Magnetic component

Abstract

To provide a magnetic component in which the influence of eddy current loss due to a leakage flux generated from a gap 18 can be reduced.SOLUTION: A magnetic component 1 includes a coil 10, a core 24, and a bobbin 16. The coil 10 is formed by winding a conductive member once or less. The core 24 includes a gap 18 in a part of which a magnetic path is not formed. The bobbin 16 includes a coil positioning part 22 that positions the coil 10 so that the distance between the gap 18 and the coil 10 becomes a predetermined size, and a core positioning part that positions the core 24 so that the distance between a lowermost surface of the core 24 and a lowermost surface 16a of the bobbin 16 becomes a predetermined size. The bobbin lowermost surface 16a exists lower than a core lowermost surface 14a. The bobbin 16 is provided so that the bobbin lowermost surface is placed on an upper surface of an external substrate.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a magnetic component using a bobbin, comprising a coil, a core, and a bobbin. [Background Technology]

[0002] When forming a one-turn coil, which is a magnetic component, a one-turn through-type core shape is often used, in which a wire is passed through a center hole of a toroidal type or UU (UI) type.When forming a one-turn coil, a one-turn through-type core shape is often used, in which a wire is passed through a center hole of a toroidal type or UU (UI) type.

[0003] Patent Document 1 discloses an inductor having a dust core and a coil. The dust core has at least one through hole. Each through hole penetrates the dust core in the vertical direction and has an inner peripheral surface in a horizontal plane perpendicular to the vertical direction. The dust core has an outer peripheral surface in the horizontal plane. The coil is partially located inside each through hole and is wound so as not to cover the outer periphery. The outer periphery has a shape without corners in the horizontal plane. Each inner peripheral surface has a shape without corners in the horizontal plane.

[0004] Patent Document 2 discloses a coil having a low-cost and easy-to-manufacture structure in which a bus bar is inserted into a core and fixed with a strip-shaped member to realize a one-turn through shape. The coil includes a core with two through holes, a U-shaped busbar with opposing plate-like parts, a bobbin that insulates the core and the busbar, the busbar with its plate-like part inserted into the through hole, and a tape that fixes the bobbin and the core. Furthermore, the busbar is a U-shaped member formed by flatwise bending a metal plate.

[0005] Patent Document 3 discloses a transformer in which single-turn coils are laminated. A primary coil formed by laminating substantially U-shaped single-turn coils punched out from a copper plate is inserted into a frame-shaped box case made of an insulating resin, and the frame-shaped box cases are mated. The other primary coil is also incorporated into cases in the same manner as the above-mentioned primary coil, and the coil part of the transformer is formed by sandwiching a secondary coil having a substantially U-shaped single-turn coil punched out, and an E-shaped core made of ferrite is incorporated to form a high-current transformer.

[0006] Patent Document 4 discloses a high-voltage transformer that achieves miniaturization. In a high-voltage transformer including a core, a bobbin having a hollow hole that can be attached to the core, and a coil wound around the bobbin, flanges are provided at both ends of the bobbin. One of the flanges has a primary-side coil formed by a single-turn coil made of a U-shaped conductor, and one terminal of the secondary-side coil wound in a single-layer aligned winding between the flanges at both ends of the bobbin is wired to a secondary terminal through between the terminals of the primary-side coil.

Prior Art Documents

Patent Documents

[0007]

Patent Document 1

Patent Document 2

Patent Document 3

Patent Document 4

Summary of the Invention

Problems to be Solved by the Invention

[0008] When forming a one-turn coil, which is a magnetic component, like a resonant choke coil, due to core loss suppression, a ferrite core is used for the core material and a large GAP is provided. When applying it to a choke coil with characteristics such as a strict L-value tolerance, a large leakage magnetic flux, and a non-negligible influence of eddy current loss, there are the following problems in the toroidal type or UU (UI) type.

[0009] That is, since insulation is required between the core and the wire, a bobbin or a case is used. However, if there is nothing to fix and support the wire, it has to be wound along while contacting the inner core part. Then, due to the magnetic flux leaking from the GAP provided in the inner core of the core, a large eddy current loss is generated in the wire, causing heat generation.

[0010] This becomes a problem with a conventional general-purpose bobbin for transformers. Also, if the wire is just wound along while simply contacting the bobbin, the position of the wire is not fixed and moves. Therefore, in order to fix it at a predetermined position during mounting, it is necessary to fix it with tape or the like. There is also a problem that for the lead-out part for mounting on the substrate, a fixing base or the like needs to be provided, resulting in extra cost for fixing members, man-hours, etc. In addition, in the case of a resonant coil or a coil used in a high-voltage circuit, there are many cases where a creepage distance from the core is also required.

[0011] With a conventional general-purpose bobbin for transformers, the structure is not such that a reliable distance from the outer leg core can be obtained, and it has a structure that easily moves and touches, resulting in a problem that insulation cannot be maintained.

[0012] To address this, it was necessary to use triple-insulated wire for the wire, perform processes such as winding an insulating tape or tube, or provide another resin case such as a core protection case.

[0013] An object of the present invention is to provide a magnetic component that solves the above problems.

Means for Solving the Problems

[0014] The magnetic component (1) according to the present invention includes a coil (10), a core (24), and a bobbin (16). The coil (10) is formed by winding a conductive member one or fewer times. The core (24) has a gap (18) in which a magnetic path is not formed in part. The bobbin (16) has a coil positioning portion (22) for positioning the coil (10) such that the distance between the gap (18) and the coil (10) becomes a predetermined dimension, and a core positioning portion (16c) for positioning the core (24) such that the distance between the lowermost surface (14a) of the core (24) and the lowermost surface (16a) of the bobbin becomes a predetermined dimension. The lowermost surface (16a) of the bobbin is positioned below the lowermost surface (14a) of the core, and the bobbin (16) is provided such that the lowermost surface (16a) of the bobbin is placed on the upper surface (100a) of the external substrate (100).

[0015] According to the present invention, the bobbin (16) has a coil positioning portion (22) for positioning the coil (10) such that the distance between the gap (18) and the coil (10) becomes a predetermined dimension, and a core positioning portion (16c) for positioning the core (24) such that the distance between the lowermost surface (14a) of the core (24) and the lowermost surface (16a) of the bobbin becomes a predetermined dimension. The lowermost surface (16a) of the bobbin is positioned below the lowermost surface (14a) of the core, and the bobbin (16) is provided such that the lowermost surface (16a) of the bobbin is placed on the upper surface (100a) of the external substrate (100). Thus, the coil (10) and the core (24) can be positioned via the bobbin (16), and the gap (18), the coil (10), and the upper surface (100a) of the external substrate (100) can be separated by a predetermined distance, and the influence of eddy current loss due to leakage magnetic flux generated from the gap (18) can be reduced.

[0016] The coil positioning portion (22) is formed as a recess (22a) into which a part of the coil (10) is inserted at the central portion (16b´) of the upper end (16b) of the bobbin (16). The lower end portion (10a) of the coil (10) is formed as a terminal portion (10a´) for insertion into the through hole (110) of the external substrate (100). By inserting a part of the coil (10) into the recess (22a) and positioning it at the central portion (16b´) of the upper end (16b) of the bobbin (16), and by exposing the terminal portion (10a´) downward from the lowermost surface (16a) of the bobbin and inserting it into the through hole (110) of the external substrate (100), the coil (10) can be provided on the external substrate (100) while being positioned at the central portion (16b´) of the upper end (16b) of the bobbin (16).

[0017] When viewed from above, the gap (18) and the coil (10) are arranged at non-overlapping positions, so that the influence of the eddy current loss caused by the leakage magnetic flux from the gap (18) on the coil (10) can be reduced.

[0018] When viewed from above, the coils (10) are arranged in parallel at non-overlapping positions so as to avoid the gap (18), and the gap (18) is arranged between the plurality of coils (10), so that the influence of the eddy current loss on the coils (10) can be surely reduced.

[0019] The coil (10) is formed in a flat plate shape and a U shape with a predetermined width dimension. Both lower end portions (10a) of the U shape are inserted into the through hole (110) of the external substrate (100) as the terminal portion (10a´), and the intermediate portion (10b) of the U shape is positioned so as to be fitted into the coil positioning portion (22) of the bobbin (16). Thus, the coil (10) can be provided on the external substrate (100) while being positioned via the bobbin (16).

[0020] The bobbin (16) has a plate-shaped first side portion (161), second side portion (162), bottom portion (163), intermediate portion (164), first support portion (165), and second support portion (166). The first side portion (161) and the second side portion (162) are provided so as to stand on the upper surface (163a) of the bottom portion (163) and be parallel to each other. The intermediate portion (164) has a first intermediate portion side portion (164a), a second intermediate portion side portion (164b), and an intermediate portion upper portion (164c). The first intermediate portion side portion (164a) and the second intermediate portion side portion (164b) are parallel to the first side portion (161) and the second side portion (162) with a predetermined gap (161´, 162´) therebetween, between the first side portion (161) and the second side portion (162), and are provided so as to stand on the upper surface (164a´´) of the intermediate portion (164) and be parallel to each other, and further parallel to the first side portion (161) and the second side portion (162). The intermediate portion upper portion (164c) is provided so as to connect the upper end (164a´) of the first intermediate portion side portion (164a) and the upper end (164b´) of the second intermediate portion side portion (164b), and be parallel to the bottom portion (163). The first support portion (165) and the second support portion (166) are provided so as to stand on the intermediate portion upper portion (164c) and be parallel to each other, and further parallel to the first side portion (161) and the second side portion (162). A coil positioning portion (22) formed as a recess (22a) is provided at the upper ends (165´, 166´) of the first support portion (165) and the second support portion (166). The bottom portion (163) has, on the upper surface (163a) side, a first bottom connecting portion (163´) that connects the lower side of the first side portion (161) and the lower side of the first intermediate portion side portion (164a), and a second bottom connecting portion (163´´) that connects the lower side of the second side portion (162) and the lower side of the second intermediate portion side portion (164b). First bottom holes (163b) and second bottom holes (163c) are provided in the first bottom connecting portion (163´) and the second bottom connecting portion (163´´) so as to communicate with the gap (161´, 162´). Further, the bottom portion (163) has a protruding portion (163d) that protrudes outward from the first side portion (161) and the second side portion (162), and has a leg portion (163f) that extends downward from the lower surface (163e) of the bottom portion (163). The lowermost surface of the leg portion (163f) can be the bobbin lowermost surface (16a).

[0021] While fitting and positioning the U-shaped intermediate portion (10b) of the coil (10) into the coil positioning portion (22) of the bobbin (16), insert the terminal portion (10a') of the coil (10) into the first bottom hole (163b) of the bobbin (16), insert it into the second bottom hole (163c) of the bobbin (16), and further insert it into the through hole (110) of the external substrate (100) so that the terminal portion (10a') of the coil (10) is exposed downward from the bottom surface of the bobbin (16a). By assembling the coil (10) to the bobbin (16), the coil (10) can be positioned via the bobbin (16) and provided on the external substrate (100).

[0022] The core (24) has a first core portion (241) and a second core portion (242). The first core portion (241) is formed in an E shape when viewed from above, and has a base portion (241a), a first side portion (241b) extending from one end of the base portion (241a), a second side portion (241c) extending from the other end of the base portion (241a), and an intermediate portion (241d) extending from the middle of the base portion (241a) so as to be parallel to the first side portion (241b) and the second side portion (241c). The intermediate portion (241d) is set to be shorter in length than the first side portion (241b) and the second side portion (241c). The second core portion (242) is formed in an I shape when viewed from above. When the first core portion (241) and the second core portion (242) are opposed to each other and the end portion (241b') of the first side portion (241b) of the first core portion (241) and one end portion (242b') of the second core portion (242) are butted against each other, and the end portion (241c') of the second side portion (241c) of the first core portion (241) and the other end portion (242c') of the second core portion (242) are butted against each other, a gap (18) can be formed at the end portion (241d') of the intermediate portion (241d) of the core (24) by the separation between the end portion (241d') of the intermediate portion (241d) of the first core portion (241) and the intermediate portion (242d) of the second core portion (242).

[0023] Insert the middle part (241d) of the first core part (241) into the space (167) inside the middle part (164) of the bobbin (16), abut the end (241b') of the first side part (241b) of the first core part (241) against one end (242b') of the second core part (242), and abut the end (241c') of the second side part (241c) of the first core part (241) against the other end (242c') of the second core part (242), so as to sandwich the first side part (161) and the first middle part side part (164a) of the bobbin (16) between the middle part (241d) and the first side part (241b), and sandwich the second side part (162) and the second middle part side part (164b) of the bobbin (16) between the middle part (241d) and the second side part (241c). Further, separate the space between the end (241d') of the middle part (241d) of the first core part (241) and the middle part (242d) of the second core part (242) to form a gap (18) at the central part of the core (24). Furthermore, by assembling the core (24) to the bobbin (16) such that the lowermost surface (24a) of the core (24) is placed on the protruding part (163d) of the bottom (163), the core (24) can be positioned via the bobbin (16).

Effect of the Invention

[0024] According to the present invention, the coil 10 and the core 24 can be positioned via the bobbin 16, and the gap 18, the coil 10, and the upper surface 100a of the external substrate 100 can be separated by a predetermined distance, and the influence of eddy current loss due to the leakage magnetic flux generated from the gap 18 can be reduced.

Brief Description of the Drawings

[0025]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Embodiments for Carrying Out the Invention

[0026] Hereinafter, an example of an embodiment will be described. It should be noted that the present invention is not limited to the embodiments described below, and can be appropriately changed without changing the gist of the invention.

[0027] Embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is an exploded perspective view showing the configuration of a magnetic component according to an embodiment of the present invention, FIG. 2 is a view showing the configuration of the magnetic component, FIG. 3 is a view showing the configuration of a core in the magnetic component, FIGS. 4 and 5 are views showing the configuration of a bobbin in the magnetic component, FIG. 6 is a front view for explaining a method of assembling the magnetic component, FIG. 7 is a plan view following FIG. 6 for explaining the method of assembling the magnetic component, FIG. 8 is a plan view following FIG. 7 for explaining the method of assembling the magnetic component, FIG. 9 is a plan view following FIG. 8 for explaining the method of assembling the magnetic component, FIG. 10 is a front view following FIG. 9 for explaining the method of assembling the magnetic component, and FIG. 11 is a front view following FIG. 8 for explaining the method of assembling the magnetic component.

[0028] As shown in FIGS. 1 to 5, a magnetic component 1 according to an embodiment of the present invention includes a coil 10, a core 24, and a bobbin 16. The coil 10 is formed by winding a conductive member one or fewer times. The core 24 has a gap 18 in which a magnetic path is not formed in part. The bobbin 16 has a coil positioning portion 22 that positions the coil 10 so that the distance between the gap 18 and the coil 10 becomes a predetermined dimension, and a core positioning portion 16c that positions the core 24 so that the distance between the lowermost surface 14a of the core 24 and the lowermost surface 16a of the bobbin 16 becomes a predetermined dimension. The lowermost surface 16a of the bobbin is located below the lowermost surface 14a of the core, and the bobbin 16 is provided so that the lowermost surface 16a of the bobbin is placed on the upper surface 100a of the external substrate 100.

[0029] The coil positioning portion 22 is formed as a recess 22a into which a part of the coil 10 is inserted at the central portion 16b' of the upper end 16b of the bobbin 16. The lower end portion 10a of the coil 10 is formed as a terminal portion 10a' for insertion into the through hole 110 of the external substrate 100. A part of the coil 10 is inserted into the recess 22a and positioned at the central portion 16b' of the upper end 16b of the bobbin 16. At the same time, the terminal portion 10a' is exposed downward from the lowermost surface 16a of the bobbin and inserted into the through hole 110 of the external substrate 100, and the coil 10, the gap 18, and the external substrate 100 are positioned. The terminal portion 10a' is connected and fixed to the through hole 110 of the external substrate 100 with solder or the like. The through hole 110 is a through hole provided in the external substrate 100.

[0030] When viewed from above, the magnetic component 1, the gap 18, and the coil 10 are arranged at overlapping positions.

[0031] The coil 10 is formed in a flat plate shape and a U shape with a predetermined width dimension. Both lower end portions 10a of the U shape are inserted into the through holes 110 of the external substrate 100 as terminal portions 10a', and the intermediate portion 10b of the U shape is positioned so as to be fitted into the coil positioning portion 22 of the bobbin 16.

[0032] The coil 10 is formed of copper. The core 24 has a first core portion 241 and a second core portion 242. When viewed from above, the first core portion 241 is formed in an E shape and has a base portion 241a, a first side portion 241b extending from one end of the base portion 241a, a second side portion 241c extending from the other end of the base portion 241a, and an intermediate portion 241d extending from the middle of the base portion 241a so as to be parallel to the first side portion 241b and the second side portion 241c. The intermediate portion 241d is set to be shorter in length than the first side portion 241b and the second side portion 241c. When viewed from above, the second core portion 242 is formed in an I shape. The first core portion 241 and the second core portion 242 are opposed to each other. When the end portion 241b' of the first side portion 241b of the first core portion 241 is abutted against one end portion 242b' of the second core portion 242 and the end portion 241c' of the second side portion 241c of the first core portion 241 is abutted against the other end portion 242c' of the second core portion 242, a gap is formed between the end portion 241d' of the intermediate portion 241d of the first core portion 241 and the intermediate portion 242d of the second core portion 242. This separated portion becomes the gap 18.

[0033] The bobbin 16 has a plate-shaped first side portion 161, a second side portion 162, a bottom portion 163, an intermediate portion 164, a first support portion 165, and a second support portion 166. The first side portion 161 and the second side portion 162 are provided so as to stand on the upper surface 163a of the bottom portion 163 and to be parallel to each other. The intermediate portion 164 has a first intermediate portion side portion 164a, a second intermediate portion side portion 164b, and an intermediate portion upper portion 164c. The first intermediate portion side portion 164a and the second intermediate portion side portion 164b are parallel to the first side portion 161 and the second side portion 162 with a predetermined gap 161', 162' therebetween, and stand on the upper surface 164a'' of the intermediate portion 164 and are parallel to each other, and are further parallel to the first side portion 161 and the second side portion 162. The intermediate portion upper portion 164c is provided so as to connect the upper end 164a' of the first intermediate portion side portion 164a and the upper end 164b' of the second intermediate portion side portion 164b, and is parallel to the bottom portion 163. The first support portion 165 and the second support portion 166 are provided so as to stand on the intermediate portion upper portion 164c and to be parallel to each other, and are further parallel to the first side portion 161 and the second side portion 162. Coil positioning portions 22 formed as recesses 22a are provided at the upper ends 165', 166' of the first support portion 165 and the second support portion 166. The bottom portion 163 has, on the upper surface 163a side, a first bottom connection portion 163' that connects the lower side of the first side portion 161 and the lower side of the first intermediate portion side portion 164a, and a second bottom connection portion 163'' that connects the lower side of the second side portion 162 and the lower side of the second intermediate portion side portion 164b. First bottom holes 163b and second bottom holes 163c are provided in the first bottom connection portion 163' and the second bottom connection portion 163'' so as to communicate with the gaps 161', 162'. Further, the bottom portion 163 has a protruding portion 163d that protrudes outward from the first side portion 161 and the second side portion 162, and has a leg portion 163f that extends downward from the lower surface 163e of the bottom portion 163. The lowermost surface of the leg portion 163f is the bobbin lowermost surface 16a. The upper surface 163a of the bottom portion 163 of the bobbin 16 functions as a core positioning portion 16c for positioning the core 24. The magnetic component 1 configured as described above can be assembled as shown in FIGS. 6 to 11.

[0034] That is, as shown in FIG. 6, a bobbin 16 is provided such that the lowermost surface 16a of the bobbin is placed on the upper surface 100a of the external substrate 100.

[0035] Next, as shown in FIGS. 7 to 9, the intermediate portion 241d of the first core portion 241 is inserted into the space 167 inside the intermediate portion 164 of the bobbin 16, and the end portion 241b' of the first side portion 241b of the first core portion 241 is abutted against one end portion 242b' of the second core portion 242, and the end portion 241c' of the second side portion 241c of the first core portion 241 is abutted against the other end portion 242c' of the second core portion 242. Then, the first side portion 161 and the first intermediate portion side portion 164a of the bobbin 16 are sandwiched between the intermediate portion 241d and the first side portion 241b, and the second side portion 162 and the second intermediate portion side portion 164b of the bobbin 16 are sandwiched between the intermediate portion 241d and the second side portion 241c. Further, a gap 18 is formed in the core 24 by separating the space between the end portion 241d' of the intermediate portion 241d of the first core portion 241 and the intermediate portion 242d of the second core portion 242. Furthermore, the core 24 is assembled to the bobbin 16 such that the lowermost surface 24a of the core 24 is placed on the protruding portion 163d of the bottom portion 163.

[0036] Subsequently, as shown in FIGS. 10 and 11, while fitting and positioning the U-shaped intermediate portion 10b of the coil 10 into the coil positioning portion 22 of the bobbin 16, one terminal portion 10a' of the coil 10 is inserted into the first bottom hole 163b through the gap 161' of the bobbin 16, and the other terminal portion 10a' of the coil 10 is inserted into the second bottom hole 163c through the gap 162' of the bobbin 16. Further, the terminal portion 10a' of the coil 10 is inserted into the through hole 110 of the external substrate 100 so as to be exposed downward from the lowermost surface 16a of the bobbin 16, and the coil 10 is assembled to the bobbin 16. The terminal portion 10a' of the coil 10 is connected and fixed to the through hole 110 of the external substrate 100 with solder or the like.

[0037] As described above, according to the present embodiment, the bobbin 16 has a coil positioning portion 22 that positions the coil 10 such that the distance between the gap 18 and the coil 10 becomes a predetermined dimension, and a core positioning portion 16c that positions the core 24 such that the distance between the lowermost surface 14a of the core 24 and the lowermost surface 16a of the bobbin becomes a predetermined dimension. The lowermost surface 16a of the bobbin is positioned below the lowermost surface 14a of the core, and the bobbin 16 is provided such that the lowermost surface 16a of the bobbin is placed on the upper surface 100a of the external substrate 100. Thus, the coil 10 and the core 24 can be positioned via the bobbin 16, and the gap 18, the coil 10, and the upper surface 100a of the external substrate 100 can be separated by a predetermined distance, reducing the influence of eddy current loss caused by the leakage magnetic flux generated from the gap 18.

[0038] Also, according to the present embodiment, the coil positioning portion 22 is formed as a recess 22a into which a part of the coil 10 is inserted at the central portion 16b´ of the upper end 16b of the bobbin 16. The lower end portion 10a of the coil 10 is formed as a terminal portion 10a´ for insertion into the through-hole 110 of the external substrate 100. By inserting a part of the coil 10 into the recess 22a and positioning it at the central portion 16b´ of the upper end 16b of the bobbin 16, and by exposing the terminal portion 10a´ downward from the lowermost surface 16a of the bobbin and inserting it into the through-hole 110 of the external substrate 100, the coil 10 can be positioned at the central portion 16b´ of the upper end 16b of the bobbin 16 and provided on the external substrate 100.

[0039] Furthermore, according to the present embodiment, when viewed from above, the gap 18 and the coil 10 are arranged at non-overlapping positions, thereby reducing the influence of eddy current loss caused by the leakage magnetic flux generated from the gap 18 on the coil 10. Also, since the gap 18 and the coil 10 are arranged at non-overlapping positions, the coil 10 can also serve as a shield against noise components.

[0040] Furthermore, according to the present embodiment, when viewed from above, the coils 10 are arranged in parallel at non-overlapping positions so as to avoid the gap 18, and the gap 18 is arranged between the plurality of coils 10, thereby reliably reducing the influence of the eddy current loss on the coils 10.

[0041] Still further, according to the present embodiment, the coil 10 is formed in a flat plate shape and a U shape with a predetermined width dimension, and both lower end portions 10a of the U shape are inserted into the through holes 110 of the external substrate 100 as terminal portions 10a', and the intermediate portion 10b of the U shape is positioned so as to be fitted into the coil positioning portion 22 of the bobbin 16, whereby the coil 10 can be provided on the external substrate 100 while being positioned via the bobbin 16.

[0042] Also, according to the present embodiment, the bobbin 16 has a plate-shaped first side portion 161, a second side portion 162, a bottom portion 163, an intermediate portion 164, a first support portion 165, and a second support portion 166. The first side portion 161 and the second side portion 162 are provided so as to stand on the upper surface 163a of the bottom portion 163 and be parallel to each other. The intermediate portion 164 has a first intermediate portion side portion 164a, a second intermediate portion side portion 164b, and an intermediate portion upper portion 164c. The first intermediate portion side portion 164a and the second intermediate portion side portion 164b are parallel to the first side portion 161 and the second side portion 162 with a predetermined gap 161', 162' therebetween between the first side portion 161 and the second side portion 162, and are further provided so as to stand on the upper surface 164a'' of the intermediate portion 164 and be parallel to each other, and also parallel to the first side portion 161 and the second side portion 162. The intermediate portion upper portion 164c is provided so as to connect the upper end 164a' of the first intermediate portion side portion 164a and the upper end 164b' of the second intermediate portion side portion 164b, and be parallel to the bottom portion 163. The first support portion 165 and the second support portion 166 are provided so as to stand on the intermediate portion upper portion 164c and be parallel to each other, and also parallel to the first side portion 161 and the second side portion 162. A coil positioning portion 22 formed as a recess 22a is provided at the upper ends 165', 166' of the first support portion 165 and the second support portion 166. The bottom portion 163 has, on the upper surface 163a side, a first bottom connecting portion 163' that connects the lower side of the first side portion 161 and the lower side of the first intermediate portion side portion 164a, and a second bottom connecting portion 163'' that connects the lower side of the second side portion 162 and the lower side of the second intermediate portion side portion 164b. First bottom holes 163b and second bottom holes 163c are provided in the first bottom connecting portion 163' and the second bottom connecting portion 163'' so as to communicate with the gaps 161', 162'. Further, the bottom portion 163 has a protruding portion 163d that protrudes outward from the first side portion 161 and the second side portion 162, and a leg portion 163f that extends downward from the lower surface 163e of the bottom portion 163. The lowermost surface of the leg portion 163f can be the bobbin lowermost surface 16a. The bobbin 16 has legs 163f extending downward from the lower surface 163e of the bottom portion 163, and the lowermost surface of the legs 163f is the bobbin lowermost surface 16a. By arranging the bobbin 16 such that the bobbin lowermost surface 16a is placed on the upper surface 100a of the external substrate 100, the position of the core 24 in the height direction can be adjusted so as to avoid the influence of leakage magnetic flux to the external substrate 100 side.

[0043] Furthermore, according to the present embodiment, while fitting and positioning the U-shaped intermediate portion 10b of the coil 10 into the coil positioning portion 22 of the bobbin 16, the terminal portion 10a' of the coil 10 is inserted into the first bottom hole 163b of the bobbin 16 and also inserted into the second bottom hole 163c of the bobbin 16. Further, the terminal portion 10a' of the coil 10 is inserted into the through hole 110 of the external substrate 100 so as to be exposed downward from the bobbin lowermost surface 16a, and the coil 10 is assembled to the bobbin 16. Thus, the coil 10 can be positioned via the bobbin 16 and provided on the external substrate 100. Furthermore, according to the present embodiment, the core 24 has a first core portion 241 and a second core portion 242. The first core portion 241 is formed in an E shape when viewed from above, and has a base portion 241a, a first side portion 241b extending from one end portion of the base portion 241a, a second side portion 241c extending from the other end portion of the base portion 241a, and an intermediate portion 241d extending from the middle of the base portion 241a so as to be parallel to the first side portion 241b and the second side portion 241c. The intermediate portion 241d is set to be shorter in length than the first side portion 241b and the second side portion 241c. The second core portion 242 is formed in an I shape when viewed from above. When the first core portion 241 and the second core portion 242 are opposed to each other and the end portion 241b' of the first side portion 241b of the first core portion 241 is abutted against one end portion 242b' of the second core portion 242, and the end portion 241c' of the second side portion 241c of the first core portion 241 is abutted against the other end portion 242c' of the second core portion 242, a gap 18 can be formed between the end portion 241d' of the intermediate portion 241d of the first core portion 241 and the intermediate portion 242d of the second core portion 242.

[0044] Also, according to the present embodiment, the intermediate portion 241d of the first core portion 241 is inserted into the space 167 inside the intermediate portion 164 of the bobbin 16, and the end portion 241b' of the first side portion 241b of the first core portion 241 is abutted against one end portion 242b' of the second core portion 242, and the end portion 241c' of the second side portion 241c of the first core portion 241 is abutted against the other end portion 242c' of the second core portion 242. The first side portion 161 and the first intermediate portion side portion 164a of the bobbin 16 are sandwiched between the intermediate portion 241d and the first side portion 241b, and the second side portion 162 and the second intermediate portion side portion 164b of the bobbin 16 are sandwiched between the intermediate portion 241d and the second side portion 241c. Further, a gap 18 is formed in the core 24 by separating the space between the end portion 241d' of the intermediate portion 241d of the first core portion 241 and the intermediate portion 242d of the second core portion 242. Furthermore, the core 24 can be positioned via the bobbin 16 such that the lowermost surface 24a of the core 24 is placed on the protruding portion 163d of the bottom portion 163.

[0045] Furthermore, according to the present embodiment, on the upper surface 263a side of the bottom 263 of the bobbin 26, the first side portion 241b of the first core portion 241 is inserted between the first side portion 261 and the first support portion 265 of the bobbin 26, and the second side portion 241c of the first core portion 241 is inserted between the second side portion 262 and the second support portion 266 of the bobbin 26. Also, the intermediate portion 241d of the first core portion 241 is inserted between the first support portion 265 and the second support portion 266 of the bobbin 26. The end portion 241b' of the first side portion 241b of the first core portion 241 is exposed outside the bobbin 26, and the exposed end portion 241b' is abutted against the end portion 242b' of the second core portion 242. The end portion 241c' of the second side portion 241c of the first core portion 241 is exposed outside the bobbin 26, and the exposed end portion 241c' is abutted against the end portion 242c' of the second core portion 242. Further, a gap 18 is formed at the end portion 241d' of the intermediate portion 241d of the core 24 by separating the space between the end portion 241d' of the intermediate portion 241d of the first core portion 241 and the intermediate portion 242d of the second core portion 242. By assembling the core 24 to the bobbin 26 such that the lowermost surface 24a of the core 24 is placed on the bottom 263, a gap 18 can be formed at the end portion 241d' of the intermediate portion 241d of the core 24.

[0046] [Modification Example] A modification example of the present invention will be described in detail with reference to the drawings. FIG. 12 is a diagram showing a modification example of the coil of the magnetic component, FIG. 13 is a diagram showing another modification example of the coil of the magnetic component, and FIG. 14 is a diagram showing another modification example of the coil of the magnetic component.

[0047] In the magnetic component 2 shown in FIG. 12, when viewed from above, the gap 18 and the coil 10 are arranged at non-overlapping positions.

[0048] Also, in the magnetic component 3 shown in FIG. 13, when viewed from above, the coils 10 are arranged in a plurality of non-overlapping parallel positions so as to avoid the gap 18, and the gap 18 is arranged between the plurality of coils 10.

[0049] Furthermore, when viewed from above, the magnetic component 4 shown in FIG. 14 is arranged such that the gap 18 and the coil 10 do not overlap each other.

[0050] That is, when viewed from above, a through hole 12 is formed at a position corresponding to the gap 18 in the coil 10, the gap 18 and the through hole 12 are arranged at overlapping positions, the through hole 12 is provided to include the gap 18 in the region inside the through hole 12, and the gap 18 and the main body 10' of the coil 10 are arranged at non-overlapping positions.

[0051] As described above, according to this modification, when viewed from above, the gap 18 and the coil 10 are arranged at non-overlapping positions, so that the influence of eddy current loss caused by the leakage magnetic flux generated from the gap 18 on the coil 10 can be reduced.

[0052] Also, according to this modification, when viewed from above, the coils 10 are arranged in parallel at non-overlapping positions so as to avoid the gap 18, and the gap 18 is arranged between the plurality of coils 10, so that the influence of eddy current loss on the coils 10 can be surely reduced.

[0053] Furthermore, according to this modification, when viewed from above, a through hole 12 is formed at a position corresponding to the gap 18 in the coil 10, the gap 18 and the through hole 12 are arranged at overlapping positions, the through hole 12 is provided to include the gap 18 in the region inside the through hole 12, and the gap 18 and the main body 10' of the coil 10 are arranged at non-overlapping positions, so that the influence of eddy current loss on the main body 10' of the coil 10 can be surely reduced.

Description of Reference Numerals

[0054] 1, 2, 3, 4: Magnetic component 10: Coil 10a: Lower end portion 10': Main body 12: Through hole 16: Bobbin 16a: Lowest part 16b: Upper end 16b´: Central part 16c: Core positioning part 161: First side part 161´: Gap 162: Second side part 162´: Gap 163: Bottom part 163a: Upper surface 163b: First bottom hole 163c: Second bottom hole 163d: Protruding part 163e: Lower surface 163f: Leg part 163´: First bottom connecting part 163´´: Second bottom connecting part 164: Middle part 164a: First middle part side part 164a´´: Upper surface 164a´: Upper end 164b: Second middle part side part 164b´: Upper end 164c: Upper part of the middle part 165: First support part 165´: Upper end 166: Second support part 166´: Upper end 167: Space 18: Gap 22: Coil positioning part 22a: Concave part 10a´: Terminal part 24: Core 241: First core part 241a: Base part 241b: First side part 241b´: End part 241c: Second side part 241c´: End part 241d: Middle part 241d´: End part 242: Second core part 242b´: End part 242c´: End part 242d: Middle part 100: External substrate 100a: Upper surface 110: Through hole

Claims

1. The coil (10), the core (24), and the bobbin (16), The coil (10) is made of a conductive material with one or less turns, The core (24) has a gap (18) in a portion where no magnetic path is formed, The bobbin (16) has a coil positioning portion (22) that positions the coil (10) so that a distance between the gap (18) and the coil (10) is a predetermined dimension, and a core positioning portion (16c) that positions the core (24) so ​​that a distance between a lowermost surface (14a) of the core (24) and a lowermost surface (16a) of the bobbin (16) is a predetermined dimension, The bobbin (16) is provided such that the bottom surface (16a) of the bobbin is located below the bottom surface (14a) of the core, and the bottom surface (16a) of the bobbin is placed on the upper surface (100a) of an external substrate (100); A magnetic component (1).

2. The coil positioning portion (22) is formed as a recess (22a) into which a part of the coil (10) is inserted at a central portion (16b') of an upper end (16b) of the bobbin (16), A lower end portion (10a) of the coil (10) is formed as a terminal portion (10a') to be inserted into a through hole (110) of the external substrate (100), a portion of the coil (10) is inserted into the recess (22a) and positioned at the center (16b') of the upper end (16b) of the bobbin (16), and the terminal portion (10a') is exposed downward from the bottom surface (16a) of the bobbin and inserted into a through hole (110) of the external substrate (100), thereby positioning the coil (10), the gap (18), and the external substrate (100); 2. A magnetic component (1) according to claim 1, characterized in that

3. 2. The magnetic component (1) according to claim 1, characterized in that, when viewed from above, the gap (18) and the coil (10) are arranged in a non-overlapping position.

4. The magnetic component (1) according to claim 3, characterized in that, when viewed from above, the coils (10) are arranged in parallel in a non-overlapping position so as to avoid the gap (18), and the gap (18) is arranged between the multiple coils (10).

5. The magnetic component (1) of claim 1, characterized in that, when viewed from above, the coil (10) has a through hole (12) formed at a position corresponding to the gap (18), the gap (18) and the through hole (12) are arranged in an overlapping position, the through hole (12) is arranged so as to include the gap (18) in the inner region of the through hole (12), and the gap (18) and the main body (10') of the coil (10) are arranged in a non-overlapping position.

6. The magnetic component (1) described in claim 1, characterized in that the coil (10) is formed in a flat U-shape with a predetermined width dimension, both lower ends (10a) of the U-shape are inserted into a through hole (110) of the external substrate (100) as the terminal portion (10a'), and the U-shaped middle portion (10b) is positioned to be fitted into the coil positioning portion (22) of the bobbin (16).

7. 2. The magnetic component (1) according to claim 1, characterized in that the coil (10) is made of copper.

8. The bobbin (16) has a plate-shaped first side portion (161), a second side portion (162), a bottom portion (163), a middle portion (164), a first support portion (165), and a second support portion (166), The first side portion (161) and the second side portion (162) are provided so as to stand on the upper surface (163a) of the bottom portion (163) and to be parallel to each other, The intermediate portion (164) has a first intermediate side portion (164a), a second intermediate side portion (164b), and an intermediate top portion (164c); the first intermediate side portion (164a) and the second intermediate side portion (164b) are provided between the first side portion (161) and the second side portion (162) so as to be parallel to the first side portion (161) and the second side portion (162) with a predetermined gap (161', 162'), to be erected on the upper surface (164a'') of the intermediate portion (164) and to be parallel to each other, and further to be parallel to the first side portion (161) and the second side portion (162); The intermediate upper portion (164c) is provided so as to connect the upper end (164a') of the first intermediate side portion (164a) and the upper end (164b') of the second intermediate side portion (164b) and to be parallel to the bottom portion (163); the first support portion (165) and the second support portion (166) are provided so as to stand on the upper portion (164c) of the intermediate portion and to be parallel to each other and further to be parallel to the first side portion (161) and the second side portion (162), and the coil positioning portion (22) formed as the recess (22a) is provided at upper ends (165', 166') of the first support portion (165) and the second support portion (166), The bottom portion (163) has, on its upper surface (163a) side, a first bottom connecting portion (163') that connects the lower side of the first side portion (161) to the lower side of the first intermediate portion side portion (164a), and a second bottom connecting portion (163'') that connects the lower side of the second side portion (162) to the lower side of the second intermediate portion side portion (164b), and a first bottom hole (163b) and a second bottom hole (163c) are provided in the first bottom connecting portion (163') and the second bottom connecting portion (163'') so as to communicate with the gap (161', 162'); The magnetic component (1) of claim 1, further characterized in that the bottom (163) has a protruding portion (163d) that protrudes outward from the first side (161) and the second side (162), and has a leg portion (163f) that extends downward from a lower surface (163e) of the bottom (163), and the lowest surface of the leg portion (163f) is the lowest surface (16a) of the bobbin.

9. The magnetic component (1) according to claim 1, characterized in that while the U-shaped intermediate portion (10b) of the coil (10) is fitted into the coil positioning portion (22) of the bobbin (16) to position it, one of the terminal portions (10a') of the coil (10) is inserted into the first bottom hole (163b) through the gap (161') of the bobbin (16), and the other terminal portion (10a') of the coil (10) is inserted into the second bottom hole (163c) through the gap (162') of the bobbin (16), and further, the terminal portion (10a') of the coil (10) is inserted into a through hole (110) of the external substrate (100) so that it is exposed downward from the bottom surface (16a) of the bobbin, thereby assembling the coil (10) to the bobbin (16).

10. The core (24) has a first core portion (241) and a second core portion (242), The first core portion (241) is formed in an E-shape when viewed from above, and has a base portion (241a), a first side portion (241b) extending from one end of the base portion (241a), a second side portion (241c) extending from the other end of the base portion (241a), and an intermediate portion (241d) extending from the middle of the base portion (241a) so as to be parallel to the first side portion (241b) and the second side portion (241c), and the intermediate portion (241d) is set to be shorter in length than the first side portion (241b) and the second side portion (241c), The second core portion (242) is formed in an I-shape when viewed from above, The magnetic component (1) according to claim 1, characterized in that when the first core portion (241) and the second core portion (242) are opposed to each other, an end (241b') of the first side portion (241b) of the first core portion (241) is butted against one end (242b') of the second core portion (242), and an end (241c') of the second side portion (241c) of the first core portion (241) is butted against the other end (242c') of the second core portion (242), there is a separation between the end (241d') of the intermediate portion (241d) of the first core portion (241) and the intermediate portion (242d) of the second core portion (242).

11. The intermediate portion (241d) of the first core portion (241) is inserted into the space (167) inside the intermediate portion (164) of the bobbin (16), and an end portion (241b') of the first side portion (241b) of the first core portion (241) is butted against one end portion (242b') of the second core portion (242), and an end portion (241c') of the second side portion (241c) of the first core portion (241) is butted against the other end portion (242c') of the second core portion (242), so that the first side portion (161) and the first intermediate portion side portion (164a) of the bobbin (16) are sandwiched between the intermediate portion (241d) and the first side portion (241b). The magnetic component (1) of claim 1, characterized in that the second side portion (162) and the second intermediate side portion (164b) of the bobbin (16) are sandwiched between the intermediate portion (241d) and the second side portion (241c), and further, the end portion (241d') of the intermediate portion (241d) of the first core portion (241) is spaced from the intermediate portion (242d) of the second core portion (242) to form the gap (18) in the center of the core (24), and further, the core (24) is assembled to the bobbin (16) so that the bottom surface (24a) of the core (24) is placed on the protruding portion (163d) of the bottom portion (163).

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