Inductor and component mounting module

Abstract

To inhibit deterioration of insulation reliability of an inductor and inhibit nonuniformity in the heat dissipation of the inductor.SOLUTION: An inductor 1 comprises: a magnetic core 10 with a first main surface 18 and a second main surface 19 facing away from each other, as well as side surfaces connecting the first main surface 18 and the second main surface 19; a coil section 20 disposed within the magnetic core 10; electrode sections 30 connected to the coil section 20 at the side surfaces and disposed outside the magnetic core 10; and a cover member 50 with insulating properties that covers part of the first main surface 18 and part of the second main surface 19.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to an inductor and a component mounting module in which the inductor is mounted. [Background technology]

[0002] As vehicles become more computerized, the number of electronic devices installed in vehicles is increasing. Power supply devices such as DC-DC converters that drive these electronic devices use components such as inductors to step up and down the power supply voltage and smooth the direct current. In power supply devices that input or output high voltages, the power increases and the inductors generate a lot of heat, so it is necessary to take measures to dissipate heat from the inductors.

[0003] Patent Document 1 discloses a structure in which a thermally conductive member (heat transfer sheet) and a heat dissipation member (heat equalizing plate) are arranged in this order on an inductor. With this structure, heat generated in the inductor can be dissipated to the heat dissipation member via the thermally conductive member. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2015-82960 A Summary of the Invention [Problem to be solved by the invention]

[0005] However, the structure disclosed in Patent Document 1 may result in reduced insulation reliability of the inductor, or variations in the heat dissipation performance of the inductor.

[0006] The present disclosure provides an inductor etc. that can suppress both or either of a decrease in insulation reliability and variation in heat dissipation performance. [Means for solving the problem]

[0007] An inductor according to one embodiment of the present disclosure comprises a magnetic core having first and second main surfaces facing each other and a side surface connecting the first and second main surfaces, a coil portion provided inside the magnetic core, an electrode portion connected to the coil portion at the side surface and provided outside the magnetic core, and an insulating cover member covering a portion of the first main surface and a portion of the second main surface.

[0008] A component mounting module according to one embodiment of the present disclosure comprises the above-mentioned inductor, a cooling section for cooling the inductor, and a thermally conductive member in contact with the cooling section, wherein the thermally conductive member is in contact with at least one of the first main surface and the second main surface of the magnetic core.

[0009] A component mounting module according to one embodiment of the present disclosure comprises the above-mentioned inductor, a cooling section for cooling the inductor, and a thermally conductive member in contact with the cooling section, wherein the cooling section has a concave accommodating section, the inductor is accommodated in the accommodating section, and the thermally conductive member is in contact with a surface of the magnetic core within the accommodating section. Effect of the Invention

[0010] According to the present disclosure, it is possible to suppress both or either of a decrease in the insulation reliability of an inductor or the like and the occurrence of variations in heat dissipation properties. [Brief description of the drawings]

[0011] [Figure 1] 1 is a perspective view of an inductor according to an embodiment; [Diagram 2] 11 is a diagram showing the inductor according to the embodiment with a cover member removed; FIG. [Diagram 3] 1 is a view of an inductor according to an embodiment as viewed from a first main surface side. [Figure 4] 1 is a side view of an inductor according to an embodiment; [Diagram 5] 2 is a perspective view of a magnetic core and an electrode portion of the inductor according to the embodiment. FIG. [Figure 6]2 is a perspective view of a cover member of the inductor according to the embodiment. FIG. [Figure 7] 4 is a flowchart showing a method for manufacturing an inductor according to an embodiment. [Figure 8] FIG. 13 is a perspective view of an inductor according to a modified example of the embodiment. [Figure 9] 13 is a perspective view of a cover member of an inductor according to a modified example of the embodiment. FIG. [Figure 10] 1 is a side view of a component mounting module according to an embodiment; [Figure 11] 11 is a side view of a component mounting module according to a first modified example of the embodiment. FIG. [Figure 12] 11 is a side view of a component mounting module according to a second modified example of the embodiment. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] For example, electric vehicles and hybrid vehicles using a motor as a drive source use power supply devices such as a charger that converts commercial AC voltage into a DC voltage of 200V to 800V and charges a high-voltage battery, an inverter that converts the DC voltage of the high-voltage battery into an AC voltage and outputs it to the motor, or a DC-DC converter that converts the DC voltage of the high-voltage battery into a DC of 12V and outputs it to an auxiliary battery. These power supply devices such as chargers, inverters, and DC-DC converters use electronic components such as inductors, but as described above, electric vehicles and hybrid vehicles use high-voltage power supplies and therefore generate a lot of power, which leads to a lot of heat generation from the inductors.

[0013] If the inductor's temperature becomes too high due to heat generation, the inductor's performance will deteriorate, so some kind of heat dissipation measure must be taken for the inductor. Patent Document 1 discloses a structure in which a thermally conductive member and a heat dissipation member are arranged in that order on an inductor.

[0014] However, for example, when assembling an inductor and a metal heat dissipation member via a thermally conductive member, if the inductor is tilted or misaligned, the distance between the inductor and the heat dissipation member becomes shorter than necessary, resulting in a problem of reduced insulation reliability of the inductor. Also, if the inductor is tilted or misaligned, the distance between the inductor and the heat dissipation member varies depending on the location on the inductor, resulting in a problem of variation in the heat dissipation performance of the inductor.

[0015] The present disclosure has the following configuration in order to suppress both or either of a decrease in insulation reliability and a variation in heat dissipation. Hereinafter, the embodiment will be specifically described with reference to the drawings.

[0016] Note that the embodiments described below each show a specific example of the present disclosure. The numerical values, shapes, materials, components, component arrangement positions, connection forms, steps, and order of steps shown in the following embodiments are merely examples and are not intended to limit the present disclosure. Furthermore, among the components in the following embodiments, components that are not described in the independent claims are described as optional components.

[0017] Furthermore, in this specification, terms indicating the relationship between elements, such as "parallel," terms indicating the shape of an element, such as "cuboid," and numerical ranges are not expressions that only express a strict meaning, but are expressions that include a substantially equivalent range, for example, a difference of about a few percent.

[0018] In addition, each figure is a schematic diagram in which emphasis, omission, or adjustment of the ratio is appropriately performed in order to illustrate the present disclosure, and is not necessarily precisely illustrated, and may differ from the actual shape, positional relationship, and ratio. In each figure, the same reference numerals are given to substantially the same configurations, and duplicated explanations may be omitted or simplified.

[0019] In addition, each figure shows an X-axis, a Y-axis, and a Z-axis, which represent three mutually orthogonal directions, and these axes and the axial directions along these axes are used as necessary for explanation. Note that each axis is added for explanation purposes only, and does not limit the direction and posture in which the inductor is used.

[0020] (Embodiment) [Inductor structure] The configuration of an inductor according to an embodiment will be described with reference to Figures 1 to 6. An inductor is a passive element that stores electrical energy flowing through a coil element as magnetic energy.

[0021] Fig. 1 is a perspective view of an inductor 1 according to an embodiment. Fig. 2 is a view showing a state in which a cover member 50 of the inductor 1 is removed from a magnetic core 10. Fig. 3 is a view of the inductor 1 seen from the first main surface 18 side. Fig. 4 is a view of the inductor 1 seen from a side. Note that Fig. 4(a) shows a view of the inductor 1 seen from the first side surface 11, and Fig. 4(b) shows a view of the inductor 1 seen from the fourth side surface 14.

[0022] As shown in FIGS. 1 to 4, inductor 1 includes a magnetic core 10, a coil portion 20 provided inside magnetic core 10, and an electrode portion 30 connected to coil portion 20 and provided outside magnetic core 10.

[0023] The electrode portion 30 is composed of a pair of a first electrode portion 31 and a second electrode portion 32. The coil portion 20 is composed of a winding portion 21 formed by winding a conductive wire, and a pair of lead portions 22a and 22b.

[0024] The inductor 1 also includes an insulating cover member 50. The cover member 50 is provided to suppress a decrease in the insulation reliability of the inductor 1, or to suppress variations in the heat dissipation performance of the inductor 1. Each component of the inductor 1 will be described below. Note that the cover member 50 of this embodiment is composed of multiple cover members, but in the following, one or all of the multiple cover members may be referred to as the cover member 50.

[0025] The approximate outer shape of the inductor 1 is determined by the shape of the magnetic core 10, which is, for example, a rectangular parallelepiped magnetic compact. The magnetic core 10 can be molded into any shape by die molding. For example, the magnetic core 10 has a dimension of 40 mm in the X-axis direction, a dimension of 40 mm in the Y-axis direction, and a dimension of 18 mm in the Z-axis direction. The magnetic core 10 is appropriately selected, for example, from the ranges of 17 mm to 70 mm in the X-axis direction, 17 mm to 70 mm in the Y-axis direction, and 7 mm to 50 mm in the Z-axis direction.

[0026] The magnetic core 10 is a powder magnetic core including a mixture of a magnetic material powder such as a metal magnetic powder and a binder made of a resin material or the like. The magnetic core 10 may be formed using a magnetic material. The magnetic material may be ferrite or other magnetic materials. The metal magnetic powder may be a particulate material having a predetermined element composition, such as Fe-Si-Al, Fe-Si, Fe-Si-Cr, or Fe-Si-Cr-B. The resin material may be a material such as a silicone resin that can maintain a certain shape by binding the particles of the metal magnetic powder while insulating them from each other. The thermal conductivity of the magnetic core 10 is, for example, 3 W / (m·k) or more and 5 W / (m·k) or less.

[0027] The shape of the magnetic core 10 is, for example, a rectangular parallelepiped. The magnetic core 10 has a first main surface 18 on the top side, a second main surface 19 on the bottom side, and a side surface connecting the first main surface 18 and the second main surface 19. The side surface has a first side surface 11, a second side surface 12, a third side surface 13, and a fourth side surface 14. The first main surface 18, the second main surface 19, the first side surface 11, the second side surface 12, the third side surface 13, and the fourth side surface 14 are each a flat plane. The first main surface 18 and the second main surface 19 are parallel to each other and are back-to-back with each other in the Z-axis direction. The first side surface 11 and the second side surface 12 are back-to-back with each other in the Y-axis direction. The third side surface 13 and the fourth side surface 14 are back-to-back with each other in the X-axis direction.

[0028] The first main surface 18 and the second main surface 19 extend in a direction intersecting with the first side surface 11, the second side surface 12, the third side surface 13, and the fourth side surface 14, specifically in a direction perpendicular to the first side surface 11 and the second side surface 12, and the third side surface 13 and the fourth side surface 14 extend in a direction intersecting with the first side surface 11 and the second side surface 12, specifically in a direction perpendicular to the first side surface 11 and the second side surface 12.

[0029] 2, the magnetic core 10 has a corner r1 connecting the first side surface 11 and the third side surface 13, a corner r2 connecting the first side surface 11 and the fourth side surface 14, a corner r3 connecting the second side surface 12 and the third side surface 13, and a corner r4 connecting the second side surface 12 and the fourth side surface 14. Each of the corners r1 to r4 is a portion where a cover member 50, which will be described later, is provided.

[0030] Each of the corners r1 to r4 has a rounded shape when viewed from a direction perpendicular to the first main surface 18 (or the second main surface 19). When the magnetic core 10 is viewed from a direction perpendicular to the first main surface 18, each of the corners r1 to r4 includes a rounded region, that is, a sector-shaped region with a central angle of 90°.

[0031] Each of the corners r1 to r4 may include a region that is wider than the rounded region. For example, the four corners r1 to r4 may include a region where both the region outside both ends of the winding portion 21 in the Y-axis direction and the region outside both ends of the winding portion 21 in the X-axis direction overlap when the magnetic core 10 is viewed from a direction perpendicular to the first main surface 18. In other words, the four corners r1 to r4 may include a region where both the region outside both ends of the winding portion 21 in the Y-axis direction overlap when the magnetic core 10 is viewed from a direction perpendicular to the fourth side surface 14 and the region outside both ends of the winding portion 21 in the X-axis direction overlap when the magnetic core 10 is viewed from a direction perpendicular to the first side surface 11.

[0032] Fig. 5 is a perspective view of the magnetic core 10 and the electrode portion 30 of the inductor 1. Fig. 5(a) shows the magnetic core 10 and the electrode portion 30 as viewed obliquely from above, and Fig. 5(b) shows the magnetic core 10 and the electrode portion 30 as viewed obliquely from below. Note that Fig. 5 also shows a cover member 50.

[0033] 5, a plurality of recesses are formed in the magnetic core 10. The plurality of recesses are portions into which protrusions of a cover member 50, which will be described later, fit.

[0034] The multiple recesses are provided on each of the first main surface 18 and the second main surface 19 of the magnetic core 10. The multiple recesses are configured of four first recesses 18r and four second recesses 19r. The four first recesses 18r are formed on the first main surface 18, and the four second recesses 19r are formed on the second main surface 19.

[0035] As shown in FIG. 5(a), the first recesses 18r have a groove-like shape recessed from the first main surface 18 toward the second main surface 19. The four first recesses 18r are provided at positions corresponding to the four corners r1 to r4, respectively. Two of the four first recesses 18r are provided on a first diagonal line connecting the corners r1 and r4 when the magnetic core 10 is viewed from a direction perpendicular to the first main surface 18. The two first recesses 18r have a rectangular shape when viewed from a direction perpendicular to the first main surface 18, and are formed so that the long sides intersect the first diagonal line and the short sides are parallel to the first diagonal line. The other two of the four first recesses 18r are provided on a second diagonal line connecting the corners r2 and r3 when the magnetic core 10 is viewed from a direction perpendicular to the first main surface 18. The other two first recesses 18r have a rectangular shape when viewed from a direction perpendicular to the first main surface 18, and are formed so that their long sides intersect the second diagonal line and their short sides are parallel to the second diagonal line.

[0036] As shown in FIG. 5B, the second recesses 19r have a groove-like shape recessed from the second main surface 19 toward the first main surface 18. The four second recesses 19r are provided at positions corresponding to the four corners r1 to r4, respectively. Two of the four second recesses 19r are provided on a first diagonal line connecting the corners r1 and r4 when the magnetic core 10 is viewed from a direction perpendicular to the second main surface 19. The two second recesses 19r have a rectangular shape when viewed from a direction perpendicular to the second main surface 19, and are formed so that the long sides intersect the first diagonal line and the short sides are parallel to the first diagonal line. The other two of the four second recesses 19r are provided on a second diagonal line connecting the corners r2 and r3 when the magnetic core 10 is viewed from a direction perpendicular to the second main surface 19. The other two second recesses 19r have a rectangular shape when viewed from a direction perpendicular to the second main surface 19, and are formed so that their long sides intersect the second diagonal line and their short sides are parallel to the second diagonal line.

[0037] The coil portion 20, the first electrode portion 31, and the second electrode portion 32 shown in Figs. 1 to 4 are, for example, parts integrally formed by processing one member made of the same material. The coil portion 20, the first electrode portion 31, and the second electrode portion 32 are, for example, formed by a rectangular conductor wire. A cross section perpendicular to the axial direction of the conductor wire, i.e., a transverse section of the conductor wire, is rectangular, for example, with a long side of 6.0 mm and a short side of 3.5 mm. The conductor wire is composed of a metal wire and an insulating coating that covers the metal wire. The metal wire is formed of a metal material selected from metals such as aluminum, copper, silver, and gold, alloys containing one or more of these metals, and materials made of metals or alloys and other substances. The insulating coating is formed of a resin material such as polyimide or polyimide amide. The conductor wire of this embodiment is, for example, a copper wire covered with a polyimide resin.

[0038] The coil portion 20 is a portion covered by the magnetic core 10. The coil portion 20 has a circular portion, and is composed of one winding portion 21 and a pair of lead-out portions 22a and 22b connected to one end and the other end of the winding portion 21 in a one-to-one correspondence.

[0039] The winding portion 21 is composed of a conductor wound in a spiral shape around a winding axis AT, and functions as a coil. The winding portion 21 is embedded in the magnetic core 10 so that the winding axis AT intersects with the first main surface 18 and the second main surface 19. There is no particular limitation on the number of turns of the winding portion 21, and the number is appropriately selected, for example, from 1.5 turns to 10 turns, depending on the performance required for the inductor 1 and constraints such as the size of the magnetic core 10.

[0040] One of the pair of lead-out portions, lead-out portion 22a, is connected to one end of winding portion 21 and extends linearly to first side surface 11. The other lead-out portion 22b is connected to the other end of winding portion 21 and extends linearly to first side surface 11. The position of one lead-out portion 22a in contact with first side surface 11 and the position of the other lead-out portion 22b are at different height positions with respect to second main surface 19.

[0041] The electrode portion 30 is connected to the coil portion 20 on the side surface of the magnetic core 10, and is provided outside the magnetic core 10. In other words, the first electrode portion 31 and the second electrode portion 32 are not covered by the magnetic core 10, and are located outside the magnetic core 10.

[0042] The first electrode portion 31 is connected to one of the lead portions 22a at the first side surface 11, and the second electrode portion 32 is connected to the other lead portion 22b at the first side surface 11. When viewed from a direction perpendicular to the first side surface 11, the first electrode portion 31 is provided on the third side surface 13 side that is to the left of the winding axis AT, and the second electrode portion 32 is provided on the fourth side surface 14 side that is to the right of the winding axis AT. The first electrode portion 31 and the second electrode portion 32 are at different heights with respect to the second main surface 19. The first electrode portion 31 and the second electrode portion 32 may be at the same height with respect to the second main surface 19.

[0043] The first electrode portion 31 and the second electrode portion 32 each protrude from the first side surface 11 of the magnetic core 10. The first electrode portion 31 and the second electrode portion 32 extend parallel to the second main surface 19 in the Y-axis direction.

[0044] The insulating coating on the surface of the conductor is removed from the tip portions located at the protruding ends of the first electrode portion 31 and the second electrode portion 32. For example, when the inductor 1 is attached to a printed circuit board, the tip portions of the first electrode portion 31 and the second electrode portion 32 are connected to the printed circuit board using solder or the like. Also, for example, when the inductor 1 is attached to a bus bar of a power supply device, the tip portions are connected to the bus bar using welding, screw fastening, or the like.

[0045] In order to improve the insulation reliability and heat dissipation properties of the inductor 1 according to this embodiment, the inductor 1 has a cover member 50 described below.

[0046] 1 and 2, the cover member 50 is made up of a plurality of cover members and is provided at corners r1 to r4 of the magnetic core 10. The cover member 50 is formed of an insulating resin material such as an epoxy resin material or a liquid crystal polymer material. The cover member 50 is flexible and is softer than the magnetic core 10. The thermal conductivity of the cover member 50 is, for example, 0.2 W / (m·K), which is lower than that of the magnetic core 10.

[0047] The cover member 50 is composed of four cover members 51, 52, 53, and 54. The four cover members 51 to 54 are provided in one-to-one correspondence with the four corners r1 to r4 of the magnetic core 10 when viewed from a direction perpendicular to the first main surface 18. Specifically, the cover member 51 is provided corresponding to the corner r1, the cover member 52 is provided corresponding to the corner r2, the cover member 53 is provided corresponding to the corner r3, and the cover member 54 is provided corresponding to the corner r4.

[0048] 3, when viewed from a direction perpendicular to first main surface 18 of magnetic core 10, cover members 51-54 do not overlap winding portion 21 and are located outside winding portion 21. Note that when viewed from a direction perpendicular to second main surface 19 of magnetic core 10, cover members 51-54 also do not overlap winding portion 21 and are located outside winding portion 21.

[0049] 4(a) and (b), when viewed from a direction perpendicular to side surface 11 or 14 of magnetic core 10, cover members 51-54 do not overlap winding portion 21 and are located outside winding portion 21. Note that when viewed from a direction perpendicular to side surface 12 or 13 of magnetic core 10, cover members 51-54 also do not overlap winding portion 21 and are located outside winding portion 21.

[0050] FIG. 6 is a perspective view of the cover member 50 of the inductor 1. As shown in FIG.

[0051] As shown in FIG. 6, the cover member 50 has a first cover portion 61 covering a portion of the first main surface 18, a second cover portion 62 covering a portion of the second main surface 19, and a side cover portion 63 covering a portion of the side surface and connecting the first cover portion 61 and the second cover portion 62.

[0052] Each of the first cover part 61 and the second cover part 62 is formed of a polygonal plate. In this example, the first cover part 61 and the second cover part 62 have a rectangular shape with one corner cut off to provide a taper, that is, a pentagonal shape. The first cover part 61 and the second cover part 62 are parallel to each other and face each other. The thickness of each of the first cover part 61 and the second cover part 62 is 0.2 mm or more and 3.0 mm or less. The thickness of each of the first cover part 61 and the second cover part 62 is the same.

[0053] The side cover part 63 has a rectangular plate connecting one side of the first cover part 61 and one side of the second cover part 62 facing the one side of the first cover part 61. Specifically, the side cover part 63 is composed of two rectangular plates intersecting at a right angle, and has an L-shaped cross section perpendicular to the extension direction of the side cover part 63. The side cover part 63 is perpendicular to the first cover part 61 and the second cover part 62. The thickness of the side cover part 63 may be the same as the thickness of each of the first cover part 61 and the second cover part 62.

[0054] 6 has a first protrusion 61p protruding from the inner surface of the first cover part 61 toward the second cover part 62. The first protrusion 61p is a portion to be fitted into the first recess 18r, and has a shape to fit into the first recess 18r of the magnetic core 10.

[0055] The second cover part 62 has a second protrusion 62p protruding from the inner surface of the second cover part 62 toward the first cover part 61. The second protrusion 62p is a part to be fitted into the second recess 19r, and has a shape to fit into the second recess 19r of the magnetic core 10.

[0056] The cover member 50 is attached to the magnetic core 10 so that the first cover portion 61 contacts the first main surface 18 and so that the second cover portion 62 contacts the second main surface 19 .

[0057] Moreover, the cover member 50 is attached to the magnetic core 10 so that the side cover portion 63 is in contact with two orthogonal side surfaces. For example, the side cover portion 63 of the cover member 51 is in contact with the side surfaces 11 and 13, the side cover portion 63 of the cover member 52 is in contact with the side surfaces 11 and 14, the side cover portion 63 of the cover member 53 is in contact with the side surfaces 12 and 13, and the side cover portion 63 of the cover member 54 is in contact with the side surfaces 12 and 14. The side cover portion 63 may or may not be in contact with the rounded side surfaces of each of the corners r1 to r4. A space may be provided between the side cover portion 63 and the rounded side surfaces, or an adhesive may be interposed therebetween.

[0058] In the present embodiment, the first cover portion 61 protrudes outward (toward the positive Z-axis direction) from the first main surface 18 in a direction perpendicular to the first main surface 18. The amount of protrusion of the first cover portion 61 from the first main surface 18 is, for example, 0.2 mm or more and 3.0 mm or less. The second cover portion 62 protrudes outward (toward the negative Z-axis direction) from the second main surface 19 in a direction perpendicular to the second main surface 19. The amount of protrusion of the second cover portion 62 from the second main surface 19 is, for example, 0.2 mm or more and 3.0 mm or less.

[0059] The side cover portion 63 protrudes outward from the side surface in a direction perpendicular to the side surface. Specifically, the side cover portion 63 provided at the corner portion r1 protrudes outward from the side surface 11 (negative side in the Y-axis direction) and outward from the side surface 13 (negative side in the X-axis direction). The side cover portion 63 provided at the corner portion r2 protrudes outward from the side surface 11 (negative side in the Y-axis direction) and outward from the side surface 14 (positive side in the X-axis direction). The side cover portion 63 provided at the corner portion r3 protrudes outward from the side surface 12 (positive side in the Y-axis direction) and outward from the side surface 13 (negative side in the X-axis direction). The side cover portion 63 provided at the corner portion r4 protrudes outward from the side surface 12 (positive side in the Y-axis direction) and outward from the side surface 14 (positive side in the X-axis direction). The protrusion amount of the side cover portion 63 from the side surface is, for example, 0.2 mm or more and 3.0 mm or less.

[0060] Since the cover member 50 is configured to protrude from each face of the magnetic core 10 in this manner, for example, when the magnetic core 10 is placed adjacent to another member, a minimum distance can be ensured between the magnetic core 10 and the other member. Also, since the cover member 50 is configured to protrude from each face of the magnetic core 10, for example, when the cover member 50 is placed adjacent to or in contact with the other member, the posture or orientation of the magnetic core 10 relative to the other member can be stabilized.

[0061] As described above, the inductor 1 of this embodiment comprises a magnetic core 10 having a first main surface 18 and a second main surface 19 facing each other, as well as a side surface connecting the first main surface 18 and the second main surface 19, a coil portion 20 provided inside the magnetic core 10, an electrode portion 30 connected to the coil portion 20 at the side surface and provided outside the magnetic core 10, and a cover member 50 that is insulating and covers a portion of the first main surface 18 and a portion of the second main surface 19.

[0062] In this way, by providing the cover member 50 so as to cover a part of the first main surface 18 and a part of the second main surface 19 of the magnetic core 10, for example, when the magnetic core 10 is placed close to another metal member, it is possible to prevent the distance between the magnetic core 10 and the other metal member from becoming shorter than necessary. This makes it possible to prevent the insulation reliability of the inductor 1 from decreasing. Also, by providing the cover member 50 so as to cover a part of the first main surface 18 and a part of the second main surface 19 of the magnetic core 10, it is possible to stabilize the posture or orientation of the magnetic core 10 with respect to the other member, for example, when the cover member 50 is placed close to or in contact with the other metal member. This makes it possible to prevent variations in the heat dissipation performance of the inductor 1 from occurring.

[0063] [Inductor manufacturing method] A method for manufacturing the inductor 1 will be described with reference to FIG.

[0064] FIG. 7 is a flowchart showing a method for manufacturing an inductor according to an embodiment.

[0065] As shown in FIG. 7, the method for manufacturing the inductor 1 includes a coil element forming step S101, a powder magnetic core forming step S103, and a cover member attaching step S105.

[0066] In the coil element forming step S101, a coil element is formed by winding a rectangular conductor wire. Specifically, the short side of the rectangular conductor wire is parallel to the winding axis AT, and the rectangular conductor wire is wound 2.5 turns around the winding axis AT to form the coil element.

[0067] In the powder core forming process S103, the magnetic core 10 is press-molded together with the coil element. In this process, a part of the coil element is placed in a die and covered with a mixture containing magnetic material powder and a binder, and the other part of the coil element is not covered with the mixture, and press-molded to form the magnetic core 10. The part of the coil element covered by the magnetic core 10 becomes the winding portion 21 and the lead-out portions 22a, 22b, and the other part of the coil element not covered by the magnetic core 10 becomes the first electrode portion 31 and the second electrode portion 32. During this press molding, the first recess 18r and the second recess 19r of the magnetic core 10 are formed. The pressure during press molding is, for example, 5 ton / cm. 2 and the heat curing temperature is, for example, 185°C.

[0068] In the cover member attachment step S105, each of the cover members 51-54, which have been resin-molded in advance, is attached to each of the corners r1-r4 of the magnetic core 10. For example, each of the cover members 51-54 is attached to each of the corners r1-r4 one by one. During this attachment, the first convex portion 61p of the cover members 51-54 fits into the first concave portion 18r of the magnetic core 10, and the second convex portion 62p fits into the second concave portion 19r of the magnetic core 10. This fitting can prevent the cover members 51-54 from falling off from each of the corners r1-r4. Through these steps shown in FIG. 7, the inductor 1 is manufactured.

[0069] [Modification of inductor] A modified example of the inductor will be described with reference to Figures 8 and 9. In the modified example, an example in which the areas of the first cover portion 61 and the second cover portion 62 of the cover member 50A are increased will be described.

[0070] FIG. 8 is a perspective view of an inductor 1A according to a modified example of the embodiment.

[0071] 8, inductor 1A of the modified example includes magnetic core 10, coil portion 20 provided inside magnetic core 10, electrode portion 30 connected to coil portion 20 and provided outside magnetic core 10, and insulating cover member 50A. The configurations of magnetic core 10, coil portion 20, and electrode portion 30 are the same as those of the embodiment.

[0072] The cover member 50A of the modified example is made up of four cover members 51A, 52A, 53A and 54A. The four cover members 51A to 54A are provided in one-to-one correspondence with the four corners r1 to r4 of the magnetic core 10 when viewed from a direction perpendicular to the first main surface 18.

[0073] When viewed from a direction perpendicular to the first main surface 18 of the magnetic core 10, the cover members 51A to 54A do not overlap the winding portion 21 and are located outside the winding portion 21. In addition, when viewed from a direction perpendicular to the side surface of the magnetic core 10, the cover members 51A to 54A do not overlap the winding portion 21 and are located outside the winding portion 21.

[0074] FIG. 9 is a perspective view of a cover member 50A of an inductor 1A according to a modified example.

[0075] As shown in FIG. 9, the cover member 50A has a first cover portion 61A covering a portion of the first main surface 18, a second cover portion 62A covering a portion of the second main surface 19, and a side cover portion 63A covering a portion of the side surface and connecting the first cover portion 61A and the second cover portion 62A.

[0076] Each of the first cover part 61A and the second cover part 62A is formed of a polygonal plate. The first cover part 61A and the second cover part 62A have a rectangular shape with one corner cut off to provide a taper, that is, a pentagonal shape. The first cover part 61A and the second cover part 62A are parallel to each other and face each other. The thickness of each of the first cover part 61A and the second cover part 62A is 0.2 mm or more and 3.0 mm or less. The thickness of each of the first cover part 61A and the second cover part 62A is the same.

[0077] The first cover portion 61A and the second cover portion 62A of the modified example have a larger area and a longer side than the first cover portion 61 and the second cover portion 62 of the embodiment.

[0078] The side cover part 63A is formed of a plate connecting one side of the first cover part 61A and one side of the second cover part 62A facing the one side of the first cover part 61A. The side cover part 63A is formed of two plates intersecting at a right angle, and has an L-shaped cross section perpendicular to the extension direction of the side cover part 63A. The side cover part 63A is perpendicular to the first cover part 61A and the second cover part 62A. The thickness of the side cover part 63A may be the same as the thickness of each of the first cover part 61A and the second cover part 62A.

[0079] A portion of the side cover portion 63A of the modified example is wider than the side cover portion 63 of the embodiment. Specifically, the width of both ends of the side cover portion 63A connected to the first cover portion 61A and the second cover portion 62A is wider than the center portion.

[0080] Even in the modified example, cover member 50A is configured to protrude from each face of magnetic core 10, so that, for example, when magnetic core 10 is placed close to another member, a minimum distance can be ensured between magnetic core 10 and the other member. Also, because cover member 50A is configured to protrude from each face of magnetic core 10, for example, when cover member 50A is placed close to or in contact with another member, the posture or orientation of magnetic core 10 relative to the other member can be stabilized.

[0081] [Component mounting module configuration] The configuration of a component mounting module in which the above-described inductor 1 is mounted will be described with reference to FIG.

[0082] 10 is a side view of the component mounting module 2 according to the embodiment. In the figure, the printed circuit board 70, the cooling unit 91, and the thermally conductive member 99 are hatched in order to make them easier to see.

[0083] The component mounting module 2 includes an inductor 1, a printed circuit board 70 on which the inductor 1 is mounted, and a thermally conductive member 99 and a cooling section 91 for cooling the inductor 1.

[0084] In the figure, one inductor 1 is mounted on the printed circuit board 70, but in reality, electronic components other than the inductor 1 are also mounted on the printed circuit board 70.

[0085] This example also employs an inductor 1 in which the electrode portion 30 is bent toward the printed circuit board 70. Specifically, each of the first electrode portion 31 and the second electrode portion 32 is bent toward the second main surface 19 at a position away from the first side surface 11, extends toward the second main surface 19 along the first side surface 11, and further extends to a position beyond a plane including the second main surface 19.

[0086] The printed circuit board 70 has a pair of through holes 71 penetrating the printed circuit board 70 in the thickness direction, and a pair of lands (not shown) formed on a back surface 70b opposite to the mounting surface 70a. The first electrode portion 31 and the second electrode portion 32 of the inductor 1 are connected to the lands using solder sp in a state where they are inserted through the through holes 71 and protrude downward from the back surface 70b.

[0087] 10, one thermally conductive member 99 and a cooling unit 91 are arranged in this order on the first main surface 18 side of the magnetic core 10 of the inductor 1. That is, one thermally conductive member 99 is provided between the magnetic core 10 and the cooling unit 91. Furthermore, the other thermally conductive member 99 is arranged on the second main surface 19 side of the magnetic core 10 of the inductor 1. The other thermally conductive member 99 is provided between the magnetic core 10 and the printed circuit board 70.

[0088] The cooling unit 91 is a member that functions as a heat sink. The cooling unit 91 is a part of a housing made of a metal such as aluminum. The cooling unit 91 is plate-shaped and is disposed at a predetermined distance from the first main surface 18 of the magnetic core 10. The cooling unit 91 absorbs heat generated in the inductor 1 via the thermally conductive member 99.

[0089] The thermally conductive member 99 is a gel-like member. The thermally conductive member 99 is a thermal interface material (TIM), and is formed by mixing a filler with a resin material such as silicone or epoxy. One of the thermally conductive members 99 contacts the first main surface 18 and the cooling unit 91, and the other thermally conductive member 99 contacts the second main surface 19 of the magnetic core 10 and the printed circuit board 70.

[0090] Four cover members 51 to 54 are provided on the magnetic core 10. For example, first cover portions 61 of the four cover members 51 to 54 are arranged on the first main surface 18 side of the magnetic core 10. The first cover portions 61 have a predetermined thickness and protrude outward (toward the positive side of the Z axis) from the first main surface 18. Second cover portions 62 of the four cover members 51 to 54 are arranged on the second main surface 19 side of the magnetic core 10. The second cover portions 62 have a predetermined thickness and protrude outward (toward the negative side of the Z axis) from the second main surface 19. The first cover portions 61 and the second cover portions 62 have the same thickness.

[0091] In this way, by providing the cover member 50 so as to cover a part of the first main surface 18 and a part of the second main surface 19 of the magnetic core 10, it is possible to prevent the distance between the magnetic core 10 and the metallic cooling unit 91 from becoming shorter than necessary. This makes it possible to prevent the insulation reliability of the component mounting module 2 including the inductor 1 from decreasing. Furthermore, by providing the cover member 50 so as to cover a part of the first main surface 18 and a part of the second main surface 19 of the magnetic core 10, it is possible to stabilize the attitude or orientation of the magnetic core 10 with respect to the cooling unit 91. This makes it possible to prevent variations in the heat dissipation performance of the component mounting module 2 including the inductor 1 from occurring.

[0092] [Configuration of component mounting module according to modification 1 of embodiment] The configuration of a component mounting module 2A according to a first modification of the embodiment will be described with reference to Fig. 11. In the first modification, an example in which an inductor 1 is attached to a cooling section 92 having a stepped shape will be described.

[0093] 11 is a side view of a component mounting module 2A according to Modification 1. In the figure, the cooling unit 92 and the thermally conductive member 99 are hatched to make them easier to see. Also, in the figure, a part of the cover member 54 is cut away.

[0094] The component mounting module 2A of the first modification includes an inductor 1, and a thermally conductive member 99 and a cooling section 92 for cooling the inductor 1.

[0095] The cooling portion 92 has a stepped shape, and has a bottom surface portion 92a, a side wall portion 92b standing on the bottom surface portion 92a, and an upper surface portion 92c connected to the side wall portion 92b.

[0096] 11, a thermally conductive member 99 and a side wall portion 92b of a cooling portion 92 are arranged in this order on the second main surface 19 of a magnetic core 10 of an inductor 1. This thermally conductive member 99 is provided between the magnetic core 10 and the side wall portion 92b. Furthermore, a thermally conductive member 99 and a bottom surface portion 92a of a cooling portion 92 are arranged in this order on a second side surface 12 of a magnetic core 10 of an inductor 1. This thermally conductive member 99 is provided between the magnetic core 10 and the bottom surface portion 92a.

[0097] The cooling unit 92 is a member that functions as a heat sink. The cooling unit 92 is a part of a housing made of a metal such as aluminum. The cooling unit 92 is disposed at a predetermined interval from each of the second main surface 19 and the second side surface 12 of the magnetic core 10. The cooling unit 92 absorbs heat generated in the inductor 1 via the thermally conductive member 99.

[0098] The thermally conductive member 99 is a gel-like member. The thermally conductive member 99 is a TIM, and is formed by mixing a filler with a resin material such as silicone or epoxy. The thermally conductive member 99 on the side wall portion 92b side is in contact with the second main surface 19 and the side wall portion 92b, and the lower thermally conductive member 99 is in contact with the second side surface 12 and the bottom surface portion 92a.

[0099] Four cover members 51 to 54 are provided on the magnetic core 10. For example, second cover portions 62 of the four cover members 51 to 54 are arranged on the second main surface 19 side of the magnetic core 10. The second cover portions 62 have a predetermined thickness and protrude outward (toward the negative Z-axis) beyond the second main surface 19. Furthermore, side cover portions 63 of the two cover members 53, 54 are arranged on the second side surface 12 side of the magnetic core 10. The side cover portions 63 have a predetermined thickness and protrude outward (toward the positive Y-axis) beyond the second side surface 12.

[0100] In this way, by providing the cover member 50 so as to cover a part of the second main surface 19 and a part of the second side surface 12 of the magnetic core 10, it is possible to prevent the distance between the magnetic core 10 and the metallic cooling unit 92 from becoming shorter than necessary. This makes it possible to prevent the insulation reliability of the component mounting module 2A including the inductor 1 from decreasing. Furthermore, by providing the cover member 50 so as to cover a part of the second main surface 19 and a part of the second side surface 12 of the magnetic core 10, it is possible to stabilize the attitude or orientation of the magnetic core 10 with respect to the cooling unit 92. This makes it possible to prevent variations in the heat dissipation performance of the component mounting module 2A including the inductor 1 from occurring.

[0101] [Configuration of component mounting module according to modified example 2 of embodiment] The configuration of a component mounting module 2B according to a second modification of the embodiment will be described with reference to Fig. 12. In the second modification, an example in which the inductor 1 is housed in a cooling section 93 will be described.

[0102] 12 is a side view of a component mounting module 2B according to Modification 2. In the figure, the cooling unit 93 and the thermally conductive member 99 are hatched to make them easier to see.

[0103] The component mounting module 2B includes an inductor 1, and a thermally conductive member 99 and a cooling section 93 for cooling the inductor 1. The cooling section 93 has a concave housing section 94. The housing section 94 is composed of a bottom surface section 94a and four side wall sections 94b. The inductor 1 and the thermally conductive member 99 are inserted into the housing section 94 from the opening of the housing section 94.

[0104] 12, a thermally conductive member 99 and a side wall portion 94b are arranged in this order on the first main surface 18, the second main surface 19, the third side surface 13, and the fourth side surface 14 of the magnetic core 10 of the inductor 1, and a thermally conductive member 99 and a bottom surface portion 94a are arranged in this order on the second side surface 12. In other words, the thermally conductive member 99 is provided between the magnetic core 10 and the four side wall portions 94b, and between the magnetic core 10 and the bottom surface portion 94a.

[0105] The cooling unit 93 is a member that functions as a heat sink. The cooling unit 93 is, for example, a part of a housing made of a metal such as aluminum. The accommodation unit 94 of the cooling unit 93 is disposed at a predetermined interval from each of the first main surface 18, the second main surface 19, the third side surface 13, the fourth side surface 14, and the second side surface 12 of the magnetic core 10. The accommodation unit 94 absorbs heat generated in the inductor 1 via the thermally conductive member 99.

[0106] The thermally conductive member 99 is a gel-like member. The thermally conductive member 99 is a TIM, and is formed by mixing a filler with a resin material such as silicone or epoxy. The thermally conductive member 99 is in contact with the first main surface 18, the second main surface 19, the second side surface 12, the third side surface 13, the fourth side surface 14, the bottom surface portion 94a, and the four side wall portions 94b.

[0107] Four cover members 51-54 are provided on the magnetic core 10. For example, first cover portions 61 of the cover members 51-54 are arranged on the first main surface 18 side of the magnetic core 10, and second cover portions 62 of the cover members 51-54 are arranged on the second main surface 19 side. The first cover portions 61 have a predetermined thickness and protrude outward (positive side of the Z axis) beyond the first main surface 18. The second cover portions 62 have a predetermined thickness and protrude outward (negative side of the Z axis) beyond the second main surface 19.

[0108] The side cover parts 63 of the cover members 53, 54 are arranged on the second side surface 12 side of the magnetic core 10, the side cover parts 63 of the cover members 51, 53 are arranged on the third side surface 13 side, and the side cover parts 63 of the cover members 52, 54 are arranged on the fourth side surface 14 side. The side cover parts 63 have a predetermined thickness and protrude outward beyond the second side surface 12, the third side surface 13, or the fourth side surface 14.

[0109] In this way, the cover member 50 is provided so as to cover a part of the first main surface 18, a part of the second main surface 19, a part of the second side surface 12, a part of the third side surface 13, and a part of the fourth side surface 14 of the magnetic core 10, thereby preventing the distance between the magnetic core 10 and the metal cooling unit 93 from becoming shorter than necessary. This prevents the insulation reliability of the component mounting module 2B including the inductor 1 from decreasing. In addition, the cover member 50 is provided so as to cover a part of the first main surface 18, a part of the second main surface 19, a part of the second side surface 12, a part of the third side surface 13, and a part of the fourth side surface 14 of the magnetic core 10, thereby stabilizing the attitude or orientation of the magnetic core 10 with respect to the cooling unit 93. This prevents the heat dissipation of the component mounting module 2B including the inductor 1 from varying.

[0110] (summary) The configuration of the inductor and the like according to the embodiment will be exemplified below.

[0111] [Example 1] An inductor 1 in this embodiment comprises a magnetic core 10 having a first main surface 18 and a second main surface 19 facing each other and a side surface connecting the first main surface 18 and the second main surface 19, a coil portion 20 provided inside the magnetic core 10, an electrode portion 30 connected to the coil portion 20 at the side surface and provided outside the magnetic core 10, and a cover member 50 that is insulating and covers a part of the first main surface 18 and a part of the second main surface 19.

[0112] In this way, the cover member 50 is provided so as to cover a part of the first main surface 18 and a part of the second main surface 19 of the magnetic core 10. For example, when the first main surface 18 or the second main surface 19 of the magnetic core 10 is disposed close to another metal member, the distance between the magnetic core 10 and the other metal member can be prevented from becoming shorter than necessary. This can prevent the insulation reliability of the inductor 1 from decreasing. In addition, the cover member 50 is provided so as to cover a part of the first main surface 18 and a part of the second main surface 19 of the magnetic core 10. For example, when the cover member 50 is disposed close to or in contact with another metal member, the attitude or orientation of the magnetic core 10 with respect to the other member can be stabilized. This can prevent the heat dissipation of the inductor 1 from varying.

[0113] [Example 2] The magnetic core 10 is a rectangular parallelepiped, and the cover member 50 is made up of a plurality of cover members, which are provided at the corners of the magnetic core.

[0114] In this way, by providing the cover member 50 at the corner of the magnetic core 10, for example, when the corner of the magnetic core 10 is disposed close to another metal member, it is possible to prevent the distance between the magnetic core 10 and the other metal member from becoming shorter than necessary. This makes it possible to prevent the insulation reliability of the inductor 1 from decreasing. Also, by providing the cover member 50 at the corner of the magnetic core 10, for example, when the cover member 50 is disposed close to or in contact with another metal member, it is possible to stabilize the posture or orientation of the magnetic core 10 with respect to the other member. This makes it possible to prevent variations in the heat dissipation performance of the inductor 1 from occurring. The configuration of Example 2 is applicable to Example 1.

[0115] [Example 3] The multiple cover members are four cover members 51, 52, 53, and 54, and the four cover members 51 to 54 are provided in one-to-one correspondence with the four corners r1, r2, r3, and r4 of the magnetic core 10 when viewed from a direction perpendicular to the first main surface 18.

[0116] In this way, by providing the four cover members 51-54 at the corners r1-r4 of the magnetic core 10, for example, when the corners of the magnetic core 10 are disposed close to another metal member, the distance between the magnetic core 10 and the other metal member can be prevented from becoming shorter than necessary. This makes it possible to prevent the insulation reliability of the inductor 1 from decreasing. Also, by providing the four cover members 51-54 at the corners r1-r4 of the magnetic core 10, for example, when the cover members 51-54 are disposed close to or in contact with another metal member, the posture or orientation of the magnetic core 10 with respect to the other member can be stabilized. This makes it possible to prevent variations in the heat dissipation performance of the inductor 1 from occurring. The configuration of Example 3 is applicable to Example 2.

[0117] [Example 4] The cover member 50 has a first cover portion 61 that covers part of the first main surface 18, a second cover portion 62 that covers part of the second main surface 19, and a side cover portion 63 that covers part of the side surface and connects the first cover portion 61 and the second cover portion 62.

[0118] In this way, the first cover part 61 covers a part of the first main surface 18 of the magnetic core 10, and the second cover part 62 covers a part of the second main surface 19. For example, when the magnetic core 10 is disposed close to another metal member, the distance between the magnetic core 10 and the other metal member can be prevented from becoming shorter than necessary. This can prevent the insulation reliability of the inductor 1 from decreasing. In addition, the first cover part 61 covers a part of the first main surface 18 of the magnetic core 10, and the second cover part 62 covers a part of the second main surface 19. For example, when the first cover part 61 and the second cover part 62 are disposed close to or in contact with another metal member, the attitude or orientation of the magnetic core 10 with respect to the other member can be stabilized. This can prevent the heat dissipation of the inductor 1 from varying. The configuration of Example 4 can be applied to any of Examples 1 to 3.

[0119] [Example 5] The thickness of each of the first cover part 61 and the second cover part 62 is not less than 0.2 mm and not more than 3.0 mm.

[0120] According to this, for example, when the magnetic core 10 is arranged close to another metal member, a distance of 0.2 mm to 3.0 mm can be secured between the first main surface 18 side and the second main surface 19 side of the magnetic core 10 and the other metal member. This makes it possible to suppress a decrease in the insulation reliability of the inductor 1 even when the inductor 1 is connected to a high-voltage circuit of 200 V to 800 V, for example. In addition, for example, when the first cover part 61 and the second cover part 62 are arranged close to or in contact with another metal member, it is possible to stabilize the posture or orientation of the magnetic core 10 with respect to the other member. This makes it possible to suppress the occurrence of variations in the heat dissipation performance of the inductor 1. The configuration of Example 5 can be applied to any of Examples 1 to 4.

[0121] [Example 6] The thicknesses of the first cover portion 61 and the second cover portion 62 may be the same.

[0122] According to this, for example, when the magnetic core 10 is disposed close to another metal member, the first main surface 18 side and the second main surface 19 side of the magnetic core 10 can be secured at equal distances from the other metal member. This makes it possible to suppress a decrease in the insulation reliability of the inductor 1. Also, for example, when the first cover part 61 and the second cover part 62 are disposed close to or in contact with another metal member, the first main surface 18 side and the second main surface 19 side of the magnetic core 10 can be secured at equal distances from the other metal member. Therefore, it is possible to stabilize the posture or orientation of the magnetic core 10 with respect to the other member. This makes it possible to suppress the occurrence of variations in the heat dissipation performance of the inductor 1. The configuration of Example 6 can be applied to any of Examples 1 to 5.

[0123] [Example 7] A first recess 18r is formed on the first main surface 18, a second recess 19r is formed on the second main surface 19, the first cover portion 61 has a first convex portion 61p that fits into the first recess 18r, and the second cover portion 62 has a second convex portion 62p that fits into the second recess 19r.

[0124] According to this configuration, the cover member 50 can be reliably fixed to the magnetic core 10. This makes it possible to suppress a decrease in the insulation reliability of the inductor 1. It also makes it possible to suppress variations in the heat dissipation properties of the inductor 1. The configuration of Example 7 can be applied to any of Examples 1 to 6.

[0125] [Example 8] The first cover portion 61 protrudes outward from the first main surface 18 in a direction perpendicular to the first main surface 18, and the second cover portion 62 protrudes outward from the second main surface 19 in a direction perpendicular to the second main surface 19.

[0126] In this way, by having the first cover part 61 protrude outward from the first main surface 18 and the second cover part 62 protrude outward from the second main surface 19, for example, when the first main surface 18 or the second main surface 19 is disposed close to another metal member, the distance between the magnetic core 10 and the other metal member can be prevented from becoming shorter than necessary. This can prevent the insulation reliability of the inductor 1 from decreasing. In addition, by having the first cover part 61 protrude outward from the first main surface 18 and the second cover part 62 protrude outward from the second main surface 19, for example, when the first main surface 18 or the second main surface 19 is disposed close to or in contact with another metal member, the posture or orientation of the magnetic core 10 with respect to the other member can be stabilized. This can prevent the heat dissipation of the inductor 1 from varying. The configuration of Example 8 can be applied to any of Examples 1 to 7.

[0127] [Example 9] The side cover portion 63 protrudes outward from the side surface in a direction perpendicular to the side surface.

[0128] In this way, by having the side cover portion 63 protrude outward from the side surface of the magnetic core 10, for example, when the side surface of the magnetic core 10 is disposed close to another metal member, it is possible to prevent the distance between the magnetic core 10 and the other metal member from becoming shorter than necessary. This makes it possible to prevent the insulation reliability of the inductor 1 from decreasing. In addition, by having the side cover portion 63 protrude outward from the side surface of the magnetic core 10, for example, when the side surface of the magnetic core 10 is disposed close to or in contact with another metal member, it is possible to stabilize the posture or orientation of the magnetic core 10 with respect to the other member. This makes it possible to prevent the occurrence of variations in the heat dissipation performance of the inductor 1. The configuration of Example 9 can be applied to any of Examples 1 to 8.

[0129] [Example 10] The coil portion 20 has a winding portion 21 formed by winding a conductive wire, and the cover member 50 does not overlap the winding portion 21 when viewed from a direction perpendicular to the first main surface 18, and is located outside the winding portion 21.

[0130] This configuration can prevent the cover member 50 from adversely affecting the heat conduction path for dissipating the heat generated in the inductor 1. This can prevent variations in the heat dissipation performance of the inductor 1. The configuration of Example 10 can be applied to any of Examples 1 to 9.

[0131] [Example 11] The coil portion 20 has a winding portion 21 formed by winding a conductive wire, and the cover member 50 does not overlap the winding portion 21 when viewed from a direction perpendicular to the side surface, and is positioned outside the winding portion 21.

[0132] This configuration can prevent the cover member 50 from adversely affecting the heat conduction path for dissipating the heat generated in the inductor 1. This can prevent variations in the heat dissipation performance of the inductor 1. The configuration of Example 11 can be applied to any of Examples 1 to 10.

[0133] [Example 12] Magnetic core 10 is a dust core obtained by compacting a mixture of a metal magnetic powder having a plurality of metal magnetic particles and a binder that binds the plurality of metal magnetic particles.

[0134] In this way, by using metal magnetic powder with high thermal conductivity as the material of the magnetic core 10, it is possible to improve the heat dissipation properties of the inductor 1. The configuration of the twelfth example is applicable to any of the first to eleventh examples.

[0135] [Example 13] A component mounting module 2 (or 2A) according to the present embodiment includes the above-mentioned inductor 1, a cooling unit 91 (or 92) for cooling the inductor 1, and a thermally conductive member 99 in contact with the cooling unit 91 (or 92). The thermally conductive member 99 is in contact with at least one of the first main surface 18 and the second main surface 19 of the magnetic core 10.

[0136] According to the above-mentioned component mounting module 2 (or 2A), heat generated in the inductor 1 can be dissipated to the cooling section 91 (or 92) via the thermally conductive member 99 in contact with at least one of the first main surface 18 and the second main surface 19 of the magnetic core 10.

[0137] [Example 14] A component mounting module 2B according to the present embodiment includes the above-mentioned inductor 1, a cooling unit 93 for cooling the inductor 1, and a thermally conductive member 99 in contact with the cooling unit 93. The cooling unit 93 has a concave housing portion 94, the inductor 1 is housed in the housing portion 94, and the thermally conductive member 99 is in contact with the surface of the magnetic core 10 within the housing portion 94.

[0138] According to the component mounting module 2B described above, heat generated in the inductor 1 can be dissipated to the cooling section 93 via the thermally conductive member 99 in contact with the surface of the magnetic core .

[0139] (Other embodiments, etc.) Although the inductors and the like according to the embodiments and each modification of the present disclosure have been described above, the present disclosure is not limited to the above-mentioned embodiments and each modification. As long as it does not deviate from the gist of the present disclosure, various modifications conceived by a person skilled in the art to the embodiments and each modification, as well as other forms constructed by combining some of the components in the embodiments and each modification, are also included in the scope of the present disclosure.

[0140] In the above embodiment, an example has been shown in which the cover members 51-54 are attached to the corners r1-r4 by fitting the convex portions of the cover member 50 into the concave portions of the magnetic core 10, but the cover members 51-54 do not have to have convex portions. For example, if the cover members 51-54 are elastic, the cover members 51-54 may be fixed to the corners r1-r4 by sandwiching the magnetic core 10 from the first main surface 18 and second main surface 19 sides by elastic force.

[0141] In the above embodiment, an example has been shown in which four cover members 51 to 54 are provided to correspond to the four corners r1 to r4, but this is not limiting. For example, three cover members 50 may be provided to correspond to the second side surface 12, the third side surface 13, and the fourth side surface 14. Furthermore, three cover members 50 may be provided to correspond to the corners r1, r2, and the second side surface 12. In other words, it is sufficient that the cover members 50 are provided so as to cover a part of the first main surface 18 and a part of the second main surface 19.

[0142] In the above embodiment, the four corners r1 to r4 are covered by the four cover members 51 to 54, but the present invention is not limited thereto. For example, the four corners r1 to r4 may be covered by two cover members. Specifically, one cover member including the respective portions of the cover members 51 and 53 may be provided to cover the corners r1 and r3 and the side surface 13, and one cover member including the respective portions of the cover members 52 and 54 may be provided to cover the corners r2 and r4 and the side surface 14. For example, the four corners r1 to r4 may be covered by one U-shaped cover member. Specifically, one cover member including the respective portions of the cover members 51, 53, 54, and 52 may be provided to cover the corners r1, r3, r4, r2 and the side surfaces 13, 12, and 14.

[0143] In the embodiment, an example has been shown in which the inductor is a metal composite coil component in which the coil portion is enclosed in the magnetic material portion, but the present invention is not limited thereto, and the inductor may be a coil component that uses a so-called dust core as the magnetic material portion. In other words, the inductor may include two powder cores that are two split magnetic cores, a conductor, and two coil supports, and the magnetic material portion is formed by the two powder cores that are the two split magnetic cores, and the inductor may further include the conductor and the two coil supports.

[0144] In the above-described modified example of the embodiment, the area of ​​the first cover portion 61A and the second cover portion 62A is increased, and the width of both ends of the side cover portion 63A is increased, but the present invention is not limited thereto. For example, the area of ​​the first cover portion 61 and the second cover portion 62 may be the same as that of the embodiment, and the width of the side cover portion 63 may be narrower than that of the embodiment. Specifically, the width of the center portion excluding both ends in the direction in which the side cover portion 63 extends may be narrower. By narrowing the plate width of the side cover portion 63, the exposed area of ​​each of the side surfaces 11, 12, 13, and 14 of the magnetic core 10 can be increased more than that of the embodiment. This increases the heat dissipation area on the side surface, thereby improving the heat dissipation of the inductor.

[0145] In the above embodiment, the cross section of the conductor wire is rectangular, but the present invention is not limited to this, and the cross section of the conductor wire may be circular or square.

[0146] For example, the present disclosure also includes electrical products or electrical circuits using the above-mentioned inductor. Examples of electrical products include a power supply device including the above-mentioned inductor and various devices including the power supply device. [Industrial Applicability]

[0147] INDUSTRIAL APPLICABILITY The inductor according to the present disclosure is useful as an inductor for use in various devices and equipment. [Explanation of symbols]

[0148] 1, 1A inductor 2, 2A, 2B Component mounting module 10 magnetic core 11 First aspect 12 Second aspect 13 Third aspect 14 Fourth aspect 18 First main surface 18r 1st recess 19 Second main surface 19r 2nd recess 20 Coil section 21 Winding section 22a, 22b Pull-out section 30 Electrode section 31 1st electrode part 32 Second electrode part 50, 51, 52, 53, 54, 50A, 51A, 52A, 53A, 54A Cover parts 61, 61A First cover part 61p 1st convex part 62, 62A, Second cover part 62p 2nd convex part 63, 63A Side cover part 70 Printed Circuit Board 70a Mounting surface 70b back side 71 Through hole 91, 92, 93 Cooling section 92a, 94a Bottom part 92b, 94b side wall part 92c Top part 94 Storage unit 99 Thermally conductive materials AT Winding shaft r1, r2, r3, r4 corners sp solder

Claims

1. a magnetic core having a first main surface and a second main surface facing each other, and a side surface connecting the first main surface and the second main surface; A coil portion provided inside the magnetic core; an electrode portion connected to the coil portion at the side surface and provided outside the magnetic core; a cover member having insulating properties and covering a part of the first main surface and a part of the second main surface; An inductor comprising:

2. The magnetic core is rectangular parallelepiped-shaped, The cover member is composed of a plurality of cover members, The plurality of cover members are provided at the corners of the magnetic core.

2. The inductor of claim 1.

3. the plurality of cover members are four cover members, The four cover members are provided in one-to-one correspondence with the four corners of the magnetic core when viewed in a direction perpendicular to the first main surface.

3. The inductor according to claim 2.

4. The cover member includes a first cover portion that covers a portion of the first main surface, a second cover portion that covers a portion of the second main surface, and a side cover portion that covers a portion of the side surface and connects the first cover portion and the second cover portion.

2. The inductor of claim 1.

5. The thickness of each of the first cover portion and the second cover portion is equal to or greater than 0.2 mm and equal to or less than 3.0 mm.

5. The inductor according to claim 4.

6. The first cover portion and the second cover portion have the same thickness.

5. The inductor according to claim 4.

7. A first recess is formed in the first main surface, A second recess is formed in the second main surface, the first cover portion has a first protrusion that is fitted into the first recess, The second cover portion has a second protrusion that is fitted into the second recess.

5. The inductor according to claim 4.

8. the first cover portion protrudes outward beyond the first main surface in a direction perpendicular to the first main surface, The second cover portion protrudes outward beyond the second main surface in a direction perpendicular to the second main surface.

5. The inductor according to claim 4.

9. The side cover portion protrudes outward from the side surface in a direction perpendicular to the side surface. The inductor according to claim 4.

10. The coil portion has a winding portion in which a conductive wire is wound, The cover member does not overlap the winding portion and is positioned outside the winding portion when viewed from a direction perpendicular to the first main surface. An inductor according to any one of claims 1 to 9.

11. The coil portion has a winding portion in which a conductive wire is wound, The cover member does not overlap the winding portion when viewed from a direction perpendicular to the side surface, and is positioned outside the winding portion. An inductor according to any one of claims 1 to 9.

12. The magnetic core is a powder magnetic core obtained by pressing a mixture of a metal magnetic powder having a plurality of metal magnetic particles and a binder that binds the plurality of metal magnetic particles. An inductor according to any one of claims 1 to 9.

13. An inductor according to any one of claims 1 to 9; A cooling unit for cooling the inductor; a thermally conductive member in contact with the cooling portion; Equipped with The thermally conductive member is in contact with at least one of the first main surface and the second main surface of the magnetic core. Component mounting module.

14. An inductor according to any one of claims 1 to 9; A cooling unit for cooling the inductor; a thermally conductive member in contact with the cooling portion; Equipped with The cooling portion has a concave housing portion, The inductor is accommodated in the accommodation portion, The thermally conductive member is in contact with a surface of the magnetic core within the housing. Component mounting module.

Images