead-out portion 22C extends in a direction that intersects the direction connecting the bottom surface 11 and the top surface 12.

[0138] This ensures the length of the first connection portion 41C is adequately guaranteed. Consequently, the reliability of the inductor 100C is improved.

[0139] [Variation Example 4]

[0140] The inductor 100D of the modified embodiment 4 will be described. In the modified embodiment 4, an example will be described in which the lead-out portion 22D is composed of a first lead-out portion 22d1 and a second lead-out portion 22d2, and the first lead-out portion 22d1 and the second lead-out portion 22d2 extend along a direction that intersects the direction that connects the bottom surface 11 and the top surface 12 of the magnetic core 10.

[0141] Figure 15 This is a perspective view of the inductor 100D of Modified Example 4 of the embodiment. Figure 15 (a) is a perspective view of the inductor 100D viewed from a specified direction, and (b) is a perspective view of the inductor 100D viewed from a direction different from the specified direction.

[0142] The inductor 100D of Modification Example 4 includes a magnetic core 10, a coil element 20 having a coil portion 21 and a lead portion 22D, an electrode component 30D as an external terminal, and a connecting portion 40D connecting the lead portion 22D and the electrode component 30D.

[0143] The magnetic core 10 is, for example, a cuboid shape, having a bottom surface 11, a top surface 12 opposite to the bottom surface 11, and four side surfaces 13a, 13b, 13c, and 13d connected to the bottom surface 11 and the top surface 12. In this modified example, side surface 13c is referred to as the first side surface 13c, and side surface 13d is referred to as the second side surface 13d.

[0144] The coil portion 21 has an end 21a that connects the wound portion to a first side surface 13c of the magnetic core 10, and an end 21b that connects to a second side surface 13d. When viewed from a direction perpendicular to the first side surface 13c, the end 21a of the coil portion 21 is located closer to the side surface 13a than the winding shaft a1. The end 21b of the coil portion 21, when viewed from a direction perpendicular to the second side surface 13d, is located closer to the side surface 13a than the winding shaft a1.

[0145] The lead-out section 22D is composed of a first lead-out section 22d1 and a second lead-out section 22d2.

[0146] Electrode component 30D is composed of one electrode component 30D and another electrode component 30D. One electrode component 30D has a base plate portion 31 disposed on the bottom surface 11 side of the magnetic core 10, a side plate portion 35D connected to the base plate portion 31 and disposed on the first side surface 13c side, and a first protruding plate portion 36D connected to the side plate portion 35D. The other electrode component 30D has another base plate portion 31 disposed on the bottom surface 11 side of the magnetic core 10, another side plate portion 35D connected to the other base plate portion 31 and disposed on the second side surface 13d side, and another first protruding plate portion 36D connected to the other side plate portion 35D.

[0147] In Variation 4, the first lead-out portion 22d1 is connected to one end 21a of the coil portion 21, extends outward from the first side surface 13c of the magnetic core 10, and extends along one side plate portion 35D. Specifically, when viewed from a direction perpendicular to the first side surface 13c, the first lead-out portion 22d1 is led out from a position closer to the side surface 13a than the winding shaft a1, is bent in such a way as to cover the side plate portion 35D, extends in a direction (X-axis direction) intersecting the direction connecting the bottom surface 11 and the top surface 12, and is interrupted before reaching the end on the side surface 13b side.

[0148] The second lead-out portion 22d2 is connected to the other end 21b of the coil portion 21, and extends outward from the second side surface 13d of the magnetic core 10, along the other side plate portion 35D. Specifically, when viewed from a direction perpendicular to the second side surface 13d, the second lead-out portion 22d2 is led out from a position closer to the side surface 13a than the winding shaft a1, and is bent in such a way that it covers the other side plate portion 35D. It extends in a direction (X-axis direction) that intersects the direction connecting the bottom surface 11 and the top surface 12, and is interrupted before reaching the end on the side surface 13b side.

[0149] One electrode component 30D is electrically connected to the first lead-out portion 22d1 via a connecting portion 40D. The other electrode component 30D is electrically connected to the second lead-out portion 22d2 via a connecting portion 40D.

[0150] In the following description, we will mainly describe the negative half of the Y-axis of inductor 100D. The positive half of the Y-axis of inductor 100D has the same structure as the negative half of the Y-axis and is subject to the same description.

[0151] like Figure 15As shown in (a), one side plate portion 35D is connected to one bottom plate portion 31 and is disposed along the first side surface 13c. The side plate portion 35D is located between the first side surface 13c and the first lead-out portion 22d1. The side plate portion 35D has a top surface end portion 35k located on the top surface 12 side of the first lead-out portion 22d1 when viewed from a direction perpendicular to the first side surface 13c.

[0152] A first protruding plate portion 36D of one side plate portion 35D is connected to the top surface end portion 35k of the side plate portion 35D of the other side plate portion 35D, and protrudes in a direction away from the first side surface 13c. The first protruding plate portion 36D of one side plate portion 36D protrudes perpendicularly relative to the side plate portion 35D of the other side plate portion 35D. Furthermore, the first protruding plate portion 36D of one side plate portion 36D has an edge portion E4 located on the side opposite to the first side surface 13c and the top surface end portion 35k. At least a portion of the edge portion E4 contacts the first lead-out portion 22d1 along the extending direction of the first lead-out portion 22d1.

[0153] The first lead-out portion 22d1 has a covered area 23a with an insulating film 24 on its outer peripheral surface 23 and an exposed area 23b without the insulating film 24. The exposed area 23b, when viewed from a direction perpendicular to the first side surface 13c, is formed at least in the area closer to the top surface 12 than the axis a2 of the first lead-out portion 22d1. That is, the exposed area 23b is located on the side where one of the first protruding plates 36D is disposed.

[0154] The edge E4 of the first protruding plate portion 36D of one side contacts the exposed area 23b. A connecting portion 40D is formed at the location where the exposed area 23b contacts the edge E4 of the first protruding plate portion 36D of one side.

[0155] The connecting portion 40D has a first connecting portion 41D formed by welding the first lead-out portion 22d1 to the edge portion E4 of the first protruding plate portion 36D. The first connecting portion 41D is formed along the extending direction of the first lead-out portion 22d1. For example, the first connecting portion 41D is composed of a plurality of weld marks ws formed by laser seam welding, and the plurality of weld marks ws are connected along the extending direction of the first lead-out portion 22d1. The length of the first connecting portion 41D is, for example, more than 1.5 times and less than 10 times the diameter of the first lead-out portion 22d1.

[0156] Furthermore, the connection portion 40D of the inductor 100D has a first connection portion 41D after the second lead-out portion 22d2 is welded to the edge portion E4 of the other first protruding plate portion 36D. The structure of the second lead-out portion 22d2, the other first protruding plate portion 36D, and the first connection portion 41D is the same as the structure of the first connection portion 41D described above.

[0157] In the inductor 100D of Modified Example 4, the same effect as that of the inductor 100C of Modified Example 3 can also be obtained.

[0158] Furthermore, in the inductor 100D, a notch 19 is provided on the top surface 12 of the magnetic core 10, and a locking portion 39 is provided on the electrode component 30D. The notch 19 is a recessed portion extending from the top surface 12 toward the bottom surface 11, and is formed at the four corners of the top surface 12. The locking portion 39 is a part that locks with the notch 19 of the magnetic core 10, extends from the base plate portion 31 toward the notch 19 of the top surface 12, and bends toward the notch 19 at its front end. Each electrode component 30D has two locking portions 39, and each locking portion 39 locks with its respective notch 19. In the inductor 100D of Modified Example 4, the electrode component 30D is fixed to the magnetic core 10 in a state where it is clamped into the magnetic core 10 by the locking portion 39 and the notch 19.

[0159] In the inductor 100D of Variation 4, the aforementioned side surfaces have a first side surface 13c and a second side surface 13d facing each other. The lead-out portion 22D has a first lead-out portion 22d1 connected to one end 21a of the coil portion 21 and a second lead-out portion 22d2 connected to the other end 21b. The first lead-out portion 22d1 extends from the first side surface 13c in a direction intersecting the direction connecting the bottom surface 11 and the top surface 12. The second lead-out portion 22d2 extends from the second side surface 13d in a direction intersecting the direction connecting the bottom surface 11 and the top surface 12.

[0160] This allows for an increase in the length of the first connection portion 41D. Consequently, the reliability of the inductor 100D can be improved.

[0161] Alternatively, the magnetic core 10 may have a notch 19 provided on the top surface 12, and the electrode component 30D may also have a locking portion 39 connected to the base plate portion 31 and locked in place by the notch 19.

[0162] As a result, the electrode component 30D is engaged with the magnetic core 10, thus alleviating the stress on the connection portion 40D. This improves the reliability of the inductor 100D.

[0163] (Other implementation methods, etc.)

[0164] The embodiments and variations of the inductors described above are explained, but the present disclosure is not limited to the above embodiments and variations. Various modifications to the embodiments and variations that can be conceived by those skilled in the art, as well as other forms constructed by combining some of the constituent elements of the embodiments and variations, are also included within the scope of the present disclosure, as long as they do not depart from the spirit of the present disclosure.

[0165] In the above embodiments, an example is shown where the base plate portion 31, side plate portion 35, and first protruding plate portion 36 of the electrode component 30 are formed by processing a single component made of the same material, but this is not a limitation. For example, the electrode component 30 may also be formed by connecting the base plate portion 31, side plate portion 35, and first protruding plate portion 36, which are made of other components.

[0166] In the above embodiment, an example is shown where the coil portion 21 and the lead portion 22 of the coil element 20 are formed by processing a single component made of the same material, but this is not a limitation. The coil element 20 may also be formed by connecting the coil portion 21, which is made of other components, to the lead portion 22.

[0167] In the above embodiment, an example is shown where the cross-section of the lead-out portion 22 is circular, but it is not limited to this. The lead-out portion 22 may also extend in a flat plate shape at least partly for easy connection with the electrode component 30.

[0168] Furthermore, this disclosure also includes, for example, electrical products or circuits using the aforementioned inductors. Examples of electrical products include power supply devices equipped with the aforementioned inductors and various devices equipped with such power supply devices.

[0169] Industrial applicability

[0170] The inductor disclosed herein is practical as an inductor used in various devices and equipment.

[0171] Label Explanation

[0172] 10 magnetic cores

[0173] 11 Bottom

[0174] 12 top surfaces

[0175] Side views of 13a, 13b, 13c, and 13d

[0176] 19 gaps

[0177] 20 coil elements

[0178] 21 coil section

[0179] Ends of 21a and 21b

[0180] 22, 22B, 22C, 22D lead-out sections

[0181] 22d1 First Lead-out Section

[0182] 22d2 Second lead-out section

[0183] 23 outer periphery

[0184] 23a Coverage Area

[0185] 23b Exposed area

[0186] 24 insulating film

[0187] Electrode components 30, 30A, 30B, 30C, and 30D

[0188] 31. Bottom Plate Section

[0189] Side panels of 35, 35A, 35B, 35C, and 35D

[0190] 35h outer end

[0191] 35i inner end

[0192] 35j opening

[0193] 35k Top side end

[0194] 36, 36C, 36D First protruding plate

[0195] 37 Second protruding plate

[0196] 39-card stop section

[0197] 40, 40C, 40D connecting parts

[0198] 41, 41C, 41D First connecting parts

[0199] 42 Second connecting part

[0200] 100, 100A, 100B, 100C, 100D inductors

[0201] a1 coil section winding shaft

[0202] Axis of a2 lead-out section

[0203] The center of c1 side

[0204] Edges of E1, E2, E3, and E4

[0205] Length of L1 first connecting part

[0206] Length of L2 second connection part

[0207] Thickness of the first protruding plate t1

[0208] t2 The thickness of the second protruding plate

[0209] Cross-sectional area of ​​S-head

[0210] WS welding marks

Claims

1. An inductor, wherein, have: A magnetic core, comprising magnetic material, having a bottom surface, a top surface, and a side surface connected to the bottom surface and the top surface; A coil element has a coil portion and a lead-out portion, wherein the coil portion is embedded in the magnetic core, and the lead-out portion is connected to the end of the coil portion and extends from the side to the outside of the magnetic core. Electrode components are disposed on the aforementioned side surface and the aforementioned bottom surface; and The connecting part connects the lead-out part and the electrode component mentioned above. The electrode component described above has a base plate portion disposed along the bottom surface, a side plate portion connected to the base plate portion and disposed along the side surface, and a first protruding plate portion connected to the side plate portion and protruding in a direction away from the side surface. The aforementioned lead-out portion extends along the aforementioned side plate portion or the aforementioned side surface outside the aforementioned magnetic core; The first protruding plate portion has at least a portion of an edge portion that contacts the lead-out portion along the extending direction of the lead-out portion; The aforementioned connecting portion has a first connecting portion after the aforementioned lead-out portion is welded to the edge portion of the aforementioned first protruding plate portion; The protrusion height of the first protruding plate relative to the side plate is lower than the outer diameter of the lead-out portion. The first protruding plate does not overlap with the lead-out portion when viewed from a direction orthogonal to the side.

2. The inductor as claimed in claim 1, wherein, The first connecting portion is formed along the extending direction of the lead-out portion.

3. The inductor as claimed in claim 2, wherein, The aforementioned first connection is formed by connecting multiple weld marks.

4. The inductor as described in any one of claims 1 to 3, wherein, The aforementioned lead-out portion has a covered area with an insulating film on its outer peripheral surface and an exposed area without the insulating film; The aforementioned connection portion is formed in the aforementioned exposed area.

5. The inductor as claimed in claim 4, wherein, When the lead-out portion is viewed in cross-section, the length of the exposed area on the outer periphery of the lead-out portion is more than 30% and less than 70% of the length of the outer periphery of the lead-out portion.

6. The inductor as described in any one of claims 1 to 3, wherein, When the length of the first connecting portion in the extending direction of the lead-out portion is L1, the thickness of the first protruding plate portion is t1, and the area of ​​the cross-section of the lead-out portion is S, It has the relationship L1≥(S×0.2) / t1.

7. The inductor as described in any one of claims 1 to 3, wherein, The electrode component also has a second protruding plate portion, which sandwiches the lead-out portion and is opposite to the first protruding plate portion, and is connected to the side plate portion and protrudes in a direction away from the side. The second protruding plate portion has at least a portion of an edge portion that contacts the lead-out portion along the extending direction of the lead-out portion.

8. The inductor as claimed in claim 7, wherein, The aforementioned connecting portion also includes a second connecting portion after the aforementioned lead-out portion is welded to the edge portion of the aforementioned second protruding plate portion.

9. The inductor as claimed in claim 8, wherein, When the length of the first connecting portion in the extending direction of the lead-out portion is L1, the thickness of the first protruding plate portion is t1, and the area of ​​the cross-section of the lead-out portion is S, It has the relationship L1≥(S×0.1) / t1; When the length of the second connecting portion in the extending direction of the aforementioned lead-out portion is L2, and the thickness of the aforementioned second protruding plate portion is t2, It has the relationship L2≥(S×0.1) / t2.

10. The inductor of claim 7, wherein, The aforementioned side plate portion is located between the aforementioned side surface and the aforementioned lead-out portion; The first protruding plate portion and the second protruding plate portion protrude from both ends of the side plate portion when viewed from a direction perpendicular to the side.

11. The inductor of claim 7, wherein, The aforementioned side plate portion has an opening along the extending direction of the aforementioned lead-out portion; When viewed from a direction perpendicular to the side, the first protruding plate portion and the second protruding plate portion protrude from the regions on both outer sides of the opening of the side plate portion.

12. The inductor according to any one of claims 1 to 3, wherein, The aforementioned lead-out portion extends along the direction connecting the aforementioned bottom surface and the aforementioned top surface.

13. The inductor as described in any one of claims 1 to 3, wherein, The aforementioned lead-out portion extends in a direction that intersects the direction connecting the aforementioned bottom surface and the aforementioned top surface.

14. The inductor of claim 13, wherein, The aforementioned sides have a first side and a second side that are opposite to each other; The aforementioned lead-out portion has a first lead-out portion connected to one of the aforementioned ends of the aforementioned coil portion, and a second lead-out portion connected to the aforementioned end of the other portion; The first lead-out portion is led out from the first side and extends in a direction that intersects the direction connecting the bottom surface and the top surface; The second lead-out portion is led out from the second side and extends in a direction that intersects the direction connecting the bottom surface and the top surface.

15. The inductor as described in any one of claims 1 to 3, wherein, The magnetic core described above has a notch provided on the top surface; The electrode component also has a locking part that is connected to the base plate and engages with the notch.

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