Coil device

Abstract

Provided is a magnetic coupling coil device having excellent inductance characteristics and / or DC overlap characteristics. A coil device (1) is provided with: a core having a mounting surface (15); a first conductor having a first body portion (31) extending along the mounting surface (15) inside the core; and a second conductor having a second main body section (41) extending along the mounting surface (15) inside the core and facing the first main body section (31). The first body section (31) has a first side surface having a first thickness in a direction perpendicular to the mounting surface (15), and a first main surface having a first width in a direction parallel to the mounting surface (15). The second main body section (41) has a second side surface having a second thickness in a direction perpendicular to the mounting surface (15), and a second main surface having a second width in a direction parallel to the mounting surface (15). The second width is narrower than the first width in a direction in which the first body section (31) and the second body section (41) face each other.

Description

Technical Field

[0001] The present disclosure relates to coil arrangements that may be used, for example, as coupled inductors. Background Art

[0002] For example, in a power circuit of a server, a coil device called a coupled inductor is sometimes used to improve the response speed of a voltage regulator or to reduce the number of parts in the power circuit. As such a coil device, Patent Document 1 discloses a coil device having a core, a first winding having a first intermediate portion formed of a flat surface, and a second winding having a second intermediate portion formed of a flat surface. The first intermediate portion and the second intermediate portion are opposed to each other at a predetermined interval and are magnetically coupled.

[0003] In the coil device of Patent Document 1, the first intermediate portion and the second intermediate portion are arranged parallel to the side surface (the surface perpendicular to the mounting surface) of the core. By arranging the first intermediate portion and the second intermediate portion inside the core in this orientation, the size of the core can be reduced, and the coupled inductor can be made small and low-profile.

[0004] In recent years, in order to further improve the response speed of voltage regulators, coupled inductors are required to be not only miniaturized but also highly functional. In order to improve the response speed of voltage regulators, it is particularly necessary to further improve the inductance characteristics and / or DC superposition characteristics of coupled inductors.

[0005] Prior art literature

[0006] Patent Literature

[0007] Patent Document 1: U.S. Patent Application Publication No. 2018 / 0068778 Summary of the invention

[0008] Problems to be solved by the invention

[0009] The present disclosure has been developed in view of such actual circumstances, and an object of the present disclosure is to provide a coil device having excellent inductance characteristics and / or DC superposition characteristics.

[0010] Technical solutions to solve problems

[0011] In order to achieve the above object, the present disclosure provides a coil device having:

[0012] a core having a mounting surface;

[0013] a first conductor having a first body portion extending inside the core along the mounting surface; and

[0014] a second conductor having a second main body portion extending inside the core along the mounting surface and opposite to the first main body portion,

[0015] The first main body portion has a first side surface having a first thickness in a direction perpendicular to the mounting surface, and a first main surface having a first width in a direction parallel to the mounting surface.

[0016] The second main body portion has a second side surface having a second thickness in a direction perpendicular to the mounting surface, and a second main surface having a second width in a direction parallel to the mounting surface.

[0017] In a direction in which the first body portion and the second body portion are opposite to each other, the second width is narrower than the first width.

[0018] In the coil device disclosed in the present invention, the first main body has a first side surface having a first thickness in a direction perpendicular to the mounting surface, and a first main surface having a first width in a direction parallel to the mounting surface. In addition, the second main body has a second side surface having a second thickness in a direction perpendicular to the mounting surface, and a second main surface having a second width in a direction parallel to the mounting surface. By arranging the first main body and the second main body inside the core in such a manner that the orientations of the first side surface, the second side surface, the first main surface, and the second main surface are in the described orientation, the size of the core can be reduced, and the coil device can be made small and low in height. In addition, since the first main body and the second main body are opposite to each other, magnetic coupling between the first main body and the second main body can be ensured.

[0019] In particular, in the coil device of the present disclosure, the second width is narrower than the first width in the direction relative to the first main body and the second main body. Therefore, compared with the case where the first width and the second width are equal, more core configuration space (space corresponding to the difference between the first width and the second width) is formed around the second main body. As a result, the volume of the core increases around the second main body, and the inductance characteristics and / or DC superposition characteristics of the coil device are improved. In addition, because the first width and the second width are different, the first main body and the second main body have different resistance values. Thus, the inductance characteristics and / or DC superposition characteristics of the coil device can be adjusted according to the resistance value of the first main body or the second main body.

[0020] The first side surface and the second side surface may also be perpendicular to the mounting surface. In this case, the first side surface and the second side surface can be arranged parallel to the side surface of the core (the surface perpendicular to the mounting surface). Thus, more core arrangement space can be formed around the first side surface and the second side surface. Therefore, the inductance characteristics and / or DC superposition characteristics of the coil device are further improved.

[0021] Alternatively, the first conductor may include a first mounting portion continuous with the first main body, the second conductor may include a second mounting portion continuous with the second main body, and the cross-sectional area of ​​the first mounting portion or the second mounting portion may be greater than the cross-sectional area of ​​the second main body and less than the cross-sectional area of ​​the first main body. In this case, the contact area between the first mounting portion or the second mounting portion and the mounting substrate may be ensured. Therefore, the installation stability of the coil device is improved.

[0022] Alternatively, the first mounting portion has a third width in the axial direction of the first main body portion, and has a fourth width in the relative direction of the first main body portion and the second main body portion, the first thickness, the second thickness, and the fourth width are equal, the first thickness, the second thickness, and the fourth width are greater than the second width, and are less than the third width, and the third width is greater than the first thickness, the second thickness, and the fourth width, and is less than the first width. In particular, by satisfying the size relationship described above with the third width and the fourth width, it is easy to ensure the contact area between the first mounting portion and the mounting substrate, and the installation stability of the coil device is improved. In addition, in particular, by satisfying the size relationship described above with the first width and the second width, it is easy to ensure the volume of the core around the second main body portion, and the inductance characteristics and / or DC superposition characteristics of the coil device are improved.

[0023] Alternatively, the first mounting portion has a third width in the axial direction of the first main body portion, and a fourth width in the direction relative to the first main body portion and the second main body portion, the second mounting portion has a fifth width in the axial direction of the second main body portion, and a sixth width in the direction relative to the first main body portion and the second main body portion, the third width is equal to the fifth width, and the fourth width is equal to the sixth width. In this case, the cross-sectional area of ​​the first mounting portion is equal to the cross-sectional area of ​​the second mounting portion. Therefore, when the first mounting portion and the second mounting portion are arranged on the mounting substrate, the mounting stability of the coil device is improved.

[0024] Alternatively, the first main body and the second main body constitute a magnetic coupling portion that is magnetically coupled to each other, and the center of the magnetic coupling portion is located at the center of the core in the direction in which the first main body and the second main body are relative to each other. In this case, the volume balance of the core is improved around the first main body and around the second main body, and the saturation magnetic flux density of the core is easily uniformed.

[0025] The ratio of the first width to the second width may be 3: 1 to 4: 1. In this case, in particular, the inductance characteristics and / or DC superposition characteristics of the coil device are improved.

[0026] Alternatively, the first conductor has a first mounting portion that is continuous with the first main body and exposed from the core, the second conductor has a second mounting portion that is continuous with the second main body and exposed from the core, the first mounting portion and the second mounting portion are separated from each other along the direction in which the first main body and the second main body are opposite, and extend toward the mounting surface side of the core. By separating the first mounting portion and the second mounting portion from each other along the direction in which the first main body and the second main body are opposite, the size of the coil device is reduced in the axial direction of the first main body or the second main body. In this way, the coil device can be miniaturized.

[0027] Alternatively, the first mounting portion may include a first base end portion extending in a direction relative to the first main body portion and the second main body portion, and a first leg portion continuous with the first base end portion and extending toward the mounting surface, the second mounting portion may include a second base end portion extending in a direction relative to the first main body portion and the second main body portion, to the opposite side of the first base end portion, and a second leg portion continuous with the second base end portion and extending toward the mounting surface, the first mounting portion may be bent into an L-shape from the first base end portion to the first leg portion, and the second mounting portion may be bent into an L-shape from the second base end portion to the second leg portion. In this case, since the first base end portion and the second base end portion extend to opposite sides along the direction relative to the first main body portion and the second main body portion, the size of the coil device can be reduced in the axial direction of the first main body portion or the second main body portion. In addition, since the first mounting portion and the second mounting portion are bent into an L-shape, the mounting stability is improved when the coil device is installed. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a perspective view of a coil device according to one embodiment of the present disclosure.

[0029] Figure 2 yes Figure 1 A perspective view of the first core is shown.

[0030] Figure 3 yes Figure 1 An exploded perspective view of the coil device shown.

[0031] Figure 4 yes Figure 1 A three-dimensional view of the first conductor and the second conductor shown.

[0032] Figure 5 yes Figure 1 A cross-sectional view of the coil arrangement along line VV is shown.

[0033] Figure 6 Is installed Figure 3 A top view of the first conductor and the first core of the second conductor is shown. DETAILED DESCRIPTION

[0034] Hereinafter, the embodiments of the present disclosure will be described with reference to the accompanying drawings. In addition, for the purpose of understanding the present disclosure, the contents shown in the drawings are merely schematic and exemplary, and the appearance and dimensional ratios may be different from the actual objects. In addition, the present disclosure is not limited to the following embodiments.

[0035] Figure 1 The coil device 1 shown functions as a coupled inductor and is provided, for example, in a power supply circuit of a server. The coil device 1 includes a first core 10, a second core 20, a first conductor 30, and a second conductor 40. The core of this embodiment is composed of two cores, the first core 10 and the second core 20, but may also be composed of one core, or three or more cores.

[0036] exist Figure 1 to Figure 6 In the figure, the X-axis is an axis along the axial direction of the first conductor 30 (first main body 31) or the second conductor 40 (second main body 41). The Y-axis is an axis along the relative direction of the first conductor 30 and the second conductor 40. The Z-axis is an axis perpendicular to the X-axis and the Y-axis. The X-axis, the Y-axis and the Z-axis are perpendicular to each other. In the following, with respect to each of the X-axis, the Y-axis and the Z-axis, the direction away from the center of the coil device 1 is set as the "outside", and the direction close to the center of the coil device 1 is set as the "inside". In addition, the positive direction side of the Z-axis is set as the "upper side", and the negative direction side of the Z-axis is set as the "lower side". However, the upper side in the Z-axis direction may not be consistent with the upper side in the vertical direction. In addition, the lower side in the Z-axis direction may not be consistent with the lower side in the vertical direction.

[0037] The width of the coil device 1 in the X-axis direction is not particularly limited, and is, for example, 2.0 to 20.0 mm. The width of the coil device 1 in the Y-axis direction is not particularly limited, and is, for example, 2.0 to 10.0 mm. The thickness of the coil device 1 in the Z-axis direction is not particularly limited, and is 2.0 to 10.0 mm.

[0038] like Figure 2 As shown, the first core 10 has a first side surface 11, a second side surface 12, a third side surface 13, a fourth side surface 14, a mounting surface 15, and a mounting opposite surface 16. The first side surface 11 and the second side surface 12 have the same shape and are located on opposite sides along the Y axis. The shape of the first side surface 11 and the second side surface 12 is a rectangle, but can also be a square or other polygon. The third side surface 13 and the fourth side surface 14 have the same shape and are located on opposite sides along the X axis. The mounting surface 15 and the mounting opposite surface 16 are located on opposite sides along the Z axis.

[0039] The first core 10 has a groove 17 formed in the mounting facing surface 16. The groove 17 is located at the center in the Y-axis direction and extends along the X-axis from one end to the other end of the mounting facing surface 16 in the X-axis direction.

[0040] The groove portion 17 has a bottom surface 170 and inner walls 171 and 172. The bottom surface 170 is a flat surface parallel to the mounting surface 15. The inner walls 171 and 172 are surfaces perpendicular to the bottom surface 170. The inner wall 171 and the inner wall 172 are opposite to each other along the Y axis. In addition, in this embodiment, "parallel" is not limited to strict parallelism. In addition, "vertical" is not limited to strict verticality.

[0041] The first core 10 is formed of a composite material containing a magnetic material and a resin. The first core 10 is formed, for example, by powder pressing, injection molding, or cutting. The magnetic material constituting the first core 10 is not particularly limited, and is, for example, ferrite (Ni-Zn ferrite, Mn-Zn ferrite, etc.) or a metal magnetic body. The resin constituting the first core 10 is not particularly limited, and is, for example, an epoxy resin or a phenolic resin.

[0042] like Figure 3 As shown, the second core 20 has a rectangular parallelepiped shape. The second core 20 is formed, for example, by powder pressing, injection molding, or cutting. The second core 20 has a contact surface 21 that contacts the mounting opposite surface 16 of the first core 10. The second core 20 (contact surface 21) is bonded to the first core 10 (mounting opposite surface 16) by, for example, an adhesive.

[0043] The material constituting the second core 20 may be the same as or different from the material constituting the first core 10. The relative magnetic permeability of the second core 20 may be the same as or different from the relative magnetic permeability of the first core 10.

[0044] The width of the second core 20 in the X-axis direction is not particularly limited, but is wider than the width of the first core 10 in the X-axis direction. The width of the second core 20 in the Y-axis direction is not particularly limited, but is equal to the width of the first core 10 in the Y-axis direction. The thickness of the second core 20 in the Z-axis direction is not particularly limited, but is thinner than the thickness of the first core 10 in the Z-axis direction.

[0045] Figure 4 The first conductor 30 and the second conductor 40 shown are formed of a metal frame. The first conductor 30 and the second conductor 40 are formed by, for example, machining (for example, punching, bending, cutting, stamping, sheet metal processing, casting or forging) a metal plate (conductor plate) or a metal sheet (conductor sheet) into Figure 4 The first conductor 30 and the second conductor 40 have higher rigidity than ordinary electric wires (round wires, flat wires, etc.). The material constituting the first conductor 30 and the second conductor 40 is not particularly limited, and is, for example, copper, copper alloy, silver or nickel.

[0046] A plating film (plating layer) is formed on at least a portion (in this embodiment, the entire surface) of the first conductor 30. In addition, a plating film (plating layer) is formed on at least a portion (in this embodiment, the entire surface) of the second conductor 40. The plating film may be a single layer or a multilayer. The plating film is not particularly limited, and may be, for example, Cu plating, Ni plating, Sn plating, Ni-Sn plating, Cu-Ni-Sn plating, Ni-Au plating, or Au plating.

[0047] The first conductor 30 is a primary coil, and the second conductor 40 is a secondary coil. However, the first conductor 30 may be a secondary coil, and the second conductor 40 may be a primary coil. The first conductor 30 and the second conductor 40 constitute a coupled coil that is magnetically coupled to each other.

[0048] like Figure 4 As shown, the first conductor 30 has a first main body 31 and first mounting parts 32a and 32b. The first main body 31 extends in a straight line along the X axis. The cross-sectional shape of the first main body 31 is a rectangle, but it can also be a square, other polygons, or other shapes.

[0049] The first main body 31 has two side surfaces (first side surfaces) and two main surfaces (first main surfaces). The first main body 31 has a first outer side surface 310 and a first inner side surface 311 as first side surfaces. In addition, the first main body 31 has a first top surface 312 and a first bottom surface 313 as first main surfaces.

[0050] The first outer side surface 310 and the first inner side surface 311 are located on opposite sides along the Y axis and are parallel to each other. The first outer side surface 310 is located on the outer side of the Y axis direction than the first inner side surface 311. The first top surface 312 and the first bottom surface 313 are located on opposite sides along the Z axis and are parallel to each other. The first outer side surface 310, the first inner side surface 311, the first top surface 312, and the first bottom surface 313 are flat surfaces that are perpendicular to each other.

[0051] However, at least one of the first outer side surface 310, the first inner side surface 311, the first top surface 312, and the first bottom surface 313 may not be a flat surface, and may be, for example, an inclined surface, a concave-convex surface, a curved surface, or a curved surface. Figure 3 The mounting surface 15 may be perpendicular to the mounting surface 15, but may also be an inclined surface inclined at a specified angle (for example, greater than 30° and less than 90°) relative to the mounting surface 15.

[0052] The first mounting portion 32a is continuous with one axial end of the first main body portion 31, and the first mounting portion 32b is continuous with the other axial end of the first main body portion 31. Figure 4In FIG. 1 , the boundary between the first main body 31 and the first mounting portion 32a and the boundary between the first main body 31 and the first mounting portion 32b are indicated by a dashed line. The shape of the first mounting portion 32a is the same as that of the first mounting portion 32b, but may be different.

[0053] The first mounting parts 32a and 32b are bent into an L-shape. The first mounting parts 32a and 32b are connected to the mounting substrate by solder or a conductive adhesive, etc. The first mounting parts 32a and 32b have a base end 320, a bent part 321, and a leg part 322, respectively.

[0054] The base end portion 320 is continuous with the first main body portion 31 and extends along the Y axis in a manner orthogonal to the first main body portion 31. The bent portion 321 is bent into an L shape between the base end portion 320 and the foot portion 322. The foot portion 322 extends in a straight line along the Z axis. The foot portion 322 is orthogonal to the base end portion 320. When viewed from the X axis direction, the foot portion 322 is located further outside the first main body portion 31 in the Y axis direction. The cross-sectional shape of the foot portion 322 is a rectangle, but may also be a square, other polygons, or other shapes.

[0055] The second conductor 40 includes a second main body 41 and second mounting portions 42a and 42b. The second main body 41 extends in a straight line along the X axis. The cross-sectional shape of the second main body 41 is a rectangle, but may be a square, other polygonal, or other shapes.

[0056] The second main body 41 has two side surfaces (second side surfaces) and two main surfaces (second main surfaces). The second main body 41 has a second outer side surface 410 and a second inner side surface 411 as second side surfaces. In addition, the second main body 41 has a second top surface 412 and a second bottom surface 413 as second main surfaces.

[0057] The second outer side surface 410 and the second inner side surface 411 are located on opposite sides along the Y axis and are parallel to each other. The second outer side surface 410 is located on the outer side of the Y axis direction than the second inner side surface 411. The second top surface 412 and the second bottom surface 413 are located on opposite sides along the Z axis and are parallel to each other. The second outer side surface 410, the second inner side surface 411, the second top surface 412, and the second bottom surface 413 are flat surfaces that are perpendicular to each other.

[0058] However, at least one of the second outer side surface 410, the second inner side surface 411, the second top surface 412, and the second bottom surface 413 may not be a flat surface, and may be, for example, an inclined surface, a concave-convex surface, a curved surface, or a curved surface. Figure 3 The mounting surface 15 may be perpendicular to the mounting surface 15, but may also be an inclined surface inclined at a specified angle (for example, greater than 30° and less than 90°) relative to the mounting surface 15.

[0059] The second mounting portion 42a is continuous with one axial end of the second main body portion 41, and the second mounting portion 42b is continuous with the other axial end of the second main body portion 41. Figure 4 In FIG. 4 , the boundary between the second main body 41 and the second mounting portion 42a and the boundary between the second main body 41 and the second mounting portion 42b are indicated by a dashed line. The shape of the second mounting portion 42a is the same as that of the second mounting portion 42b, but may be different.

[0060] The second mounting parts 42a and 42b are bent into an L-shape. The second mounting parts 42a and 42b are connected to the mounting substrate by solder or a conductive adhesive, etc. The second mounting parts 42a and 42b have a base end 420, a bent part 421, and a leg part 422, respectively.

[0061] The base end portion 420 is continuous with the second main body portion 41 and extends along the Y axis in a manner orthogonal to the second main body portion 41. The bent portion 421 is bent into an L shape between the base end portion 420 and the foot portion 422. The foot portion 422 extends in a straight line along the Z axis. The foot portion 422 is orthogonal to the base end portion 420. When viewed from the X axis direction, the foot portion 422 is located further outside the second main body portion 41 in the Y axis direction. The cross-sectional shape of the foot portion 422 is a rectangle, but may also be a square, other polygons, or other shapes.

[0062] like Figure 3 As shown, the first body portion 31 and the second body portion 41 are arranged inside the groove portion 17. The first body portion 31 extends along the mounting surface 15 inside the groove portion 17. The second body portion 41 extends along the mounting surface 15 inside the groove portion 17 in parallel with the first body portion 31. The depth of the groove portion 17 is equal to or greater than the thickness of the first body portion 31 or the second body portion 41 in the Z-axis direction, so that the first body portion 31 and the second body portion 41 are not exposed from the groove portion 17. Figure 5 As shown, the first bottom surface 313 of the first main body portion 31 is bonded to the bottom surface 170 of the groove portion 17 by the adhesive 70. In addition, the second bottom surface 413 of the second main body portion 41 is bonded to the bottom surface 170 of the groove portion 17 by the adhesive 70. However, the first top surface 312 of the first main body portion 31 can also be bonded to the abutting surface 21 of the second core 20 by the adhesive 70. In addition, the second top surface 412 of the second main body portion 41 can also be bonded to the abutting surface 21 of the second core 20 by the adhesive 70.

[0063] The first inner side surface 311 and the second inner side surface 411 are opposite to each other along the Y axis at a predetermined interval. The interval W0 between the first inner side surface 311 and the second inner side surface 411 along the Y axis is not particularly limited, and is, for example, 0.05 to 0.5 mm. The magnetic coupling between the first body portion 31 and the second body portion 41 can be adjusted according to the size of the interval W0. A gap 60 is formed between the first inner side surface 311 and the second inner side surface 411.

[0064] The gap 60 is a void. However, an adhesive may be filled into the gap 60. For example, in order to set the interval W0 to a predetermined value, the first inner side surface 311 and the second inner side surface 411 may be bonded by an adhesive (e.g., a bead-embedded adhesive). Alternatively, a portion of the first core 10 or the second core 20 may be disposed in the gap 60. Alternatively, a partitioning member (spacer) or a film (film) formed of a non-conductive member such as a resin may be disposed in the gap 60.

[0065] A gap 61 is formed between the first outer side surface 310 and the inner wall 171 of the groove portion 17, but the first outer side surface 310 may abut against the inner wall 171. Alternatively, the first outer side surface 310 and the inner wall 171 may be bonded by an adhesive.

[0066] In addition, a gap 62 is formed between the second outer side surface 410 and the inner wall 172 of the groove portion 17, but the second outer side surface 410 may abut against the inner wall 172. Alternatively, the second outer side surface 410 and the inner wall 172 may be bonded by an adhesive.

[0067] The first main body 31 and the second main body 41 are accommodated in the space defined by the groove 17 in a manner of being clamped from top and bottom by the first core 10 and the second core 20. A gap is formed between the first top surface 312 of the first main body 31 and the abutting surface 21 of the second core 20, but they may also be in contact. In addition, a gap is formed between the second top surface 412 of the second main body 41 and the abutting surface 21 of the second core 20, but they may also be in contact.

[0068] The first main body portion 31 and the second main body portion 41 constitute a magnetic coupling portion 50 that is magnetically coupled to each other. The magnetic coupling portion 50 is a hypothetical structure in which the first main body portion 31 and the second main body portion 41 are regarded as one structure. In the Y-axis direction, the center C of the magnetic coupling portion 50 is located at the center of the first core 10 and / or the second core 20. However, the position of the center C of the magnetic coupling portion 50 in the Y-axis direction may not be completely consistent with the position of the center of the first core 10 and / or the second core 20 in the Y-axis direction. The center C of the magnetic coupling portion 50 may also be located within a specified length range along the Y-axis from the center of the first core 10 and / or the second core 20. However, the specified length is 5% of the width of the first core 10 or the second core 20 in the Y-axis direction.

[0069] In the present embodiment, the center of the magnetic coupling portion 50 is located at the center of the first core 10. Therefore, around the first body portion 31 (for example, outside the first outer side surface 310 in the Y-axis direction) and around the second body portion 41 (for example, outside the second outer side surface 410 in the Y-axis direction), the volume balance of the first core 10 is improved, and the saturation magnetic flux density of the first core 10 is easily uniformed.

[0070] like Figure 6 As shown, the first mounting portion 32a is arranged on the outer side of the first core 10 in the X-axis direction, adjacent to the third side surface 13. In addition, the first mounting portion 32b is arranged on the outer side of the first core 10 in the X-axis direction, adjacent to the fourth side surface 14. The first mounting portions 32a and 32b are arranged on both sides of the first core 10 in the X-axis direction in a manner of clamping the first core 10 from both sides in the X-axis direction.

[0071] The first mounting portions 32a and 32b are exposed from the first core 10 and the second core 20. The first mounting portions 32a and 32b are formed by Figure 6 The second core 20 indicated by the two-dot chain line in FIG. 8 covers from above. Therefore, when viewed from above, the first mounting portions 32a and 32b are hidden by the second core 20.

[0072] In addition, the second mounting portion 42a is arranged on the outer side of the first core 10 in the X-axis direction, adjacent to the third side surface 13. In addition, the second mounting portion 42b is arranged on the outer side of the first core 10 in the X-axis direction, adjacent to the fourth side surface 14. The second mounting portions 42a and 42b are arranged on both sides of the first core 10 in the X-axis direction in a manner of clamping the first core 10 from both sides in the X-axis direction.

[0073] The second mounting portions 42a and 42b are exposed from the first core 10 and the second core 20. The second mounting portions 42a and 42b are formed by Figure 6 The second core 20 indicated by the two-dot chain line in FIG. 2 covers from above. Therefore, the second mounting portions 42a and 42b are hidden by the second core 20 when viewed from above.

[0074] like Figure 5 As shown, when viewed from the X-axis direction, the foot 322 of the first mounting portion 32b is located on the inner side of the Y-axis direction than the second side surface 12 of the first core 10. Although detailed illustrations are omitted, the foot 322 of the first mounting portion 32a is also the same. In addition, when viewed from the X-axis direction, the foot 422 of the second mounting portion 42b is located on the inner side of the Y-axis direction than the first side surface 11 of the first core 10. Although detailed illustrations are omitted, the foot 422 of the second mounting portion 42a is also the same.

[0075] The lower portion of the leg 322 protrudes below the mounting surface 15 of the first core 10. The lower portion of the leg 422 protrudes below the mounting surface 15 of the first core 10. Therefore, the mounting surface 15 is located above the bottom surfaces of the legs 322 and 422.

[0076] like Figure 4 and Figure 5 As shown, the first outer side surface 310 has a first thickness T1 in a direction (Z-axis direction) perpendicular to the XY plane (mounting surface 15). The first inner side surface 311 is also the same, having a first thickness T1 in the same direction. In addition, the first top surface 312 has a first width W1 in a direction (Y-axis direction) parallel to the XY plane (mounting surface 15). The first bottom surface 313 is also the same, having a first width W1 in the same direction.

[0077] The second outer side surface 410 has a second thickness T2 in a direction (Z-axis direction) perpendicular to the XY plane (mounting surface 15). The second inner side surface 411 is also the same, having a second thickness T2 in the same direction. In addition, the second top surface 412 has a second width W2 in a direction (Y-axis direction) parallel to the XY plane (mounting surface 15). The second bottom surface 413 is also the same, having a second width W2 in the same direction.

[0078] In the direction (Y-axis direction) in which the first main body 31 and the second main body 41 are opposite to each other, the second width W2 is narrower than the first width W1. Therefore, compared with the case where the first width W1 and the second width W2 are equal, more configuration space for the first core 10 is formed around the second main body 41 (space corresponding to the difference between the first width W1 and the second width W2). As a result, the volume of the first core 10 increases around the second main body 41 (for example, outside the second outer side surface 410 in the Y-axis direction), and the inductance characteristics and / or DC superposition characteristics of the coil device 1 are improved.

[0079] In addition, since the first width W1 and the second width W2 are different, the first body 31 and the second body 41 have different resistance values. Therefore, the inductance characteristics and / or DC superposition characteristics of the coil device 1 can be adjusted according to the resistance value of the first body 31 or the second body 41.

[0080] In addition, by becoming Figure 4 and Figure 5 By arranging the first body portion 31 and the second body portion 41 inside the first core 10 in the manner oriented as shown, the size of the first core 10 can be reduced, and the coil device 1 can be made small and low in height. In addition, since the first body portion 31 and the second body portion 41 are opposite to each other, the magnetic coupling between the first body portion 31 and the second body portion 41 can be ensured.

[0081] The ratio between the first width W1 and the second width W2 is not particularly limited, and is 2: 1 to 5: 1, or 3: 1 to 4: 1. In this case, in particular, the inductance characteristics and / or DC superposition characteristics of the coil device 1 are improved.

[0082] In addition, the first side surface 310 and the second side surface 410 are perpendicular to the mounting surface 15. Therefore, the first outer side surface 310 is arranged in parallel with the second side surface 12 of the first core 10 (the surface perpendicular to the mounting surface 15). In addition, the second outer side surface 410 is arranged in parallel with the first side surface 11 of the first core 10 (the surface perpendicular to the mounting surface 15). Thus, more configuration space for the first core 10 can be formed around the first outer side surface 310 and the second outer side surface 410. Therefore, the inductance characteristics and / or DC superposition characteristics of the coil device 1 are further improved.

[0083] The first mounting portion 32a (leg 322) has a third width W3 along the axial direction (X-axis direction) of the first main body portion 31. In addition, the first mounting portion 32a (leg 322) has a fourth width W4 along the direction (Y-axis direction) in which the first main body portion 31 and the second main body portion 41 are opposite to each other. The first mounting portion 32b is also the same, having the third width W3 and the fourth width W4 in the same direction.

[0084] The second mounting portion 42a (leg 422) has a fifth width W5 along the axial direction (X-axis direction) of the second main body 41. In addition, the second mounting portion 42b (leg 422) has a sixth width W6 along the direction (Y-axis direction) in which the first main body 31 and the second main body 41 are opposite to each other. The second mounting portion 42b is also the same, having the fifth width W5 and the sixth width W6 in the same direction.

[0085] The third width W3 is equal to the fifth width W5. In addition, the fourth width W4 is equal to the sixth width W6. Therefore, the cross-sectional area of ​​the first mounting portion 32a is equal to the cross-sectional area of ​​the second mounting portion 42a. Thus, when the first mounting portion 32a and the second mounting portion 42a are arranged on the mounting substrate, the mounting stability of the coil device 1 is improved.

[0086] The first thickness T1, the second thickness T2, and the fourth width W4 are equal. In addition, the first thickness T1, the second thickness T2, and the fourth width W4 are greater than the second width W2, and are less than the third width W3. In addition, the third width W3 is greater than the first thickness T1, the second thickness T2, and the fourth width W4, and is less than the first width W1. In particular, by satisfying the above-mentioned size relationship between the third width W3 and the fourth width W4, it is easy to ensure the contact area between the first mounting portion 32a and the mounting substrate, and the installation stability of the coil device 1 is improved. In addition, in particular, by satisfying the above-mentioned size relationship between the first width W1 and the second width W2, it is easy to ensure the volume of the first core 10 around the second main body portion 41, and the inductance characteristics and / or DC superposition characteristics of the coil device 1 are improved.

[0087] The first thickness T1, the second thickness T2, and the sixth width W6 are equal. In addition, the first thickness T1, the second thickness T2, and the sixth width W6 are greater than the second width W2, and are less than the fifth width W5. In addition, the fifth width W5 is greater than the first thickness T1, the second thickness T2, and the sixth width W6, and is less than the first width W1. In particular, by satisfying the above-mentioned size relationship between the fifth width W5 and the sixth width W6, it is easy to ensure the contact area between the second mounting portion 42a and the mounting substrate, and the installation stability of the coil device 1 is improved. In addition, in particular, by satisfying the above-mentioned size relationship between the first width W1 and the second width W2, it is easy to ensure the volume of the first core 10 around the second main body portion 41, and the inductance characteristics and / or DC superposition characteristics of the coil device 1 are improved.

[0088] The cross-sectional area (W3×W4) of the first mounting portion 32a is greater than the cross-sectional area (T2×W2) of the second main body portion 41, and is less than the cross-sectional area (T1×W1) of the first main body portion 31. The cross-sectional area of ​​the first mounting portion 32b is also the same. In addition, the cross-sectional area (W5×W6) of the second mounting portion 42a is greater than the cross-sectional area (T2×W2) of the second main body portion 41, and is less than the cross-sectional area (T1×W1) of the first main body portion 31. The cross-sectional area of ​​the second mounting portion 42b is also the same. Therefore, the contact area between the first mounting portion 32a and / or the second mounting portion 42a and the mounting substrate can be ensured. As a result, the installation stability of the coil device 1 is improved.

[0089] like Figure 3As shown, the first mounting portion 32a and the second mounting portion 42a are separated from each other along the direction in which the first main body portion 31 and the second main body portion 41 are opposite (i.e., the Y-axis direction), and extend to the mounting surface 15 side of the first core 10. In addition, the first mounting portion 32b and the second mounting portion 42b are separated from each other along the direction in which the first main body portion 31 and the second main body portion 41 are opposite (i.e., the Y-axis direction), and extend to the mounting surface 15 side of the first core 10. By separating the first mounting portion 32a and the second mounting portion 42a from each other along the Y-axis direction, the size of the coil device 1 is reduced in the axial direction (X-axis direction) of the first main body portion 31 or the second main body portion 41. As a result, the miniaturization of the coil device 1 can be achieved.

[0090] Next, a method for manufacturing the coil device 1 will be described. First, prepare Figure 3 The first core 10, the second core 20, the first conductor 30, and the second conductor 40 are shown. Next, the first bottom surface 313 ( Figure 4 ). In addition, the second bottom surface 413 of the second main body 41 is bonded to the groove 17 by an adhesive ( Figure 4 ). At this time, a gap is set between the first main body portion 31 and the second main body portion 41, so that a gap is formed between the first main body portion 31 and the second main body portion 41. Figure 5 The gap 60 shown. In addition, Figure 3 As shown in FIG. 1 , the first mounting portions 32a and 32b are arranged outside the first core 10 in the X-axis direction, and the second mounting portions 42a and 42b are arranged outside the first core 10 in the X-axis direction. Next, the first mounting portions 32a and 32b are arranged outside the first core 10 in the X-axis direction. Figure 2 The first core 10 shown is bonded to the mounting surface 16 Figure 3 The abutment surface 21 of the second core 20 shown. As above, it is possible to manufacture Figure 1 The coil arrangement 1 is shown.

[0091] In addition, the present disclosure is not limited to the above-mentioned embodiment, and various changes can be made within the scope of the present disclosure.

[0092] For example, in the above-mentioned embodiments, an example in which the present disclosure is applied to a coupled inductor is described, but the present disclosure can also be applied to other electronic components.

[0093] like Figure 3 As shown, the core of the above embodiment is composed of two cores, the first core 10 and the second core 20, but may be composed of one core. Such a core can be formed by, for example, (1) placing the first conductor 30 and the second conductor 40 in a mold, (2) filling the mold with a core material constituting the core, and (3) compressing and curing the core material.

[0094] like Figure 3As shown, in the above embodiment, the groove 17 for accommodating the first body 31 and the second body 41 is formed in the first core 10. However, the groove for accommodating the first body 31 and the second body 41 may be formed in the second core 20.

[0095] if only Figure 4 If the second width W2 shown is smaller than the first width W1, the size of the first conductor 30 and the second conductor 40 is not particularly limited. For example, in the above embodiment, the first thickness T1, the second thickness T2, and the fourth width W4 are equal, but the first thickness T1 and the second thickness T2 may be different from the fourth width W4. In addition, the first thickness T1 and the second thickness T2 may be different. In this case, the same effect as the above embodiment can be obtained.

[0096] In addition, in the above embodiment, the first thickness T1, the second thickness T2, and the fourth width W4 are greater than the second width W2 and are less than the third width W3, but the first thickness T1, the second thickness T2, and the fourth width W4 may be less than the second width W2. In addition, the first thickness T1, the second thickness T2, and the fourth width W4 may be greater than the third width W3. In this case, the same effect as in the above embodiment can be obtained.

[0097] In addition, in the above embodiment, the third width W3 is greater than the first thickness T1, the second thickness T2, and the fourth width W4, and less than the first width W1, but the third width W3 may be smaller than the first thickness T1, the second thickness T2, and the fourth width W4. In addition, the third width W3 may be greater than the first width W1. In this case, the same effect as in the above embodiment can be obtained.

[0098] like Figure 4 As shown, in the above embodiment, the third width W3 is equal to the fifth width W5, but the third width W3 may be different from the fifth width W5. In addition, the fourth width W4 is equal to the sixth width W6, but the fourth width W4 may be different from the sixth width W6.

[0099] Description of Reference Numerals

[0100] 1…Coil device

[0101] 10…First Core

[0102] 11…First side

[0103] 12… Second side

[0104] 13…The third side

[0105] 14…The fourth side

[0106] 15…Mounting surface

[0107] 16… Installation opposite side

[0108] 17… Groove

[0109] 170…bottom

[0110] 171, 172…Inner wall

[0111] 20…Second core

[0112] 21…butting surface

[0113] 30…First conductor

[0114] 31…First body

[0115] 310…First outer side

[0116] 311…First inner side

[0117] 312…First top surface

[0118] 313…First bottom surface

[0119] 32a, 32b ... first mounting portion

[0120] 320…base end

[0121] 321…Bend

[0122] 322…Feet

[0123] 40…Second conductor

[0124] 41…Second main body

[0125] 410…Second outer side

[0126] 411…Second inner side

[0127] 412…Second top surface

[0128] 413…Second bottom surface

[0129] 42a, 42b ... second mounting portion

[0130] 420…base end

[0131] 421…Bend

[0132] 422…Feet

[0133] 50…Magnetic coupling part

[0134] 60~62…Gap

[0135] 70…Adhesive

Claims

1. A coil device, wherein: have: a core having a mounting surface; a first conductor having a first body portion extending along the mounting surface within the core; as well as a second conductor having a second main body portion extending inside the core along the mounting surface and opposite to the first main body portion, The first main body portion has a first side surface having a first thickness in a direction perpendicular to the mounting surface, and a first main surface having a first width in a direction parallel to the mounting surface. The second main body portion has a second side surface having a second thickness in a direction perpendicular to the mounting surface, and a second main surface having a second width in a direction parallel to the mounting surface. In a direction in which the first body portion and the second body portion are opposite to each other, the second width is narrower than the first width.

2. The coil device according to claim 1, wherein: The first side surface and the second side surface are perpendicular to the mounting surface.

3. The coil device according to claim 1 or 2, wherein: The first conductor has a first mounting portion continuous with the first main body portion, The second conductor has a second mounting portion continuous with the second main body portion, The cross-sectional area of ​​the first mounting portion or the second mounting portion is larger than the cross-sectional area of ​​the second main body portion and is smaller than the cross-sectional area of ​​the first main body portion.

4. The coil device according to claim 3, wherein: The first mounting portion has a third width in the axial direction of the first main body portion, and has a fourth width in the direction in which the first main body portion and the second main body portion are opposite to each other. The first thickness, the second thickness, and the fourth width are equal, The first thickness, the second thickness, and the fourth width are greater than the second width and are less than the third width. The third width is greater than the first thickness, the second thickness, and the fourth width, and less than the first width.

5. The coil device according to claim 3, wherein: The first mounting portion has a third width in the axial direction of the first main body portion, and has a fourth width in the direction in which the first main body portion and the second main body portion are opposite to each other. The second mounting portion has a fifth width in the axial direction of the second main body portion, and has a sixth width in the direction in which the first main body portion and the second main body portion are opposite to each other. The third width is equal to the fifth width, The fourth width is equal to the sixth width.

6. The coil device according to claim 1 or 2, wherein: The first main body portion and the second main body portion constitute a magnetic coupling portion that is magnetically coupled to each other. In the direction in which the first body portion and the second body portion are opposed, a central portion of the magnetic coupling portion is located at a central portion of the core.

7. The coil device according to claim 1 or 2, wherein: The ratio of the first width to the second width is 3:1 to 4:

1.

8. The coil device according to claim 1 or 2, wherein: The first conductor has a first mounting portion that is continuous with the first main body portion and exposed from the core. The second conductor has a second mounting portion that is continuous with the second body portion and exposed from the core. The first mounting portion and the second mounting portion are separated from each other along a direction in which the first body portion and the second body portion are opposed to each other, and extend toward a mounting surface side of the core.

9. The coil device according to claim 8, wherein: The first mounting portion includes a first base end portion extending in a direction in which the first main body portion and the second main body portion are opposite to each other, and a first leg portion continuous with the first base end portion and extending toward the mounting surface. The second mounting portion includes a second base end portion extending to the opposite side of the first base end portion along the direction in which the first main body portion and the second main body portion are opposite to each other, and a second leg portion continuous with the second base end portion and extending toward the mounting surface. The first mounting portion is bent into an L-shape from the first base end portion to the first leg portion. The second mounting portion is bent in an L shape from the second base end portion to the second leg portion.

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