Inductor and manufacturing method of the inductor

Abstract

To suppress deterioration of reliability of an inductor.SOLUTION: An inductor 1 comprises: a bottom surface 18; a top surface 19; a magnetic core 10 having end surfaces 13 and 14; a coil element 20; and electrode members 30 and 40. The coil element 20 includes: a winding part 21; and lead parts 23 and 24. The electrode member 30 includes: a side plate part 35 that is arranged along the end surface 13; a first lead-out part 31 that is led to an internal part of the magnetic core 10 from an end part 35a on the top surface 19 side of the side plate part 35; a connection part 34 that is connected to the lead part 23 in the internal part of the magnetic core 10 so as to be connected to the first lead-out part 31; a projection part 33 that is projected toward the top surface 19 side from the end part 35a on the top surface 19 of the side plate part 35; and a first groove part 36 that is provided to between the first lead-out part 31 and the projection part 33 in the end part 35a on the top surface 19 side of the side plate part 35. In the case of viewing it from a direction vertical to the end surface 13, a top end 33e of the projection part 33 is positioned to the top surface 19 side from the first lead-out part 31.SELECTED DRAWING: Figure 8

Description

Technical Field

[0001] The present disclosure relates to an inductor and a method for manufacturing the inductor.

Background Art

[0002] In recent years, with the improvement in performance of electronic devices, there has been a desire for miniaturization along with an increase in the current used, and an inductor that satisfies both of these is required. In addition, inductors used in harsh environments such as in-vehicle applications are also required to have vibration resistance and heat cycle resistance. Furthermore, connection reliability between the coil element and the external electrodes, and between the external electrodes and the mounting substrate is required.

[0003] Therefore, a technique for manufacturing an inductor by placing a coil element in a mixture of a metal magnetic powder and a binder composed of a thermosetting resin and performing pressure molding has been proposed (for example, Patent Document 1).

[0004] Also, in order to reduce the cost of forming the external electrodes, a technique for forming a member that becomes the external electrodes simultaneously when placing the coil element in the above mixture and performing pressure molding has been proposed (for example, Patent Document 2).

[0005] Furthermore, in order to prevent the coil end from peeling off from the terminal electrode (external electrode) during pressure molding, a technique has been proposed in which the end of the coil element is arranged at the curved engagement portion of the terminal electrode, and the end of the coil element is clamped and fixed at the curved engagement portion of the terminal electrode (for example, Patent Document 3).

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Patent Document 2

Patent Document 3

Summary of the Invention

Problems to be Solved by the Invention

[0007] In the technique described in Patent Document 3, two lead-out portions (protrusions) are provided on the upper portion of the terminal electrode, and a curved engagement portion is provided on one of the lead-out portions. However, in this structure, when the end portion of the coil element is arranged at the curved engagement portion of the terminal electrode, the winding portion of the coil element may come into contact with both or one of the two lead-out portions, damaging the coil element, and the reliability of the inductor may be reduced.

[0008] In view of the above, the present disclosure provides an inductor and the like that can suppress a decrease in the reliability of the inductor.

Means for Solving the Problems

[0009] An inductor according to an aspect of the present disclosure includes a magnetic core having a bottom surface, a top surface facing away from the bottom surface, and an end surface connecting the bottom surface and the top surface, a coil element embedded in the magnetic core, and an electrode member connected to the coil element. The coil element has a winding portion around which a conductive wire is wound and a lead portion drawn from an end portion of the winding portion. The electrode member has a side plate portion arranged along the end surface, a first lead-out portion drawn from an end portion of the side plate portion on the top surface side into the inside of the magnetic core, a connection portion connected to the first lead-out portion and connected to the lead portion inside the magnetic core, a protruding portion protruding from the end portion of the side plate portion on the top surface side toward the top surface side, and a first groove portion provided between the first lead-out portion and the protruding portion at the end portion of the side plate portion on the top surface side. When viewed from a direction perpendicular to the end surface, the tip of the protruding portion is located on the top surface side of the first lead-out portion.

[0010] A method for manufacturing an inductor according to an aspect of the present disclosure is a method for manufacturing an inductor including a coil element embedded in a magnetic core and an electrode member connected to the coil element, the method including: a coil element forming step of forming the coil element having a winding portion and a lead portion drawn from an end of the winding portion; an electrode member preliminary forming step of forming an electrode member having side plate portions arranged along a predetermined direction, a first lead-out portion bent at one end of the side plate portions in the predetermined direction, a connection portion drawn from the first lead-out portion, and a protruding portion protruding in the predetermined direction from one end of the side plate portions in the predetermined direction; a connection step of connecting the lead portion and the connection portion; and a magnetic core forming step of embedding the coil element, the first lead-out portion, and the connection portion in the magnetic core, the connection step including: a step of arranging the lead portion on the protruding portion; a step of rotating the lead portion about the winding axis of the winding portion to move the lead portion from the protruding portion, through the first lead-out portion, to the connection portion; and a step of caulking and connecting the lead portion and the connection portion.

Effects of the Invention

[0011] According to the inductor and the like of the present disclosure, it is possible to suppress a decrease in the reliability of the inductor.

Brief Description of the Drawings

[0012]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Embodiments for Carrying Out the Invention

[0013] (Background Leading to the Present Disclosure) The background leading to the present disclosure will be described with reference to FIGS. 1 to 6. Note that the comparative examples shown below are examples used for explaining the present embodiment and are not prior art.

[0014] FIG. 1 is a view showing an inductor 101 of a comparative example.

[0015] The inductor 101 of the comparative example includes a magnetic core 110, a coil element 120 having a winding portion 121 and a plurality of lead portions 123 and 124, and a plurality of electrode members 130 and 140 which are terminal electrodes. In the figure, the magnetic core 110 is shown by a broken line. The magnetic core 110 has a rectangular parallelepiped shape and has a bottom surface 118, a top surface 119, end faces 113 and 114, and side faces 115 and 116.

[0016] One lead portion 123 of the coil element 120 is caulked and fixed to the connection portion 134 of the electrode member 130, and the other lead portion 124 is caulked and fixed to the connection portion 144 of the electrode member 140. Notch recesses 136 and 146 are respectively formed in the electrode members 130 and 140. These notch recesses 136 and 146 are provided to facilitate the bending and forming of the first lead portions 131 and 141.

[0017] FIG. 2 is a diagram showing a scene of connecting the coil element 120 and the electrode members 130 and 140 in the comparative example. FIG. 3 is a diagram of the lead portion 123 of the coil element 120 and the electrode member 130 as viewed from the end face 113 side of the magnetic core 110 in the scene of connecting the coil element 120 and the electrode members 130 and 140 in FIG. 2. In FIGS. 2 and 3, a state before the connection portion 134 is caulked and fixed to the lead portion 123 is shown.

[0018] In the inductor 101 of the comparative example, first, the coil element 120 is arranged so that the lead portion 123 is positioned on the notch recess 136 of the electrode member 130. Then, by rotating the coil element 120 about the winding axis 121c of the winding portion 121, the lead portion 123 is rotationally moved and arranged at the connection portion 134. However, in the comparative example, as shown in FIG. 3, the lead portion 123 is arranged on the notch recess 136 lower than the first lead portion 131. Therefore, when the lead portion 123 is rotationally moved, the lead portion 123 catches on the side surface of the notch recess 136, and there is a problem that the lead portion 123 is damaged. Further, when the lead portion 123 catches, there is a problem that the manufacturing process of connecting the coil element 120 and the electrode member 130 stops and the production efficiency decreases.

[0019] FIG. 4 is a diagram showing the inductor 1 according to the embodiment.

[0020] The inductor 1 of the embodiment includes a magnetic core 10, a coil element 20 having a winding portion 21 and a plurality of lead portions 23 and 24, and a plurality of electrode members 30 and 40 that are terminal electrodes. In the figure, the magnetic core 10 is shown by a broken line. The magnetic core 10 has a rectangular parallelepiped shape and has a bottom surface 18, a top surface 19, end surfaces 13 and 14, and side surfaces 15 and 16.

[0021] One lead portion 23 of the coil element 20 is caulked and fixed to the connection portion 34 of the electrode member 30, and the other lead portion 24 is caulked and fixed to the connection portion 44 of the electrode member 40. Protrusions 33 and 43 are formed on the electrode members 30 and 40, respectively. In the height direction (Z-axis direction), the protrusions 33 and 43 protrude more than the first lead-out portions 31 and 41. In the embodiment, first groove portions 36 and 46 are formed to facilitate bending and forming of the first lead-out portions 31 and 41.

[0022] FIG. 5 is a diagram showing a scene of connecting the coil element 20 and the electrode members 30 and 40 in the embodiment. FIG. 6 is a diagram of viewing the lead portion 23 of the coil element 120 and the electrode member 30 from the end surface 13 side of the magnetic core 10 in the scene of connecting the coil element 20 and the electrode members 30 and 40 in FIG. 5. FIGS. 5 and 6 show a state before the connection portion 34 is caulked and fixed to the lead portion 23.

[0023] In the inductor 1 of the embodiment, first, the coil element 20 is arranged so that the lead portion 23 is located on the protrusion 33 of the electrode member 30. Then, by rotating the coil element 20 about the winding axis 21c of the winding portion 21, the lead portion 23 is rotationally moved and arranged at the connection portion 34. Different from the comparative example in the embodiment, the lead portion 23 is arranged on the protrusion 33 that is higher than the first lead-out portion 31. Therefore, when the lead portion 23 is rotationally moved, the lead portion 23 smoothly moves on the protrusion 33 and the first lead-out portion 31 and is arranged at the connection portion 34. Thereby, it is possible to suppress damage to the lead portion 23 and suppress a decrease in the reliability of the inductor 1. Further, it is possible to suppress the lead portion 23 from getting caught on the electrode member 30, so that it is possible to suppress a decrease in production efficiency.

[0024] Hereinafter, embodiments will be described in more detail with reference to the drawings. Note that each of the embodiments described below shows a specific example of the present disclosure. Numerical values, shapes, materials, components, arrangement positions of components, connection forms, steps, and the order of steps shown in the following embodiments are merely examples and are not intended to limit the present disclosure. In addition, among the components in the following embodiments, components not described in the independent claims are described as optional components.

[0025] Also, in this specification, terms indicating the relationship between elements such as parallel, terms indicating the shape of elements such as rectangular parallelepiped, and numerical ranges are not expressions representing only a strict meaning, but are expressions meaning substantially equivalent ranges, for example, including a difference of about several percent.

[0026] Each figure is a schematic diagram that has been appropriately emphasized, omitted, or adjusted in ratio to show the present disclosure, and is not necessarily drawn precisely, 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 redundant descriptions may be omitted or simplified.

[0027] Each figure shows the X-axis, Y-axis, and Z-axis, which mean three mutually orthogonal directions, and these axes and the axial directions along these axes are used for explanation as necessary. Note that each axis is attached for the purpose of explanation and does not limit the direction and posture in which the inductor is used.

[0028] Also, in this specification, the terms "top surface" and "bottom surface" in the configuration of the inductor do not refer to the top surface (the surface on the vertically upward side) and the bottom surface (the surface on the vertically downward side) in the absolute spatial recognition, but are used as terms defined by the relative positional relationship of the components of the inductor.

[0029] (Embodiment) [Configuration of Inductor] The configuration of the inductor according to the embodiment will be described with reference to FIGS. 7 and 8. An inductor is a passive element that stores electrical energy flowing through a coil element as magnetic energy.

[0030] FIG. 7 is an external view of the inductor 1 according to the embodiment. FIG. 8 is a diagram showing the coil element 20 of the inductor 1 according to the embodiment, as well as the electrode members 30 and 40.

[0031] In FIGS. 7(a) and 7(b), perspective views of the inductor 1 seen from different angles are shown respectively. In FIGS. 8(a) and 8(b), perspective views of the coil element 20 and the electrode members 30 and 40 seen from different angles are shown respectively. In FIG. 8, the outer shape of the magnetic core 10 is indicated by a dashed line.

[0032] The inductor 1 shown in FIGS. 7 and 8 includes a magnetic core 10, a coil element 20 having a winding portion 21 and a plurality of lead portions 23, 24, and a plurality of electrode members 30 and 40 that are terminal electrodes. The approximate outer shape of the inductor 1 is determined by the shape of the magnetic core 10, which is, for example, a compressed powder magnetic core. Note that the magnetic core 10 is molded into an arbitrary shape by molding. That is, an inductor 1 having an arbitrary shape is formed depending on the shape of the magnetic core 10 during molding. The magnetic core 10 of the present embodiment is in the shape of a rectangular parallelepiped, and for example, has dimensions of 10 mm in the X-axis direction, 10 mm in the Y-axis direction, and 5 mm in the Z-axis direction.

[0033] The magnetic core 10 is the outer shell portion of the inductor 1 and covers the entire coil element 20 and a part of the electrode members 30 and 40. The magnetic core 10 contains a magnetic material and is, for example, a dust core made of a mixture of a metallic magnetic powder and a resin material. Note that the magnetic core 10 only needs to be formed using a magnetic material. As the magnetic material, ferrite may be used, or other magnetic materials may be used. As the metallic magnetic powder, particulate materials having a predetermined element composition such as Fe-Si-Al-based, Fe-Si-based, Fe-Si-Cr-based, or Fe-Si-Cr-B-based are used. Also, as the resin material, a material such as a silicone-based resin that can maintain a certain shape by insulating between the particles of the metallic magnetic powder and binding the particles of the metallic magnetic powder is selected.

[0034] The magnetic core 10 has a bottom surface 18, a top surface 19 facing away from the bottom surface 18, and two end surfaces 13 and 14 connecting the bottom surface 18 and the top surface 19. Also, the magnetic core 10 has two side surfaces 15 and 16 connecting the bottom surface 18 and the top surface 19 and connected to the end surfaces 13 and 14. The magnetic core 10 is square-shaped when viewed from a direction perpendicular to the top surface 19 (Z-axis direction). The magnetic core 10 may be rectangular or square-shaped when viewed from a direction perpendicular to the top surface 19. The bottom surface 18 and the top surface 19 face away from each other in the Z-axis direction, the end surfaces 13 and 14 face away from each other in the Y-axis direction, and the side surfaces 15 and 16 face away from each other in the X-axis direction.

[0035] The bottom surface 18, the top surface 19, the end surfaces 13 and 14, and the side surfaces 15 and 16 each have a flat plane. The bottom surface 18 and the top surface 19 are arranged in the Z-axis direction and are parallel to each other. The end surfaces 13 and 14 are arranged in the Y-axis direction. The side surfaces 15 and 16 are arranged in the X-axis direction and are parallel to each other. In this example, the end surfaces 13 and 14 are inclined inward, and the distance between them becomes closer as going from the bottom surface 18 toward the top surface 19.

[0036] Further, the bottom surface 18 and the top surface 19, and the end surface 13 (or 14) have a relationship of intersecting with each other when the planes are extended. The bottom surface 18 and the top surface 19, and the side surface 15 (or 16) intersect with each other when the planes are extended, specifically having a perpendicular relationship. The end surface 13 (or 14) and the side surface 15 (or 16) have a relationship of intersecting with each other when the planes are extended.

[0037] On the bottom surface 18 of the magnetic core 10, two bottom surface recesses 18a are formed (see FIG. 4). The bottom plate portion 38 of the electrode member 30 is disposed in one of the two bottom surface recesses 18a, and the bottom plate portion 48 of the electrode member 40 is disposed in the other bottom surface recess 18a.

[0038] The coil element 20 is provided inside the magnetic core 10. That is, the entire coil element 20 is embedded in the magnetic core 10.

[0039] The coil element 20 is formed of, for example, a single conducting wire. For example, the conducting wire is a round wire, and the diameter of the cross section is 0.5 mm. Note that the diameter of the conducting wire is appropriately selected from the range of 0.2 mm or more and 1 mm or less. The conducting wire is composed of, for example, a metal wire selected from metals such as aluminum, copper, silver, and gold, an alloy containing one or more of these metals, and a material composed of a metal or an alloy and another substance, and an insulating film covering the metal wire. Specifically, the conducting wire is, for example, a copper wire covered with an insulating film.

[0040] The coil element 20 has a winding portion 21 around which a conducting wire is wound, and a plurality of lead portions 23 and 24 which are conducting wires drawn from the ends of the winding portion 21. The coil element 20 in this example is composed of one winding portion 21 and two lead portions 23 and 24. The winding portion 21 and the lead portions 23 and 24 are names given to the respective parts formed by processing a single wire made of the same material, for example. The coil element 20 is disposed in the magnetic core 10 such that the winding axis 21c of the winding portion 21 is perpendicular to the bottom surface 18 and the top surface 19.

[0041] The winding part 21 is composed of a wound conductor and functions as a coil. The winding part 21 is composed of an inner peripheral coil and an outer peripheral coil connected to the inner peripheral coil. The number of turns of the inner peripheral coil and the outer peripheral coil is 2 turns each. Note that the number of turns of the winding part 21 is not particularly limited and is appropriately selected according to the performance required for the inductor 1 and the constraints such as the size of the magnetic core 10. Both ends of the winding part 21, specifically, lead parts 23 are connected to the ends of the inner peripheral coil, and lead parts 24 are connected to the ends of the outer peripheral coil.

[0042] The lead parts 23 and 24 are composed of straight conductors. The lead parts 23 and 24 are arranged along one diagonal of the square top surface 19. The lead parts 23 and 24 are drawn out from the ends of the winding part 21 toward the surface of the magnetic core 10 and are interrupted before reaching the surface of the magnetic core 10. The distance from the end of the lead part 23 to the end of the lead part 24 is longer than the distance from the end face 13 to the end face 14 (or the distance from the protruding part 33 to the protruding part 43) and shorter than the length of the diagonal of the magnetic core 10.

[0043] One of the lead parts 23 is arranged at the corner 10r of the magnetic core 10 where the end face 13 and the side face 15 intersect when viewed from the direction perpendicular to the top surface 19 (Z-axis direction). The other lead part 24 is arranged at the corner 10r of the magnetic core 10 where the end face 14 and the side face 16 intersect when viewed from the direction perpendicular to the top surface 19. That is, the lead parts 23 and 24 are arranged at the opposing corners 10r on the diagonal of the square top surface 19. By arranging each of the lead parts 23 and 24 at each corner 10r of the magnetic core 10, the volume of the magnetic core 10 can be effectively utilized, and the overlapping characteristics of the inductor 1 can be improved.

[0044] Also, when viewed from the direction perpendicular to the end face 13, the lead part 23 is arranged at a position closer to the top surface 19 than the center of the end face 13, specifically, at a position closer to the top surface 19 than the first drawing part 31 described later. When viewed from the direction perpendicular to the end face 14, the lead part 24 is arranged at a position closer to the top surface 19 than the center of the end face 14, specifically, at a position closer to the top surface 19 than the first drawing part 41 described later.

[0045] The lead portions 23 and 24 have their insulating films removed so as to be electrically conductive with the electrode members 30 and 40, respectively. The lead portion 23 is caulked to the connection portion 34 of the electrode member 30 and further welded to be connected and fixed to the electrode member 30. The lead portion 24 is caulked to the connection portion 44 of the electrode member 40 and further welded to be connected and fixed to the electrode member 40.

[0046] The electrode member 30 and the lead portion 23, and the electrode member 40 and the lead portion 24 have a shape and a positional relationship that are point-symmetrical by 180° about the winding axis 21c. Hereinafter, among the electrode members 30 and 40, the electrode member 30 will be taken as an example for explanation.

[0047] As shown in FIG. 8, the electrode member 30 has a side plate portion 35 and a bottom plate portion 38. Further, the electrode member 30 has a first lead-out portion 31 and a connection portion 34, a protruding portion 33, a second lead-out portion 32, a first groove portion 36, and a second groove portion 37.

[0048] The electrode member 30 is formed of, for example, a metal material plate. The metal material plate is composed of a metal material selected from metals such as aluminum, copper, silver, and gold, an alloy containing one or more of these metals, and a material composed of a metal or an alloy and another substance. The plate thickness of the metal material plate is, for example, 0.15 mm. The side plate portion 35, the first lead-out portion 31 and the connection portion 34, the second lead-out portion 32, the protruding portion 33, and the bottom plate portion 38 are, for example, names given to respective portions formed by processing a single plate material made of the same material. The first groove portion 36 and the second groove portion 37 are notch grooves for facilitating bending of the first lead-out portion 31 and the second lead-out portion 32, respectively.

[0049] The side plate portion 35 is disposed along the end face 13 of the magnetic core 10 on the outside of the magnetic core 10. The side plate portion 35 is plate-shaped and is in contact with the end face 13. In the direction perpendicular to the top face 19, the length of the side plate portion 35 is shorter than the length (height) of the end face 13. The end portion 35a of the side plate portion 35 on the top face 19 side is located on the bottom face 18 side rather than the top face 19, and the end portion 35b of the side plate portion 35 on the bottom face 18 side is on the bottom face 18 side rather than the end portion 35a and is located at substantially the same height as the bottom face 18.

[0050] The bottom plate portion 38 is connected to the end portion 35b of the side plate portion 35 on the bottom face 18 side, is drawn out from the end portion 35b on the bottom face 18 side, and extends along the bottom face 18. Specifically, the bottom plate portion 38 is bent starting from the end portion 35b of the side plate portion 35 on the bottom face 18 side and is arranged so that at least a part thereof enters the bottom face recess 18a.

[0051] The outer surfaces of the side plate portion 35 and the bottom plate portion 38 are not embedded in the magnetic core 10 but are exposed. The side plate portion 35 and the bottom plate portion 38 are the portions to be joined to the circuit board by solder or the like when the inductor 1 is mounted on the circuit board.

[0052] The first lead-out portion 31, the connection portion 34, and the second lead-out portion 32 are embedded in the magnetic core 10. In the present embodiment, since the first lead-out portion 31, the connection portion 34, and the second lead-out portion 32 are embedded in the magnetic core 10, the electrode member 30 is configured not to fall out of the magnetic core 10.

[0053] The first lead-out portion 31 is connected to the end portion 35a of the side plate portion 35 on the top face 19 side and is drawn out into the magnetic core 10 from the end portion 35a on the top face 19 side. The first lead-out portion 31 is formed by being bent starting from the end portion 35a of the side plate portion 35 on the top face 19 side. The first lead-out portion 31 is arranged parallel to the top face 19.

[0054] The connecting portion 34 is connected to the first lead-out portion 31 and is connected to the lead portion 23 inside the magnetic core 10. The connecting portion 34 is caulked and fixed so as to wind and cover more than half of the outer circumference of the lead portion 23. Further, the connecting portion 34 is joined to the lead portion 23 by laser welding.

[0055] The second lead-out portion 32 is connected to the end portion 35a on the top surface 19 side of the side plate portion 35 and is drawn out from the end portion 35a on the top surface 19 side into the magnetic core 10. The second lead-out portion 32 is formed by being bent starting from the end portion 35a on the top surface 19 side of the side plate portion 35. The second lead-out portion 32 is arranged parallel to the top surface 19. Although no connecting portion is provided in the second lead-out portion 32, a through hole 32h for strengthening the prevention of coming off is formed.

[0056] The protruding portion 33 is connected to the end portion 35a on the top surface 19 side of the side plate portion 35 and protrudes further toward the top surface 19 side from the end portion 35a on the top surface 19 side. The protruding portion 33 is arranged along the end surface 13, and the outer surface of the protruding portion 33 is not embedded in the magnetic core 10. For example, the protruding portion 33 may be slightly bent toward the center 10c side of the magnetic core 10 starting from the end portion 35a on the top surface 19 side of the side plate portion 35, and the tip 33e of the protruding portion 33 may be embedded in the magnetic core 10. Further, at least a part or all of the side plate portion 35 and the protruding portion 33 having a plate thickness of 0.15 mm of the metal material plate may be embedded and fixed in the magnetic core 10, and the bottom plate portion 38 may not be embedded in the magnetic core 10. By embedding and fixing the side plate portion 35 and the protruding portion 33 in the magnetic core 10, vibration resistance can be ensured, and since the bottom plate portion 38 is not fixed to the magnetic core 11, heat cycle resistance can be improved.

[0057] The first groove portion 36 is provided between the first lead-out portion 31 and the protruding portion 33 at the end portion 35a on the top surface 19 side of the side plate portion 35. The first groove portion 36 is a groove that progresses in the plate thickness direction of the side plate portion 35. It is desirable that the dimension of the groove width of the first groove portion 36 is smaller than the width dimension of the cross section of the conductor forming the coil element 20. The groove width of the first groove portion 36 is, for example, 0.2 mm or more and 0.4 mm or less.

[0058] The second groove portion 37 is provided between the second drawer portion 32 and the protruding portion 33 at the end portion 35a on the top surface 19 side of the side plate portion 35. The second groove portion 37 is a groove that progresses in the plate thickness direction of the side plate portion 35. It is desirable that the groove width of the second groove portion 37 be the same as the groove width of the first groove portion 36.

[0059] Thus, at the end portion 35a on the top surface 19 side of the side plate portion 35, the protruding portion 33, the first groove portion 36 and the second groove portion 37, and the first drawer portion 31 and the second drawer portion 32 are provided. These protruding portion 33, first groove portion 36, second groove portion 37, first drawer portion 31, and second drawer portion 32 are provided in different regions of the end portion 35a on the top surface 19 side of the side plate portion 35.

[0060] When viewed from a direction (Z-axis direction) perpendicular to the top surface 19, the protruding portion 33 is disposed at a position overlapping a line 10cL passing through the center 10c of the magnetic core 10 and perpendicular to the end surface 13 (see (a) of FIG. 7). In other words, the protruding portion 33 is disposed at the center of the side plate portion 35 in a direction perpendicular to the side surface 15. The first groove portion 36 and the second groove portion 37 are provided on both outer sides of the protruding portion 33. That is, the first groove portion 36 is provided on the side surface 15 side when viewed from the protruding portion 33. The first drawer portion 31 is provided further on the side surface 15 side than the first groove portion 36. The second groove portion 37 is provided on the side surface 16 side when viewed from the protruding portion 33. The second drawer portion 32 is provided further on the side surface 16 side than the second groove portion 37.

[0061] In the present embodiment, when viewed from a direction perpendicular to the end face 13, the tip 33e of the protruding portion 33 is located on the top face 19 side of the first drawer portion 31. Further, when compared in terms of the position coordinates in the direction perpendicular to the top face 19 (Z-axis direction), the tip 33e of the protruding portion 33 is located on the top face 19 side of the guide surface 31g on the top face 19 side of the first drawer portion 31 and on the bottom face 18 side of the edge 34e on the top face 19 side of the connecting portion 34. The dimension by which the protruding portion 33 protrudes on the top face 19 side of the first drawer portion 31 is preferably smaller than the height dimension of the cross section of the conductive wire forming the coil element 20. The protruding height by which the protruding portion 33 protrudes on the top face 19 side of the first drawer portion 31 is, for example, 0.1 mm or more and 0.4 mm or less. Note that the guide surface 31g is a surface that abuts against the lower end of the lead portion 23 when the lead portion 23 slides on the first drawer portion 31 and moves to the connecting portion 34.

[0062] In this way, by providing the protruding portion 33 such that the tip 33e of the protruding portion 33 is located on the top face 19 side of the first drawer portion 31, for example, when the lead portion 23 of the coil element 20 is arranged on the tip 33e of the protruding portion 33 and the coil element 20 is rotated to move the lead portion 23, the lead portion 23 is not caught by the electrode member 30, and the lead portion 23 can be smoothly moved to the connecting portion 34. Thereby, it is possible to suppress damage to the lead portion 23 of the coil element 20 and suppress a decrease in the reliability of the inductor 1. Further, since the lead portion 23 can be surely arranged at the connecting portion 34, the connection reliability between the lead portion 23 and the connecting portion 34 can be improved. Further, since the positional accuracy of the lead portion 23 and the connecting portion 34 with respect to the magnetic core 10 is improved, the vibration resistance of the inductor 1 can be enhanced.

[0063] In the above description, among the electrode members 30 and 40, the electrode member 30 has been described as an example, but the same applies to the electrode member 40. In that case, the following configuration with the symbols replaced is established.

[0064] For example, in the above, the electrode member 30 is replaced with the electrode member 40, the first lead-out portion 31 is replaced with the first lead-out portion 41, the guide surface 31g is replaced with the guide surface 41g, the second lead-out portion 32 is replaced with the second lead-out portion 42, the through hole 32h is replaced with the through hole 42h, the protruding portion 33 is replaced with the protruding portion 43, the tip 33e is replaced with the tip 43e, the connection portion 34 is replaced with the connection portion 44, the edge 34e is replaced with the edge 44e, the side plate portion 35 is replaced with the side plate portion 45, the end portion 35a is replaced with the end portion 45a, the end portion 35b is replaced with the end portion 45b, the first groove portion 36 is replaced with the first groove portion 46, the second groove portion 37 is replaced with the second groove portion 47, the bottom plate portion 38 is replaced with the bottom plate portion 48, and further, the end face 13 is replaced with the end face 14, the side face 15 is replaced with the side face 16, and the lead portion 23 is replaced with the lead portion 24, and the same applies.

[0065] [Method of manufacturing an inductor] The method of manufacturing the inductor 1 described above will be described with reference to FIGS. 9 to 12.

[0066] FIG. 9 is a flowchart showing a method of manufacturing the inductor 1 according to the embodiment.

[0067] The method of manufacturing the inductor 1 includes a coil element forming step S10, an electrode member preliminary forming step S20, a connection step S30, and a magnetic core forming step S40. Further, the method of manufacturing the inductor 1 further includes a bottom plate portion forming step S50.

[0068] FIG. 10 is a view showing the coil element 20 formed by the coil element forming step S10.

[0069] In the coil element forming step S10, a coil element 20 having a winding portion 21 around which a conducting wire is wound and lead portions 23 and 24 drawn from the ends of the winding portion 21 is formed. At least a part of the lead portions 23 and 24 has the insulating coating of the conducting wire removed.

[0070] FIG. 11 is a view showing electrode members 30 and 40 formed by the electrode member preliminary formation step S20. In this figure, an example in which the electrode members 30 and 40 are formed of a hoop material is shown, but the present invention is not limited thereto, and the electrode members 30 and 40 may be fixed to a transfer jig by positioning pins or the like.

[0071] In the electrode member preliminary formation step S20, the electrode members 30 and 40 are preliminarily formed.

[0072] In this step S20, an electrode member 30 having a side plate portion 35 arranged along a predetermined direction, a first lead-out portion 31 bent at one end portion 35a in the predetermined direction of the side plate portion 35, a connection portion 34 led out from the first lead-out 31, and a protruding portion 33 protruding in the predetermined direction from one end portion 35a in the predetermined direction of the side plate portion 35 is preliminarily formed.

[0073] The preliminarily formed electrode member 30 is in a state before caulking molding, and an opening for inserting the lead portion 23 in a later process is provided in the connection portion 34. Further, the preliminarily formed electrode member 30 is in a state before the bottom plate portion 38 is bent and molded, and the lower portion of the side plate portion 35 serves as a leg portion 38a. The predetermined direction is the direction in which the leg portion 38a extends in a straight line.

[0074] Also in this step S20, an electrode member 40 having a side plate portion 45 arranged along a predetermined direction, a first lead-out portion 41 bent at one end portion 45a in the predetermined direction of the side plate portion 45, a connection portion 44 led out from the first lead-out 41, and a protruding portion 43 protruding in the predetermined direction from one end portion 45a in the predetermined direction of the side plate portion 45 is preliminarily formed.

[0075] The preliminarily formed electrode member 40 is in a state before caulking molding, and an opening for inserting the lead portion 24 in a later process is provided in the connection portion 44. Further, the preliminarily formed electrode member 40 is in a state before the bottom plate portion 48 is bent and formed, and the lower portion of the side plate portion 45 serves as a leg portion 48a. The predetermined direction is the direction in which the leg portion 48a extends in a straight line.

[0076] FIG. 12 is a diagram showing an example of a connection step S30 for connecting the coil element 20 and the electrode members 30 and 40.

[0077] In the connection step S30, the lead portion 23 and the connection portion 34 are connected, and the lead portion 24 and the connection portion 44 are connected.

[0078] Specifically, as shown in (a), the winding portion 21 of the coil element 20 is inserted into the support column 61 of the transfer jig, and the lead portion 23 is placed on the tip 33e of the protruding portion 33, and the lead portion 24 is placed on the tip 43e of the protruding portion 43.

[0079] Next, as shown in (b), the winding portion 21, the lead portions 23 and 24 of the coil element 20 are rotated about the winding axis 21c. In the figure, the coil element 20 is rotated by pushing the lead portion 23 using the rotating member 62. As a result, as shown in (c), the lead portion 23 is moved from the position on the protruding portion 33 through the first lead-out portion 31 to the connection portion 34. At the same time, the lead portion 24 is moved from the position on the protruding portion 43 through the first lead-out portion 41 to the connection portion 44 (not shown). Specifically, the lead portion 23 is moved while contacting the protruding portion 33 and the first lead-out portion 31 and inserted into the opening of the connection portion 34, and the lead portion 24 is moved while contacting the protruding portion 43 and the first lead-out portion 41 and inserted into the opening of the connection portion 44.

[0080] Next, as shown in (d), the lead portion 23 and the connection portion 34 are caulked and connected with a caulking jig (not shown). Also, the connection portion 44 is caulked and connected to the lead portion 24 with a caulking jig (not shown). After the lead portion 23 and the connection portion 34, and the lead portion 24 and the connection portion 44 are caulked, they may be joined by laser welding or resistance welding.

[0081] In the magnetic core forming step S40, the coil element 20, the first lead portions 31 and 41, and the connection portions 34 and 44 are embedded in the magnetic core 10. Note that a part of the side plate portions 35 and 45 and a part of the protruding portions 33 and 43 may be embedded in the magnetic core 10. This step S40 is executed by placing the coil element 20, the first lead portions 31 and 41, and the connection portions 34 and 44 in a molding die and pressure molding a mixture that becomes the material of the magnetic core 10. At the time of this molding, a bottom surface recess 18a is formed at a position overlapping the bottom plate portion 38 on the bottom surface 18 of the magnetic core 10.

[0082] In the bottom plate portion forming step S50, the bottom plate portions 38 and 48 are formed by bending and molding the lower portions of the side plate portions 35 and 45. The tips of the bottom plate portions 38 and 48 are bent so as to enter the bottom surface recess 18a.

[0083] According to this manufacturing method, when the lead portions 23 and 24 are rotationally moved, each of the lead portions 23 and 24 smoothly moves on the respective protruding portions 33 and 43 and on the respective first lead portions 31 and 41 and is arranged at the respective connection portions 34 and 44. Thereby, it is possible to suppress damage to the lead portions 23 and 24 and to suppress a decrease in the reliability of the inductor 1. Further, since it is possible to suppress the lead portions 23 and 24 from being caught by the respective electrode members 30 and 40, it is possible to suppress a decrease in production efficiency.

[0084] (Summary) An inductor or the like according to one aspect of the present disclosure will be exemplified.

[0085] [Example 1] The inductor 1 of Example 1 includes a magnetic core 10 having a bottom surface 18, a top surface 19 facing away from the bottom surface 18, and end surfaces 13 and 14 connecting the bottom surface 18 and the top surface 19, a coil element 20 embedded in the magnetic core 10, and electrode members 30 and 40 connected to the coil element 20. The coil element 20 has a winding portion 21 around which a conductive wire is wound and lead portions 23 and 24 drawn from ends of the winding portion 21.

[0086] The electrode member 30 includes a side plate portion 35 arranged along the end face 13, a first lead-out portion 31 drawn out from the end portion 35a on the top face 19 side of the side plate portion 35 into the core 10, a connection portion 34 connected to the first lead-out portion 31 and connected to the lead portion 23 inside the core 10, a protruding portion 33 protruding from the end portion 35a on the top face 19 side of the side plate portion 35 toward the top face 19 side, and a first groove portion 36 provided between the first lead-out portion 31 and the protruding portion 33 at the end portion 35a on the top face 19 side of the side plate portion 35. When viewed from a direction perpendicular to the end face 13, the tip 33e of the protruding portion 33 is located on the top face 19 side of the first lead-out portion 31.

[0087] In this way, by providing the protruding portion 33 such that the tip 33e of the protruding portion 33 is located on the top face 19 side of the first lead-out portion 31, for example, when the lead portion 23 of the coil element 20 is arranged on the tip 33e of the protruding portion 33 and the coil element 20 is rotated to move the lead portion 23, the lead portion 23 is not caught by the electrode member 30, and the lead portion 23 can be smoothly moved to the connection portion 34. As a result, it is possible to suppress damage to the lead portion 23 of the coil element 20 and suppress a decrease in the reliability of the inductor 1. Also, since the lead portion 23 can be surely arranged at the connection portion 34, the connection reliability between the lead portion 23 and the connection portion 34 can be improved. Further, since the positional accuracy of the lead portion 23 and the connection portion 34 with respect to the core 10 is improved, the vibration resistance of the inductor 1 can be enhanced.

[0088] In the above, the configuration of the electrode member 30 has been exemplified, but the configuration of the electrode member 40 is the same.

[0089] The electrode member 40 of Example 1 includes a side plate portion 45 arranged along the end face 14, a first lead-out portion 41 drawn from the end portion 45a on the top face 19 side of the side plate portion 45 into the inside of the magnetic core 10, a connection portion 44 connected to the lead portion 24 inside the magnetic core 10 and connected to the first lead-out portion 41, a protruding portion 43 protruding from the end portion 45a on the top face 19 side of the side plate portion 45 toward the top face 19 side, and a first groove portion 46 provided between the first lead-out portion 41 and the protruding portion 43 at the end portion 45a on the top face 19 side of the side plate portion 45. When viewed from a direction perpendicular to the end face 14, the tip 43e of the protruding portion 43 is located on the top face 19 side of the first lead-out portion 41.

[0090] In this way, by providing the protruding portion 43 such that the tip 43e of the protruding portion 43 is located on the top face 19 side of the first lead-out portion 41, for example, when the lead portion 24 of the coil element 20 is arranged on the tip 43e of the protruding portion 43 and the coil element 20 is rotated to move the lead portion 24, the lead portion 24 is not caught by the electrode member 40, and the lead portion 24 can be smoothly moved to the connection portion 44. Thereby, it is possible to suppress damage to the lead portion 24 of the coil element 20 and suppress a decrease in the reliability of the inductor 1. Further, since the lead portion 24 can be surely arranged at the connection portion 44, the connection reliability between the lead portion 24 and the connection portion 44 can be improved. In addition, since the positional accuracy of the lead portion 24 and the connection portion 44 with respect to the magnetic core 10 is improved, the vibration resistance of the inductor 1 can be enhanced.

[0091] [Example 2] The inductor 1 of Example 2 is the inductor described in Example 1. When compared in terms of the position coordinates in the direction perpendicular to the top face 19, the tip 33e of the protruding portion 33 may be located on the top face 19 side of the guide surface 31g on the top face 19 side of the first lead-out portion 31 and on the bottom face 18 side of the edge end 34e on the top face 19 side of the connection portion 34.

[0092] According to this configuration, for example, when the lead portion 23 of the coil element 20 is disposed on the tip 33e of the protruding portion 33 and the coil element 20 is rotated to move the lead portion 23, the lead portion 23 is not caught by the electrode member 30, and the lead portion 23 can be smoothly moved to the connection portion 34. Thereby, it is possible to suppress damage to the lead portion 23 of the coil element 20 and to suppress a decrease in the reliability of the inductor 1. In addition, since the lead portion 23 can be surely disposed at the connection portion 34, the connection reliability between the lead portion 23 and the connection portion 34 can be enhanced.

[0093] In the above, the configuration of the protruding portion 33 has been exemplified, but the same applies to the configuration of the protruding portion 43.

[0094] The inductor 1 of Example 2 is the inductor described in Example 1. When compared in terms of the position coordinates in the direction perpendicular to the top surface 19, the tip 43e of the protruding portion 43 may be located on the side of the top surface 19 rather than the guide surface 41g on the top surface 19 side of the first lead-out portion 41 and may be located on the side of the bottom surface 18 rather than the edge 44e on the top surface 19 side of the connection portion 44.

[0095] According to this configuration, for example, when the lead portion 24 of the coil element 20 is disposed on the tip 43e of the protruding portion 43 and the coil element 20 is rotated to move the lead portion 24, the lead portion 24 is not caught by the electrode member 40, and the lead portion 24 can be smoothly moved to the connection portion 44. Thereby, it is possible to suppress damage to the lead portion 24 of the coil element 20 and to suppress a decrease in the reliability of the inductor 1. In addition, since the lead portion 24 can be surely disposed at the connection portion 44, the connection reliability between the lead portion 24 and the connection portion 44 can be enhanced.

[0096] [Example 3] The inductor 1 of Example 3 is the inductor described in Example 1 or 2. The magnetic core 10 is in the shape of a rectangular parallelepiped and has side surfaces 15 and 16 that connect the bottom surface 18 and the top surface 19 and are connected to the end surfaces 13 and 14. When viewed from a direction perpendicular to the top surface 19, the protruding portion 33 is disposed at a position overlapping with a line 10cL passing through the center 10c of the magnetic core 10 and perpendicular to the end surface 13. The first lead-out portion 31 is disposed on the side of the side surface 15 rather than the protruding portion 33. The lead portion 23 and the connecting portion 34 may be disposed at a corner portion 10r of the magnetic core 10 where the end surface 13 and the side surface 15 intersect.

[0097] In this way, by disposing the lead portion 23 at the corner portion 10r of the magnetic core 10, the volume of the magnetic core 10 can be effectively used, and the stacking characteristics of the inductor 1 can be improved.

[0098] In the above, the configurations of the protruding portion 33, the first lead-out portion 31, and the lead portion 23 are illustrated. However, the same applies to the configurations of the protruding portion 43, the first lead-out portion 41, and the lead portion 24.

[0099] The inductor 1 of Example 3 is the inductor described in Example 1 or 2. The magnetic core 10 is in the shape of a rectangular parallelepiped and has side surfaces 15 and 16 that connect the bottom surface 18 and the top surface 19 and are connected to the end surfaces 13 and 14. When viewed from a direction perpendicular to the top surface 19, the protruding portion 43 is disposed at a position overlapping with a line 10cL passing through the center 10c of the magnetic core 10 and perpendicular to the end surface 14. The first lead-out portion 41 is disposed on the side of the side surface 16 rather than the protruding portion 43. The lead portion 24 and the connecting portion 44 may be disposed at a corner portion 10r of the magnetic core 10 where the end surface 14 and the side surface 16 intersect.

[0100] In this way, by disposing the lead portion 24 at the corner portion 10r of the magnetic core 10, the volume of the magnetic core 10 can be effectively used, and the stacking characteristics of the inductor 1 can be improved.

[0101] [Example 4] The inductor 1 of Example 4 is the inductor described in any one of Examples 1 to 3. The dimension of the groove width of the first groove portion 36 may be smaller than the width dimension of the cross section of the conductive wire forming the coil element 20.

[0102] According to this configuration, for example, when the lead portion 23 of the coil element 20 is arranged on the tip 33e of the protruding portion 33 and the coil element 20 is rotated to move the lead portion 23, the lead portion 23 is less likely to be caught by the first groove portion 36, and the lead portion 23 can be smoothly moved to the connection portion 34. Thereby, it is possible to suppress damage to the lead portion 23 of the coil element 20 and to suppress a decrease in the reliability of the inductor 1. Further, since the lead portion 23 can be surely arranged at the connection portion 34, the connection reliability between the lead portion 23 and the connection portion 34 can be enhanced.

[0103] In the above, the configuration of the first groove portion 36 has been exemplified, but the same applies to the configuration of the first groove portion 46.

[0104] The inductor 1 of Example 4 is the inductor described in any one of Examples 1 to 3, and the dimension of the groove width of the first groove portion 46 may be smaller than the width dimension of the cross section of the conductive wire forming the coil element 20.

[0105] According to this configuration, for example, when the lead portion 24 of the coil element 20 is arranged on the tip 43e of the protruding portion 43 and the coil element 20 is rotated to move the lead portion 24, the lead portion 24 is less likely to be caught by the first groove portion 46, and the lead portion 24 can be smoothly moved to the connection portion 44. Thereby, it is possible to suppress damage to the lead portion 24 of the coil element 20 and to suppress a decrease in the reliability of the inductor 1. Further, since the lead portion 24 can be surely arranged at the connection portion 44, the connection reliability between the lead portion 24 and the connection portion 44 can be enhanced.

[0106] [Example 5] The inductor 1 of Example 5 is the inductor described in any one of Examples 1 to 4, and the dimension by which the protruding portion 33 protrudes toward the top surface 19 side more than the first lead-out portion 31 may be smaller than the height dimension of the cross section of the conductive wire forming the coil element 20.

[0107] According to this configuration, for example, when the lead portion 23 of the coil element 20 is disposed on the tip 33e of the protruding portion 33 and the coil element 20 is rotated to move the lead portion 23, the dropping distance of the lead portion 23 with respect to the first lead-out portion 31 becomes small, and the lead portion 23 can be smoothly moved to the connecting portion 34. Thereby, it is possible to suppress damage to the lead portion 23 of the coil element 20 and to suppress a decrease in the reliability of the inductor 1. Further, since the lead portion 23 can be surely disposed on the connecting portion 34, the connection reliability between the lead portion 23 and the connecting portion 34 can be enhanced.

[0108] In the above, the configuration of the protruding portion 33 has been exemplified, but the same applies to the configuration of the protruding portion 43.

[0109] The inductor 1 of Example 5 is the inductor according to any one of Examples 1 to 4, and the dimension by which the protruding portion 43 protrudes toward the top surface 19 side from the first lead-out portion 41 may be smaller than the height dimension of the cross section of the conductive wire forming the coil element 20.

[0110] According to this configuration, for example, when the lead portion 24 of the coil element 20 is disposed on the tip 43e of the protruding portion 43 and the coil element 20 is rotated to move the lead portion 24, the dropping distance of the lead portion 24 with respect to the first lead-out portion 31 becomes small, and the lead portion 24 can be smoothly moved to the connecting portion 44. Thereby, it is possible to suppress damage to the lead portion 24 of the coil element 20 and to suppress a decrease in the reliability of the inductor 1. Further, since the lead portion 24 can be surely disposed on the connecting portion 44, the connection reliability between the lead portion 24 and the connecting portion 44 can be enhanced.

[0111] [Example 6] The inductor 1 of Example 6 is the inductor according to any one of Examples 1 to 5, and further, the electrode member 30 may be located on the side opposite to the first lead-out portion 31 when viewed from the protruding portion 33, and includes a second lead-out portion 32 drawn from the end portion 35a on the top surface 19 side of the side plate portion 35 into the core 10, and a second groove portion 37 provided between the second lead-out portion 32 and the protruding portion 33 at the end portion 35a on the top surface 19 side of the side plate portion 35.

[0112] By providing the second lead-out portion 32 in this way, the electrode member 30 can be stably fixed to the magnetic core 10, so that the vibration resistance of the inductor 1 can be enhanced.

[0113] In the above, the configuration of the second lead-out portion 32 has been exemplified, but the same applies to the configuration of the protruding portion 43.

[0114] The inductor 1 of Example 6 is the inductor described in any one of Examples 1 to 5, and further, the electrode member 40 is located on the side opposite to the first lead-out portion 41 when viewed from the protruding portion 43, and a second lead-out portion 42 drawn out from the end portion 45a on the top surface 19 side of the side plate portion 45 into the magnetic core 10, and a second groove portion 47 provided between the second lead-out portion 42 and the protruding portion 43 at the end portion 45a on the top surface 19 side of the side plate portion 45.

[0115] By providing the second lead-out portion 42 in this way, the electrode member 40 can be stably fixed to the magnetic core 10, so that the vibration resistance of the inductor 1 can be enhanced.

[0116] [Example 7] The inductor 1 of Example 7 is the inductor described in Example 6, and further, the electrode member 30 has a bottom plate portion 38 extending along the bottom surface 18 from the end portion 35b on the bottom surface 18 side of the side plate portion 35. The first lead-out portion 31, the connection portion 34, and the second lead-out portion 32 are embedded in the magnetic core 10, and the outer surfaces of the side plate portion 35, the protruding portion 33, and the bottom plate portion 38 may be exposed.

[0117] By embedding the first lead-out portion 31, the connection portion 34, and the second lead-out portion 32 in the magnetic core 10 in this way, it is possible to prevent the electrode member 30 from falling out of the magnetic core 10. Further, since the outer surfaces of the side plate portion 35 and the bottom plate portion 38 are exposed, it becomes possible to mount the inductor 1 on a circuit board using the side plate portion 35 and the bottom plate portion 38.

[0118] In the above description, the configurations such as the first lead-out portion 31, the connection portion 34, and the second lead-out portion 32 have been exemplified. However, the same applies to the configurations such as the first lead-out portion 41, the connection portion 44, and the second lead-out portion 42.

[0119] The inductor 1 of Example 7 is the inductor described in Example 6. Further, the electrode member 40 has a bottom plate portion 48 that extends along the bottom surface 18 from an end portion 45b on the bottom surface 18 side of the side plate portion 45. The first lead-out portion 41, the connection portion 44, and the second lead-out portion 42 are embedded in the magnetic core 10, and the outer surfaces of the side plate portion 45, the protruding portion 43, and the bottom plate portion 48 are exposed.

[0120] By embedding the first lead-out portion 41, the connection portion 44, and the second lead-out portion 42 in the magnetic core 10 in this way, it is possible to prevent the electrode member 40 from falling out of the magnetic core 10. Further, since the outer surfaces of the side plate portion 45 and the bottom plate portion 48 are exposed, it becomes possible to mount the inductor 1 on a circuit board using the side plate portion 45 and the bottom plate portion 48.

[0121] [Example 8] The manufacturing method of the inductor 1 in Example 8 is a manufacturing method of an inductor including a coil element 20 embedded in a magnetic core 10, and electrode members 30 and 40 connected to the coil element 20. The method includes a coil element forming step of forming a coil element 20 having a winding portion 21 and lead portions 23 and 24 drawn from ends of the winding portion 21; an electrode member preliminary forming step of forming electrode members 30 and 40 having side plate portions 35 and 45 arranged along a predetermined direction, first lead-out portions 31 and 41 bent at one end 35a and 45a in the predetermined direction of the side plate portions 35 and 45, connection portions 34 and 44 drawn from the first lead-out portions 31 and 41, and protruding portions 33 and 43 protruding in the predetermined direction from one end 35a and 45a in the predetermined direction of the side plate portions 35 and 45; a connection step of connecting the lead portions 23 and 24 and the connection portions 34 and 44; and a magnetic core forming step of embedding the coil element 20, the first lead-out portions 31 and 41, and the connection portions 34 and 44 in the magnetic core 10. The connection step includes a step of arranging the lead portions 23 and 24 on the protruding portions 33 and 43; a step of rotating the lead portions 23 and 24 about the winding axis 21c of the winding portion 21 to move the lead portions 23 and 24 from above the protruding portions 33 and 43 through the first lead-out portions 31 and 41 to the connection portions 34 and 44; and a step of caulking and connecting the lead portions 23 and 24 and the connection portions 34 and 44.

[0122] According to this manufacturing method, when the lead portions 23 and 24 are rotationally moved, each of the lead portions 23 and 24 smoothly moves on the protruding portions 33 and 43 and on the first lead-out portions 31 and 41 and is arranged at the connection portions 34 and 44. Thereby, it is possible to suppress damage to the lead portions 23 and 24 and suppress a decrease in the reliability of the inductor 1. Further, since it is possible to suppress the lead portions 23 and 24 from getting caught on the respective electrode members 30 and 40, it is possible to suppress a decrease in production efficiency.

[0123] (Other embodiments, etc.) The above has described the inductor and the like according to the embodiments of the present disclosure. However, the present disclosure is not limited to the above embodiments. Without departing from the gist of the present disclosure, various modifications conceived by those skilled in the art applied to the embodiments, as well as other forms constructed by combining some of the components in the embodiments, are also included in the scope of the present disclosure.

[0124] In the above embodiment, an example is shown in which the connection part 34 connected to the first lead-out part 31 and the lead part 23 are joined, and the connection part 44 connected to the first lead-out part 41 and the lead part 24 are joined. However, it is not limited thereto. For example, when a connection part is provided not to the first lead-out part but to the second lead-out part, the connection part connected to the second lead-out part 32 and the lead part 23 may be joined, and the connection part connected to the second lead-out part 42 and the lead part 24 may be joined.

[0125] In the above embodiment, an example is shown in which the cross section of the conducting wire is circular. However, it is not limited thereto. The cross section of the conducting wire may be rectangular. The lead part may be at least partially extended in a flat plate shape in order to facilitate connection with the electrode member.

[0126] Also, for example, the electrical products or electrical circuits using the above-described inductor are also included in the present disclosure. Examples of the electrical products include a power supply device including the above-described inductor and various devices including the power supply device.

Industrial Applicability

[0127] The inductor according to the present disclosure is useful as an inductor used in various devices and equipment.

Explanation of Reference Numerals

[0128] 1 Inductor 10 Core 10c Center 10cL Line 10r Corner 13, 14 End Face 15, 16 Side Face 18 Bottom Face 18a Bottom surface recess 19 Top surface 20 Coil element 21 Winding part 21c Winding shaft 23, 24 Lead parts 30, 40 Electrode members 31, 41 First extraction part 31g, 41g Guide surface 32, 42 Second extraction part 32h, 42h Through hole 33, 43 Protrusion 33e, 43e Tip 34, 44 Connection part 34e, 44e Edge end 35, 45 Side plate part 35a, 45a End part on the top surface side 35b, 45b End part on the bottom surface side 36, 46 First groove part 37, 47 Second groove part 38, 48 Bottom plate part 38a, 48a Leg part 61 Support pillar 62 Rotating member

Claims

1. A magnetic core having a bottom surface, a top surface facing away from the bottom surface, and an end surface connecting the bottom surface and the top surface; A coil element embedded in the magnetic core; An electrode member connected to the coil element; Comprising: The coil element has a wound portion around which a conducting wire is wound and a lead portion drawn from an end of the wound portion; The electrode member: A side plate portion disposed along the end surface; A first lead-out portion drawn from an end of the side plate portion on the top surface side into the magnetic core; A connection portion connected to the lead portion inside the magnetic core and connected to the first lead-out portion; A protruding portion protruding from an end of the side plate portion on the top surface side toward the top surface; A first groove portion provided between the first lead-out portion and the protruding portion at an end of the side plate portion on the top surface side; Having: When viewed from a direction perpendicular to the end surface, the tip of the protruding portion is located on the top surface side of the first lead-out portion. An inductor.

2. When compared with the position coordinates in the direction perpendicular to the top surface, the tip of the protruding portion is located on the top surface side of the guiding surface on the top surface side of the first lead-out portion and on the bottom surface side of the edge on the top surface side of the connection portion. The inductor according to Claim 1.

3. The magnetic core is in the shape of a rectangular parallelepiped and has side surfaces connecting the bottom surface and the top surface and connected to the end surface. When viewed from a direction perpendicular to the top surface: The protruding portion is disposed at a position overlapping a line passing through the center of the magnetic core and perpendicular to the end surface. The first lead-out portion is disposed on the side surface side of the protruding portion. The lead portion and the connection portion are disposed at a corner of the magnetic core where the end surface and the side surface intersect. The inductor according to Claim 1.

4. The dimension of the groove width of the first groove portion is smaller than the width dimension of the cross-section of the conducting wire forming the coil element. The inductor according to Claim 1.

5. The dimension by which the protruding portion protrudes on the top surface side of the first lead-out portion is smaller than the height dimension of the cross-section of the conducting wire forming the coil element. The inductor according to Claim 1.

6. Furthermore, the electrode member: A second lead-out portion located on the side opposite to the first lead-out portion when viewed from the protruding portion and drawn from an end of the side plate portion on the top surface side into the magnetic core; A second groove portion provided between the second lead-out portion and the protruding portion at an end of the side plate portion on the top surface side; Comprising: The inductor according to any one of Claims 1 to 5.

7. Furthermore, the electrode member has a bottom plate portion extending along the bottom surface from an end portion on the bottom surface side of the side plate portion, the first lead-out portion, the connection portion, and the second lead-out portion are embedded in the magnetic core, outer surfaces of the side plate portion, the protruding portion, and the bottom plate portion are exposed The inductor according to claim 6.

8. A method for manufacturing an inductor including a coil element embedded in a magnetic core and an electrode member connected to the coil element, a coil element forming step of forming the coil element having a winding portion and a lead portion drawn from an end portion of the winding portion, an electrode member preliminary forming step of forming an electrode member having a side plate portion arranged along a predetermined direction, a first lead-out portion bent at one end portion of the side plate portion in the predetermined direction, a connection portion drawn from the first lead-out portion, and a protruding portion protruding in the predetermined direction from one end portion of the side plate portion in the predetermined direction, a connection step of connecting the lead portion and the connection portion, a magnetic core forming step of embedding the coil element, the first lead-out portion, and the connection portion in the magnetic core, including the connection step includes a step of arranging the lead portion on the protruding portion, a step of moving the lead portion from the protruding portion, through the first lead-out portion, to the connection portion by rotating the lead portion about the winding axis of the winding portion, a step of caulking and connecting the lead portion and the connection portion, including A method for manufacturing an inductor.

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