Magnetic components and electrical devices

Abstract

This magnetic component is configured to be used with a coil wound around a central axis extending in an axial direction. The magnetic component has first to third magnetic bodies. The first magnetic body is configured to pass a magnetic flux generated by the coil, extends in the axial direction, has ends along the axial direction, and, when viewed in a direction perpendicular to the axial direction, includes a portion overlapping the coil. The second magnetic body is disposed on the opposite side of the coil with respect to one of the ends of the first magnetic body in the axial direction. The third magnetic body is disposed on the opposite side of the coil with respect to the second magnetic body in the axial direction. The third magnetic body has a magnetic anisotropy greater than that of either the first magnetic body or the second magnetic body, and has an easy direction of magnetization, which is a direction easily magnetized compared to other directions. The easy direction of magnetization of the third magnetic body is perpendicular to the axial direction. With the magnetic component, it is possible to reduce magnetic loss.

Description

[Technical field]

[0001] The present disclosure relates to magnetic components for use with coils and electrical devices including magnetic components. [Background technology]

[0002] Patent Document 1 discloses a coil component, such as a laminated inductor, that includes a coil, an isotropic magnetic material layer, an anisotropic magnetic material layer, and a core portion.

[0003] The isotropic magnetic material layer is provided on at least one of the upper and lower surfaces of the coil. The anisotropic magnetic material layer is laminated on the surface of the isotropic magnetic material layer opposite the coil. The anisotropic magnetic material layer is made of a first anisotropic magnetic material having an easy magnetization direction perpendicular to the lamination direction of the isotropic magnetic material layer and the anisotropic magnetic material layer. The core portion is provided inside the coil. The core portion is made of a second anisotropic magnetic material having an easy magnetization direction parallel to the lamination direction of the isotropic magnetic material layer and the anisotropic magnetic material layer. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2018-125527 A Summary of the Invention

[0005] The magnetic component is configured to be used with a coil wound around a central axis extending in the axial direction. The magnetic component includes first to 5 The first magnetic body is configured to pass magnetic flux generated by the coil, extends in the axial direction, has both ends along the axial direction, and The first magnetic body has a portion that overlaps with the coil when viewed in a direction perpendicular to the axial direction. The second magnetic body is disposed on the opposite side of the coil in the axial direction with one of the ends of the first magnetic body as a reference. The third magnetic body is disposed on the opposite side of the coil in the axial direction with the second magnetic body as a reference.The fourth magnetic body is disposed on the opposite side of the coil in the axial direction with respect to the other of the two ends of the first magnetic body. The fifth magnetic body is disposed on the opposite side of the coil in the axial direction with respect to the fourth magnetic body. The coil is wound so as to surround an internal space through which the central axis passes. The first magnetic body has a first portion that extends in the axial direction, passes through the internal space of the coil and is connected to the second magnetic body and the fourth magnetic body, and a second portion that extends in the axial direction, passes through the space outside the coil and is connected to the second magnetic body and the fourth magnetic body. The third magnetic body has a larger magnetic anisotropy than both the first magnetic body and the second magnetic body, and has an easy magnetization direction in which the third magnetic body is more easily magnetized than other directions. The easy magnetization direction of the third magnetic body is perpendicular to the axial direction. The fifth magnetic body has a larger magnetic anisotropy than the first magnetic body, the second magnetic body, and the fourth magnetic body, and has an easy magnetization direction in which the fifth magnetic body is more easily magnetized than other directions. The easy magnetization direction of the fifth magnetic body is perpendicular to the axial direction. The dimension of the second magnetic body in the axial direction is 30 to 60% of the sum of the dimension of the second magnetic body in the axial direction and the dimension of the third magnetic body in the axial direction. The dimension of the first magnetic body in the axial direction is 50 to 100% of the sum of the dimension of the second magnetic body in the axial direction and the dimension of the third magnetic body in the axial direction.

[0006] This magnetic component can reduce magnetic loss. [Brief description of the drawings]

[0007] [Figure 1A] FIG. 1A is a perspective view of an electrical device according to an embodiment. [Figure 1B] FIG. 1B is a cross-sectional view of the electrical device shown in FIG. 1A taken along line IB-IB. [Diagram 2] FIG. 2 is a diagram illustrating magnetic flux generated in the electric device according to the embodiment. [Diagram 3] FIG. 3 is a diagram illustrating a method for manufacturing an electric device according to an embodiment. [Figure 4] FIG. 4 is a diagram for explaining materials used in the method for manufacturing an electric device according to the embodiment. [Diagram 5] FIG. 5 is a diagram for explaining materials used in the method for manufacturing an electric device according to the embodiment. [Figure 6A] FIG. 6A is a diagram showing a simulation result of the intensity distribution of magnetic flux density in a magnetic component in an electric device of a comparative example. [Figure 6B] FIG. 6B is a diagram showing a simulation result of the intensity distribution of magnetic flux density in a magnetic component in an electric device of a comparative example. [Figure 7] FIG. 7 is a flow chart of a method for manufacturing an electrical device according to an embodiment. [Figure 8] FIG. 8 is a flow chart of another method for manufacturing an electrical device according to an embodiment. [Figure 9] FIG. 9 is a diagram showing a simulation result of the intensity distribution of magnetic flux density in a magnetic component of an electric device according to an embodiment. [Figure 10] FIG. 10 is a diagram showing a simulation result of the intensity distribution of magnetic flux density in a magnetic component of an electric device according to an embodiment. [Figure 11] FIG. 11 is a diagram showing a simulation result of the intensity distribution of magnetic flux density in a magnetic component of an electric device according to an embodiment. [Figure 12] FIG. 12 is a diagram showing a simulation result of the intensity distribution of magnetic flux density in a magnetic component of an electric device according to an embodiment. [Figure 13] FIG. 13 is a diagram showing a simulation result of the intensity distribution of magnetic flux density in a magnetic component of an electric device according to an embodiment. [Figure 14] FIG. 14 is a diagram showing a simulation result of the intensity distribution of magnetic flux density in a magnetic component of an electric device according to an embodiment. [Figure 15] FIG. 15 is a diagram showing a simulation result of the intensity distribution of magnetic flux density in a magnetic component of an electric device according to an embodiment. [Figure 16] FIG. 16 is a diagram showing a simulation result of the intensity distribution of magnetic flux density in a magnetic component of an electric device according to an embodiment. [Figure 17] FIG. 17 is a flow chart of yet another method for manufacturing an electrical device according to an embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] Hereinafter, magnetic components and electric devices according to embodiments will be described with reference to the accompanying drawings. However, the following embodiment is merely one of various embodiments of the present disclosure. The following embodiment can be modified in various ways depending on the design, etc., as long as the object of the present disclosure can be achieved. In addition, each figure described in the following embodiment is a schematic diagram, and the size and thickness ratios of each component in the figure do not necessarily reflect the actual dimensional ratios.

[0009] (1) Overview Fig. 1A is a perspective view of an electric device 100 according to an embodiment. Fig. 1B is a cross-sectional view of the electric device 100 taken along line IB-IB shown in Fig. 1A. The electric device 100 includes a magnetic component 1 and a coil 2.

[0010] Fig. 2 shows magnetic flux generated in electric device 100. Fig. 3 is a diagram for explaining a manufacturing method of electric device 100. Coil 2 has a winding 20 wound around an imaginary central axis A1 extending in axial direction X1. Coil 2 is wound so as to surround internal space 21 through which central axis A1 passes.

[0011] The magnetic component 1 includes a magnetic body 11, a magnetic body 12 (121, 122), and a magnetic body 13 (131, 132). All of the magnetic bodies 11 to 13 are made of a magnetic material.

[0012] The magnetic body 11 is disposed in the same layer as the coil 2 in the axial direction X1. That is, the magnetic body 11 has a portion that overlaps with the coil 2 when viewed in a direction perpendicular to the axial direction X1. The magnetic body 11 has a portion 111 that passes through the internal space 21 surrounded by the coil 2, and a portion 112 that is located outside the coil 2. Both the portions 111 and 112 of the magnetic body 11 have portions that overlap with the coil 2 when viewed in a direction perpendicular to the axial direction X1.

[0013] The magnetic body 12 is disposed outside the coil 2 and outside the magnetic body 11 in the axial direction X1. The magnetic body 12 covers the outer surface of the coil 2 in the axial direction X1, i.e., the surface of the coil 2 that intersects with the axial direction X1.

[0014] The magnetic body 13 is disposed outside the magnetic body 12 in the axial direction X1. The magnetic body 13 covers the outer surface of the magnetic body 12 in the axial direction X1, i.e., the surface of the magnetic body 12 farther from the coil 2. The magnetic body 12 is disposed between the coil 2 and the magnetic body 13 in the axial direction X1. The magnetic body 12 is also disposed between the magnetic body 11 and the magnetic body 13 in the axial direction X1.

[0015] The magnetic body 13 has a larger magnetic anisotropy than both the magnetic body 11 and the magnetic body 12. A magnetic body having magnetic anisotropy has a magnetic permeability that changes depending on the direction of the magnetic flux passing through it. For example, the magnitude of the magnetic anisotropy is expressed as the ratio of the maximum value of the magnetic permeability values ​​for the magnetic flux in all directions passing through the magnetic body to the minimum value, and in this case, the larger the ratio, the larger the magnetic anisotropy. The magnetic body 13 has an easy magnetization direction in which it is more easily magnetized than other directions. The magnetic bodies 11 and 12 may also have an easy magnetization direction in which it is more easily magnetized than other directions. In other words, the magnetic body 13 has a more pronounced direction of the easy magnetization axis than both the magnetic bodies 11 and 12.

[0016] In the magnetic component 1, the direction of easy magnetization of the magnetic body 13 is perpendicular to the axial direction X1.

[0017] In the magnetic component 1 and the electric device 100 of the present embodiment, the magnetic flux B1 generated by the current flowing through the coil 2 passes from the portion 111 of the magnetic body 11 at the center, through the upper magnetic body 12 (121), the upper magnetic body 13 (131), the upper magnetic body 12, the portion 112 of the outer magnetic body 11, the lower magnetic body 12 (122), the lower magnetic body 13 (132), the lower magnetic body 12 (122), and the portion 111 of the magnetic body 11 at the center, as shown in FIG. 2. The magnetic flux B1 is directed in a direction substantially perpendicular to the axial direction X1 in the magnetic body 13. As described above, the magnetization easy direction of the magnetic body 13 is perpendicular to the axial direction X1. Therefore, the direction of the magnetic flux B1 generated by the current flowing through the coil 2 is the magnetization easy direction in the magnetic body 13. This improves the effective permeability of the magnetic body 13, and improves the inductance of the magnetic component 1.

[0018] Moreover, the magnetic anisotropy of the magnetic body 11 and the magnetic anisotropy of the magnetic body 12 are smaller than the magnetic anisotropy of the magnetic body 13. Therefore, the magnetic flux B1 generated by the current flowing through the coil 2 is not easily affected by the magnetization easy direction of the magnetic body in the magnetic body 11 and the magnetic body 12. Therefore, in the magnetic component 1, for example, near the boundary between the magnetic body 11 and the magnetic body 12, an event in which the direction of the magnetic flux B1 is suddenly changed by the magnetization easy direction of the magnetic body is unlikely to occur. Therefore, in the magnetic component 1, the magnetic flux density is easily made uniform in the magnetic body 11. As a result, it is possible to reduce the magnetic loss of the magnetic component 1.

[0019] (2)Details The magnetic component 1 and the electric device 100 of this embodiment will be described in more detail below with reference to the drawings. The electric device 100 of this embodiment is a so-called inductor 200 including a core 10 as the magnetic component 1 and a coil 2.

[0020] (2.1) Configuration of Electrical Device 100 The inductor 200 as the electric device 100 includes a coil 2 and a core 10. Here, the inductor 200 is a metal composite type inductor in which the coil 2 is integrally molded with the core 10 containing metal magnetic powder. In other words, the core 10 (magnetic component 1) is an integrally molded product in which the coil 2 is integrally molded with the core 10 so as to incorporate the coil 2. In short, the inductor 200 includes a gapless core 10. As shown in FIG. 1B, in the inductor 200, there is no gap between the coil 2 and the core 10.

[0021] As shown in FIG. 3, the coil 2 is composed of a winding 20 wound around a virtual central axis A1 and having a rectangular cross section. The winding 20 is, for example, a flat conductor with an insulating coating. The coil 2 is provided at one end and the other end of the winding 20, and includes an electrode 201 and an electrode 202 configured to be electrically connected to an external power source. The material of the conductor is, for example, copper. The winding 20 is wound around the central axis A1 in a spiral shape so that the diameter gradually decreases from the electrode 201 in the same plane to form a first layer, and the minimum diameter part of the first layer is shifted in the axial direction X1, which is the thickness direction, to form a step shape, and is wound in a spiral shape so that the diameter gradually increases in another plane to form a second layer, which is connected to the electrode 202. That is, the coil 2 is equipped with a spiral-shaped winding 20. The winding 20 is spiral-shaped, so that the height of the electric device 100 (inductor 200) equipped with the coil 2 can be reduced.

[0022] Furthermore, the coil 2 has a space 21 at its center where the winding 20 is not present and through which the central axis A1 passes.

[0023] Electrodes 201 and 202 are connected to an external power supply, and a voltage is applied between electrodes 201 and 202 from the external power supply, causing a current to flow through coil 2. When a current flows through coil 2, a magnetic field is generated around coil 2.

[0024] As shown in FIG. 1B, the core 10 includes a magnetic body 11, a magnetic body 12 (121, 122), and a magnetic body 13 (131, 132).

[0025] As described above, the magnetic body 11 is arranged in the same layer as the coil 2 in the axial direction X1. In this case, the magnetic body 11 is arranged in the same plane as the coil 2 when viewed from a direction perpendicular to the axial direction X1. Here, the magnetic body 11 includes a portion 111 arranged inside the coil 2 in a direction perpendicular to the axial direction X1. The winding 20 of the coil 2 is wound around the portion 111 in the magnetic body 11. The magnetic body 11 further includes a portion 112 arranged outside the coil 2 in a direction perpendicular to the axial direction X1. The portion 112 is located outside the winding 20 of the coil 2 when viewed from the axial direction X1 in the magnetic body 11. The portion 112 has, for example, a prism shape. The magnetic body 11 extends in the axial direction X1 and has opposite ends 11A and 11B in the axial direction X1. The portion 111 of the magnetic body 11 extends in the axial direction X1 and has opposite ends 111A and 111B in the axial direction X1. The portion 112 of the magnetic body 11 extends in the axial direction X1 and has opposite ends 112A and 112B in the axial direction X1. The ends 111A and 112A of the portions 111 and 112 of the magnetic body 11 constitute the end 11A of the magnetic body 11. The ends 111B and 112B of the portions 111 and 112 of the magnetic body 11 constitute the end 11B of the magnetic body 11.

[0026] The magnetic body 11 has a thickness dimension D1 along the axial direction X1.

[0027] As described above, the magnetic bodies 12 (121, 122) are disposed outside the coil 2 and outside the magnetic body 11 in the axial direction X1. The magnetic body 12 is in a different layer from the magnetic body 11 in the axial direction X1. The magnetic body 121 covers the outer surface of the coil 2 (upper surface in FIG. 1B) and the outer surface of the magnetic body 11 on one side (upper side in FIG. 1B) in the axial direction X1. The magnetic body 122 covers the outer surface of the coil 2 (lower surface in FIG. 1B) and the outer surface of the magnetic body 11 on the other side (lower side in FIG. 1B) in the axial direction X1. That is, the magnetic body 12 covers both outer sides of the coil 2 in the axial direction X1. The magnetic body 121 is directly connected to the end 11A of the magnetic body 11, i.e., the ends 111A and 112A of the parts 111 and 112 of the magnetic body 11, and the magnetic body 122 is directly connected to the end 11B of the magnetic body 11, i.e., the ends 111B and 112B of the parts 111 and 112 of the magnetic body 11.

[0028] The magnetic body 12 has a thickness dimension D2 along the axial direction X1. The magnetic bodies 121 and 122 have the same thickness dimension D2.

[0029] As described above, the magnetic body 13 (131, 132) is disposed outside the magnetic body 12 in the axial direction X1. The magnetic body 13 is in a layer different from the magnetic body 11 and the magnetic body 12 in the axial direction X1. The magnetic body 131 covers the outer surface (upper surface in FIG. 1B) of the magnetic body 12 (part 121) on one side (upper side in FIG. 1B) in the axial direction X1. The magnetic body 132 covers the outer surface (lower surface in FIG. 1B) of the magnetic body 12 (122) on the other side (lower side in FIG. 1B) in the axial direction X1. The magnetic body 13 constitutes the outermost layer of the magnetic component 1 in the axial direction X1. The magnetic body 131 is directly connected to the magnetic body 121, and the magnetic body 132 is directly connected to the magnetic body 122.

[0030] The magnetic body 13 has a thickness dimension D3 along the axial direction X1. The magnetic bodies 131 and 132 have the same thickness dimension D3.

[0031] The magnetic bodies 11 to 13 have substantially the same shape as each other on the outer periphery as viewed in the axial direction X1.

[0032] The magnetic body 11 is made of an isotropic magnetic material. The magnetic body 12 is made of an isotropic magnetic material. In the embodiment, the magnetic bodies 11 and 12 are made of the same material (isotropic magnetic material).

[0033] Fig. 4 is a schematic cross-sectional view of the isotropic magnetic material forming the magnetic bodies 11 and 12. The isotropic magnetic material is a composite material containing spherical metal magnetic powder 31 and resin 32. The composite material containing the metal magnetic powder 31 and resin 32 is molded into, for example, a sheet shape so that the metal magnetic powder 31 is distributed approximately evenly within the resin 32, thereby forming an isotropic magnetic body sheet 30. In the isotropic magnetic body sheet 30 shown in Fig. 4, the spherical metal magnetic powder 31 is evenly distributed, and isotropic magnetic permeability is obtained.

[0034] On the other hand, the magnetic body 13 is made of an anisotropic magnetic material.

[0035] FIG. 5 is a schematic cross-sectional view of an anisotropic magnetic material forming the magnetic body 13. The anisotropic magnetic material is a composite material containing flat metal magnetic powder 41 and resin 42. The metal magnetic powder 41 has a metal foil shape having surfaces 41A and 41B opposite to each other in the direction DX and an end surface 41C connected to the outer periphery of the surfaces 41A and 41B. The thickness of the metal magnetic powder 41 in the direction DX is, for example, about 1 μm, and the aspect ratio, which is the ratio of the width in the direction DM perpendicular to the direction DX to the thickness in the direction DX, is 20 or more. The composite material containing the metal magnetic powder 41 and the resin 42 is oriented so that the directions of the surfaces 41A and 41B of the metal magnetic powder 41 are aligned with each other in the direction DX, and the composite material is formed into a sheet shape to form an anisotropic magnetic material sheet 40. The anisotropic magnetic material sheet 40 has a large magnetic anisotropy, and the easy magnetization direction is along a plane extending in the direction DM and perpendicular to the direction DX.

[0036] The inductor 200 can be manufactured, for example, by stacking and pressure-molding the above-mentioned coil 2, the isotropic magnetic sheet 30, and the anisotropic magnetic sheet 40. The manufacturing method of the inductor 200 will be described later.

[0037] The inductor 200 may include a housing that houses the core 10 and the coil 2. The electrodes 201 and 202 are held in the housing so as to be exposed, for example, to the outer surface of the housing.

[0038] The advantages of the magnetic component 1 (core 10) including the magnetic bodies 11 to 13 will be described below.

[0039] Fig. 6A shows a simulation result of the magnetic flux density intensity distribution in the core 10 of the inductor 200 of this embodiment. Fig. 6B shows a simulation result of the magnetic flux density intensity distribution in the core 310 of the inductor 300 of the comparative example. In Figs. 6A and 6B, the magnitude of the magnetic flux density is shown in gray scale so that the higher the magnetic flux density, the closer to white it becomes. The blackest parts in Figs. 6A and 6B represent the coil 2.

[0040] As described above, in the inductor 200 of this embodiment, the magnetic bodies 11 and 12 are made of an isotropic magnetic material, and the magnetic body 13 is made of an anisotropic magnetic material.

[0041] In the simulation of Fig. 6A, the relative permeability of the magnetic body 11 and the magnetic body 12 is 30. The relative permeability in the axial direction X1, which is the thickness direction of the magnetic body 13, is 2, and the relative permeability in the length direction of the magnetic body 13, i.e., the direction perpendicular to the axial direction X1, is 200. In the simulation shown in Fig. 6A, the ratio of the thickness dimension D2 of the magnetic body 12 to the total dimension of the thickness dimension D2 of the magnetic body 12 and the thickness dimension D3 of the magnetic body 13 is 0.4.

[0042] The inductor 300 of the comparative example includes a coil 302 and magnetic bodies 311, 312, and 313 having the same geometric structures as the coil 2 and magnetic bodies 11, 12, and 13 of the inductor 200 of the embodiment. In the inductor 300 of the comparative example, the coil 302 and the magnetic bodies 312 and 313 are the same as the coil 2 and the magnetic bodies 12 and 13 of the inductor 200 of the embodiment, including the materials. However, in the inductor 300 of the comparative example, the magnetic body 311 is made of an anisotropic magnetic material, and its easy magnetization direction is along the axial direction X1.

[0043] In the simulation shown in FIG. 6B, the relative permeability of the magnetic body 312 is 30, the value of the relative permeability in the axial direction X1, which is the thickness direction of the magnetic body 313, is 2, and the value of the relative permeability in the length direction of the magnetic body 313, i.e., in the direction perpendicular to the axial direction X1, is 200. In the simulation shown in FIG. 6B, the relative permeability in the axial direction X1, which is the thickness direction of the magnetic body 311, is 200, and the relative permeability in the length direction of the magnetic body 311, i.e., in the direction perpendicular to the axial direction X1, is 2. In the simulation shown in FIG. 6B, as in FIG. 6A, the ratio of the thickness dimension D2 of the magnetic body 312 to the total dimension of the thickness dimension D2 of the magnetic body 312 and the thickness dimension D3 of the magnetic body 313 is 0.4.

[0044] 6B, in the inductor 300 of the comparative example, in a region R10 in the center of the magnetic body 311, the boundary between a portion with a relatively high magnetic flux density intensity and a portion with a relatively low magnetic flux density intensity extends substantially along the axial direction X1. On the other hand, in the inductor 200 of the present embodiment, in a region R1 of the portion 111 of the magnetic body 11, the portion with a relatively high magnetic flux density intensity extends to near the center of the region R1. Also, in the inductor 200 of the present embodiment, in a region R2 in the magnetic body 13 near the boundary with the magnetic body 12, the area of ​​the portion with the highest magnetic flux density intensity (the brightest portion) is smaller than that of the inductor 300 of the comparative example.

[0045] 6A and 6B, in the inductor 300 of the comparative example, the region with high magnetic flux density is concentrated in a portion closer to the coil 2 in the core 10 than in the inductor 200 of the present embodiment. In other words, in the inductor 200 of the present embodiment, the magnitude of the magnetic flux density in the core is more uniform than in the inductor 300 of the comparative example. Since the magnetic loss of an inductor tends to increase depending on the magnetic flux density in the core, the magnetic loss is reduced by uniforming the magnetic flux density. Therefore, the inductor 200 of the present embodiment can reduce the magnetic loss compared to the inductor 300 of the comparative example.

[0046] The inductor 200 of the embodiment further satisfies the following first and second conditions.

[0047] The first condition is that the dimension D2 of the magnetic body 12 is 30% to 65% of the total dimension of the dimension D2 of the magnetic body 12 and the dimension D3 of the magnetic body 13 in the axial direction X1.

[0048] In short, the first condition is expressed by the following (Equation 1).

[0049] 0.3≦D2 / (D2+D3)≦0.65 (Formula 1) The second condition is that in the axial direction X1, the dimension D1 of the magnetic body 11 is 50% to 100% of the sum of the dimension D2 of the magnetic body 12 (e.g., the magnetic body 121) located on one side of the coil 2 in the axial direction X1 and the dimension D3 of the magnetic body 13 (e.g., the magnetic body 131).

[0050] In short, the second condition is expressed by the following (Equation 2).

[0051] 0.5≦D1 / (D2+D3)≦1 (Formula 2) Although details will be described later, by satisfying the above (Formula 1) and (Formula 2), it is possible to improve the inductance of inductor 200 while reducing magnetic loss.

[0052] (2.2) Manufacturing method Next, a method for manufacturing the inductor 200 of this embodiment will be described with reference to Figures 3 and 7. In the following, the inductor 200 is manufactured by a sheet molding method.

[0053] FIG. 7 is a flow chart showing the steps of a sheet molding method, which is a manufacturing method for the inductor 200 of this embodiment. The sheet molding method includes a granulation step ST11, a molding step ST12, and a hardening step ST13.

[0054] In the granulation step ST11, an isotropic magnetic material that will be the base of the magnetic bodies 11 and 12 that constitute the core 10, and an anisotropic magnetic material that will be the base of the magnetic body 13 are prepared.

[0055] As described above, the raw materials of the isotropic magnetic material and the anisotropic magnetic material include the metal magnetic powder 31, 41 and the resin 32, 42. The material of the metal magnetic powder 31, 41 is not particularly limited, but is selected from magnetic metals such as Fe-Si-Al alloys, Fe-Si alloys, Fe-Si-Cr alloys, Fe-Ni alloys, amorphous alloys, nanocrystalline alloys, etc. The resins 32, 42 are, for example, thermosetting resins. The material of the resins 32, 42 is not particularly limited, but is selected from, for example, epoxy resins, phenolic resins, silicone resins, etc.

[0056] The raw materials of the isotropic magnetic material and the anisotropic magnetic material may optionally contain at least one of an inorganic insulating material and an additive. The inorganic insulating material is in powder form, and suppresses an increase in eddy current loss while reducing the contact probability between the metal magnetic powders 31 and 41, for example. In other words, the metal magnetic powders 31 and 41 are insulated from each other by the inorganic insulating material being present between them, so that the size of the conductor through which eddy current can flow can be suppressed. The material of the inorganic insulating material is not particularly limited, but is selected from, for example, boron nitride, talc, mica, zinc oxide, titanium oxide, silicon oxide, aluminum oxide, iron oxide, barium sulfate, and the like. The additive improves the dispersibility of the metal magnetic powders 31 and 41, and modifies the surface of the metal magnetic powders 31 and 41, for example. The additive is not particularly limited, but is selected from, for example, a silane coupling agent, a titanium-based coupling agent, a titanium alkoxide, a titanium chelate, and the like.

[0057] In the granulation step ST11, the metal magnetic powder 31 and the inorganic insulating material are mixed and dispersed in each other to prepare a mixed powder (kneading and dispersion). Then, the obtained mixed powder is mixed with the resin 32 and additives and kneaded to prepare a paste-like granulated powder (pasting). Similarly, the metal magnetic powder 41 and the inorganic insulating material are mixed and dispersed in each other to prepare a mixed powder, and the obtained mixed powder is mixed with the resin 42 and additives and kneaded to prepare a paste-like granulated powder.

[0058] The apparatus and method used in the granulation step ST11 are not particularly limited. For example, various ball mills such as a rotary ball mill and a planetary ball mill, or a V blender, a planetary mixer, etc. can be used. In the granulation step ST11, an organic solvent such as toluene or ethanol can be mixed as appropriate. It is also possible to add the resin 32 and additives at the same time when the metal magnetic powder 31 and the inorganic insulator are mixed and dispersed, and it is also possible to add the resin 42 and additives at the same time when the metal magnetic powder 41 and the inorganic insulator are mixed and dispersed.

[0059] In the molding step ST12, the obtained granulated powder is molded into a sheet shape to form the isotropic magnetic material sheet 30 and the anisotropic magnetic material sheet 40 (sheet molding). The apparatus and method used in the molding step ST12 are not particularly limited. For example, a doctor blade type sheet molding machine, an extrusion molding machine, etc. can be used. The isotropic magnetic material sheet 30 and the anisotropic magnetic material sheet 40 may be formed by cutting a sheet-like molded body obtained by molding the granulated powder into a certain dimensional shape as necessary.

[0060] As described above, the isotropic magnetic sheet 30 provides isotropic magnetic permeability. On the other hand, the anisotropic magnetic sheet 40 has an easy magnetization direction along the surface of the anisotropic magnetic sheet 40, i.e., along the direction DM perpendicular to the thickness direction DX (see FIG. 5).

[0061] In the molding step ST12, as shown in Fig. 3, the anisotropic magnetic material sheet 40, the isotropic magnetic material sheet 30, the coil 2, the isotropic magnetic material sheet 30, and the anisotropic magnetic material sheet 40 are stacked in this order from below, and pressure-molded to obtain a coil-embedded compact. The device and method used for this pressure molding are not particularly limited, and a normal pressure molding method can be used.

[0062] In this pressure molding, the central portions of the isotropic magnetic material sheet 30 located on both the upper and lower sides of the coil 2 enter the internal space 21 at the center of the coil 2, and the peripheral portions of the isotropic magnetic material sheet 30 enter the space outside the coil 2. The portion of the isotropic magnetic material sheet 30 that enters the internal space 21 becomes the portion 111 of the magnetic material 11, and the portion of the isotropic magnetic material sheet 30 that enters the space outside the coil 2 becomes the portion 112 of the magnetic material 11. When manufacturing the isotropic magnetic material sheet 30, the isotropic magnetic material sheet 30 may be formed to have a shape having protrusions corresponding to at least a part of the portion 111 and / or the portion 112 of the magnetic material 11.

[0063] Of the isotropic magnetic material sheet 30, the portions located outside (above and below) the coil 2 in the axial direction X1 become the magnetic materials 12 in the magnetic component 1.

[0064] The anisotropic magnetic material sheet 40 serves as the magnetic material 13 in the magnetic component 1 .

[0065] In the curing process ST13, the pressure-molded body is heated at a temperature in the range of, for example, 150°C or higher and 250°C or lower to cure the resins 32, 42 (thermosetting resins) contained in the isotropic magnetic sheet 30 and the anisotropic magnetic sheet 40 (resin curing).

[0066] By such a sheet molding method, the inductor 200 shown in Figures 1A and 1B can be manufactured.

[0067] The method for manufacturing the inductor 200 is not limited to the sheet molding method. Fig. 8 is a flow chart showing steps of a powder molding method, which is another method for manufacturing the inductor 200 of this embodiment.

[0068] As shown in FIG. 8, the powder molding method includes a granulating step ST21, a molding step ST22, and a hardening step ST23.

[0069] In the granulation step ST21, an isotropic magnetic material that serves as the base of the magnetic bodies 11 and 12 that constitute the core 10 and an anisotropic magnetic material that serves as the base of the magnetic body 13 are prepared. As the raw materials for the isotropic magnetic material and the anisotropic magnetic material, the same materials as those described in the sheet molding method can be used.

[0070] In the granulation step ST21, the metal magnetic powder 31 and the inorganic insulating material are mixed and dispersed with each other to prepare a mixed powder (kneading and dispersion). Then, the obtained mixed powder is mixed with the resin 32 and additives to prepare a granulated powder (hereinafter also referred to as "isotropic magnetic powder") (granulation). Also, the metal magnetic powder 41 and the inorganic insulating material are mixed and dispersed with each other to prepare a mixed powder, and the obtained mixed powder is mixed with the resin 42 and additives to adjust the granulated powder (hereinafter also referred to as "anisotropic magnetic powder"). In order to improve the moldability by increasing the fluidity of the granulated powder and reliably filling it into the mold, it is preferable to classify the obtained granulated powder to make the particle size uniform (classification). Note that in the granulation step ST21, unlike the granulation step ST11, the granulated powder is not made into a paste form.

[0071] In the molding step ST22, the granulated powder and coil 2 are arranged in a mold so that the isotropic magnetic powder is located inside and around the coil 2, and are pressure molded. Thereafter, anisotropic magnetic bodies made of anisotropic magnetic powder are arranged on both sides (upper and lower) of the isotropic magnetic body made of isotropic magnetic powder in the axial direction X1 of the coil 2, and pressure molded to obtain a molded body (coil-embedded integral molding). The apparatus and method used for this pressure molding are not particularly limited, and a normal pressure molding method can be used.

[0072] In the curing step ST23, the pressure-molded body is heated to cure the resins 32, 42 (thermosetting resins) contained in the isotropic magnetic powder and the anisotropic magnetic powder (resin curing).

[0073] The inductor 200 shown in FIGS. 1A and 1B can also be manufactured by such a powder molding method.

[0074] The core 10 of the inductor 200 manufactured by the above-mentioned sheet molding method and powder molding method includes magnetic bodies 11 and 12 made of an isotropic magnetic material and a magnetic body 13 made of an anisotropic magnetic material. This makes it possible to reduce magnetic loss in the magnetic component 1. In addition, the core 10 of the inductor 200 manufactured by the sheet molding method and powder molding method can have a gapless structure in which there is no gap within the core 10 or between the core 10 and the coil 2.

[0075] (2.3) Thickness of magnetic material As a result of intensive research, the inventors of the present application have found a preferable relationship among the thickness dimension D1 of the magnetic body 11, the thickness dimension D2 of the magnetic body 12, and the thickness dimension D3 of the magnetic body 13, for reducing magnetic loss while improving the inductance of the magnetic component 1. Hereinafter, the relationship among the thickness dimension D1 of the magnetic body 11, the thickness dimension D2 of the magnetic body 12, and the thickness dimension D3 of the magnetic body 13 will be described.

[0076] First, the inventors of the present application investigated the preferable value of the ratio P1 (=D2 / (D2+D3)) of the thickness of the isotropic magnetic material (magnetic body 12) to the total thickness of the magnetic bodies (magnetic bodies 12 and 13) located outside coil 2 (above and below coil 2).

[0077] For this study, the inventors of the present application performed a simulation of the intensity distribution of the magnetic flux density in the core 10 while changing the value of the ratio P1 in various ways. In this simulation, as in the case of Fig. 6A, the values ​​of the relative permeability of the magnetic bodies 11 and 12 were set to 30, the value of the relative permeability in the axial direction X1, which is the thickness direction of the magnetic body 13, was set to 2, and the value of the relative permeability in the length direction of the magnetic body 13, i.e., the direction perpendicular to the axial direction X1, was set to 200. In addition, the ratio of the thickness dimension D1 of the magnetic body 11 to the sum of the thickness dimension D2 of the magnetic body 12 and the thickness dimension D3 of the magnetic body 13 was set to 0.9 (D1 / (D2+D3)=0.9).

[0078] Figures 9 and 10 show the simulation results. In Figures 9 and 10, as in Figure 6A, the magnitude of the magnetic flux density is shown in gray scale so that the greater the magnetic flux density, the closer it is to white. Also, the blackest part in Figures 9 and 10 represents coil 2.

[0079] Fig. 9(a) shows the simulation result when ratio P1 = 0, Fig. 9(b) shows the simulation result when ratio P1 = 0.2, Fig. 9(c) shows the simulation result when ratio P1 = 0.3, and Fig. 9(d) shows the simulation result when ratio P1 = 0.6. Fig. 10(a) shows the simulation result when ratio P1 = 0.65, Fig. 10(b) shows the simulation result when ratio P1 = 0.7, Fig. 10(c) shows the simulation result when ratio P1 = 0.75, and Fig. 10(d) shows the simulation result when ratio P1 = 0.8. Fig. 6A corresponds to the result when ratio P1 = 0.4.

[0080] As shown in Figures 9(a) to 9(c), as the ratio P1 increases from 0 to 0.3, the magnetic flux density intensity distribution in the portion 111 of the magnetic body 11 gradually becomes more uniform. Also, as shown in Figures 9(c), 6A, 9(d), and 10(a), when the ratio P1 is in the range of 0.3 to 0.65, the magnetic flux density intensity distribution in the portion 111 of the magnetic body 11 is kept uniform. Also, as shown in Figure 10, as the ratio P1 increases from 0.65 to 0.8, the uniformity of the magnetic flux density intensity distribution in the portion 111 of the magnetic body 11 gradually decreases.

[0081] The strength of the magnetic flux density in the portion of magnetic body 13 near the boundary with magnetic body 12 (especially near the center) is very strong when ratio P1 is 0 (when magnetic body 12 is not present) and when ratio P1 is 0.7 or greater.

[0082] Table 1 shows the inductance of the inductor 200 when the ratio P1 is changed in various ways. In Table 1, the inductance is a standardized value with the value of an inductor with a ratio P1 of 0 set to 100. In other words, the inductance is a value expressed as a percentage relative to the inductance of an inductor with a ratio P1 of 0. Table 1 also shows the evaluation results of the inductance. The inductance was evaluated based on whether the inductance was larger than that of an inductor without the magnetic body 12 (ratio P1 = 0), and an inductor with an inductance of 100 or less was marked as defective with "NG", and an inductor with an inductance of more than 100 was marked as passable with "G". Table 1 also shows the evaluation results of the magnetic flux uniformity for each value of the ratio P1. The magnetic flux uniformity was confirmed by visually checking the distribution of strength, and inductors with high uniformity were marked as passable with "G", and inductors with low uniformity were marked as passable with "NG".

[0083] [Table 1]

[0084] As shown in Table 1, in inductor 200, by providing magnetic body 12 up to a predetermined thickness range satisfying P1<0.7, the inductance is larger than when there is no magnetic body 12 (P1=0). This is presumably because magnetic body 11 is not in direct contact with magnetic body 13, and magnetic body 12 is there between, so that the magnetic flux from magnetic body 13 to magnetic body 11 can change its direction within magnetic body 12, and the cross-sectional area of ​​the part of magnetic body 11 that can be effectively used as a magnetic path is increased.

[0085] From Table 1, when the inductance value and the uniformity of the magnetic flux are taken into consideration, it is preferable that the ratio P1 is within a range of 0.3 to 0.65, that is, 30% to 65%, which satisfies the first condition described above.

[0086] The inventors of the present application have investigated a preferable value for the ratio P2 (=D1 / (D2+D3)) of the thickness of magnetic body 11 (the thickness of coil 2) to the total thickness of magnetic bodies 12, 13 located outside coil 2 (above and below coil 2).

[0087] For this study, the inventors of the present application performed a simulation of the intensity distribution of magnetic flux density in core 10 while changing the value of ratio P2 for each of various values ​​of ratio P1. In this simulation, as in the case of Fig. 6A, the relative permeability of magnetic bodies 11 and 12 was set to 30, the relative permeability of magnetic body 13 in axial direction X1 was set to 2, and the relative permeability in the length direction of magnetic body 13, i.e., the direction perpendicular to axial direction X1, was set to 200. Note that Figs. 6A, 9, and 10 show the simulation results when ratio P2=0.9.

[0088] The simulation results are shown in Figures 11 to 16. In Figures 11 to 16, as in Figure 6A, the magnitude of the magnetic flux density is shown in gray scale so that the greater the magnetic flux density, the closer to white it becomes. Also, the blackest part in Figures 11 to 16 indicates coil 2.

[0089] Fig. 11 shows the simulation results when the ratio P2 = 0.5. Fig. 11(a) shows the simulation results when the ratio P2 = 0.5 and the ratio P1 = 0, Fig. 11(b) shows the simulation results when the ratio P2 = 0.5 and the ratio P1 = 0.3, Fig. 11(c) shows the simulation results when the ratio P2 = 0.5 and the ratio P1 = 0.4, and Fig. 11(d) shows the simulation results when the ratio P2 = 0.5 and the ratio P1 = 0.65.

[0090] Fig. 12 shows the simulation results when ratio P2 = 0.7. Fig. 12(a) shows the simulation results when ratio P2 = 0.7 and ratio P1 = 0, Fig. 12(b) shows the simulation results when ratio P2 = 0.7 and ratio P1 = 0.3, Fig. 12(c) shows the simulation results when ratio P2 = 0.7 and ratio P1 = 0.4, and Fig. 12(d) shows the simulation results when ratio P2 = 0.7 and ratio P1 = 0.65.

[0091] Fig. 13 shows the simulation results when the ratio P2 = 0.9. Fig. 13(a) shows the simulation results when the ratio P2 = 0.9 and the ratio P1 = 0, Fig. 13(b) shows the simulation results when the ratio P2 = 0.9 and the ratio P1 = 0.3, Fig. 13(c) shows the simulation results when the ratio P2 = 0.9 and the ratio P1 = 0.4, and Fig. 13(d) shows the simulation results when the ratio P2 = 0.9 and the ratio P1 = 0.65.

[0092] Figures 14 and 15 show the simulation results when ratio P2 = 1. Figure 14(a) shows the simulation results when ratio P2 = 1 and ratio P1 = 0, Figure 14(b) shows the simulation results when ratio P2 = 1 and ratio P1 = 0.3, Figure 14(c) shows the simulation results when ratio P2 = 1 and ratio P1 = 0.4, Figure 15(a) shows the simulation results when ratio P2 = 1 and ratio P1 = 0.6, and Figure 15(b) shows the simulation results when ratio P2 = 1 and ratio P1 = 0.65.

[0093] Fig. 16 shows the simulation results when the ratio P2 = 1.1. Fig. 16(a) shows the simulation results when the ratio P2 = 1.1 and the ratio P1 = 0, Fig. 16(b) shows the simulation results when the ratio P2 = 1.1 and the ratio P1 = 0.3, and Fig. 16(c) shows the simulation results when the ratio P2 = 1.1 and the ratio P1 = 0.65.

[0094] Table 2 shows the inductance of inductor 200 when ratio P2 and ratio P1 are variously changed. The inductance is shown as a normalized value with the value when ratio P1 is 0 at each value of ratio P1 being 100. The evaluation of magnetic flux uniformity in Table 2 is the same as that in Table 1.

[0095] [Table 2]

[0096] As shown in Table 2, in inductor 200, when thickness dimension D1 of magnetic body 11 becomes too large (P2=1.1), the effect of increasing inductance by providing magnetic body 12 becomes small. This is presumably because the increase in thickness dimension D1 of magnetic body 11 reduces the effect of magnetic body 12 in increasing inductance, which is caused by an increase in the cross-sectional area of ​​the portion of magnetic body 11 that can be effectively used as a magnetic path.

[0097] From Table 2, when the inductance value and the uniformity of the magnetic flux are taken into consideration, it is desirable that the ratio P2 is 1, i.e., 100% or less. Also, if the thickness dimension D1 of the magnetic body 11, which is the thickness of the coil 2, is small, it becomes difficult to increase the number of turns of the winding 20. Therefore, it is desirable that the ratio P2 is 0.5 or more.

[0098] In short, it is preferable that the magnetic component 1 satisfies the above-mentioned second condition. The second condition is that the dimension D1 of the magnetic body 11 in the axial direction X1 is within a range of 50% to 100% of the total dimension of the dimension D2 of the magnetic body 12 (e.g., magnetic body 121) located on one side of the coil 2 in the axial direction X1 and the dimension D3 of the magnetic body 13 (e.g., magnetic body 131).

[0099] In addition, taking into consideration the results when the ratio P2=1, it is more preferable that the ratio P1 is 0.3 to 0.6 (30% to 60%).

[0100] In this way, by setting the thickness dimensions of magnetic body 11, magnetic body 12 (121, 122), and magnetic body 13 (131, 132) so as to satisfy the first and second conditions, it is possible to increase the inductance of inductor 200 while reducing magnetic loss.

[0101] (3) Modifications The above-described embodiment is merely one of various embodiments of the present disclosure. The above-described embodiment can be modified in various ways depending on the design and the like as long as the object of the present disclosure can be achieved. Below, modifications of the above-described embodiment are listed. The modifications described below can be applied in appropriate combination with the above-described embodiment.

[0102] Inductor 200 is not limited to being an integrally molded product integrally molded with coil 2 so as to incorporate coil 2. Core 10 of inductor 200 may be manufactured separately from coil 2 and assembled to coil 2. Core 10 may be, for example, a dust core (powder magnetic core) made by compacting magnetic powder.

[0103] The following describes a method for manufacturing the inductor 200 of this modified example. Fig. 17 is a flowchart showing a method for manufacturing the inductor 200, which is an electric device of this modified example.

[0104] As shown in FIG. 17, the manufacturing method of this modified example includes a granulating step ST31, a core manufacturing step ST32, and an assembling step ST33.

[0105] In the granulation step ST31, an isotropic magnetic material that is the base of the magnetic bodies 11 and 12 that constitute the core 10, and an anisotropic magnetic material that is the base of the magnetic body 13 are prepared. As the raw materials for the isotropic magnetic material and the anisotropic magnetic material, the same materials as those described in the sheet molding method of the above embodiment can be used.

[0106] In the granulation step ST31, the resin 32 containing an organic solvent and the metal magnetic powder 31 are kneaded to generate a clay-like mixture in which the metal magnetic powder 31 is dispersed (kneading and dispersion). In the granulation step ST31, the resin 42 containing an organic solvent and the metal magnetic powder 41 are kneaded to generate a clay-like mixture in which the metal magnetic powder 41 is dispersed. At this time, an inorganic insulating material and an additive may be further mixed.

[0107] In the granulation step ST31, the mixture is formed into a predetermined lump shape (e.g., a columnar shape) and dried to remove the solvent contained in the mixture. The lump of the mixture is then pulverized to obtain solid pieces after pulverization (granulation). These solid pieces are formed as an aggregate of multiple powders of various sizes with a resin film of approximately uniform thickness applied around the surface of the metal magnetic powders 31, 41. The solid pieces are then classified to obtain granulated powder with particle sizes limited to a desired size range (classification).

[0108] In the core manufacturing process ST32, the granulated powder is pressure-molded in a molding die to form a green body of a desired shape (high pressure press molding). In this pressure molding, for example, two split cores having an E-shaped cross section and two plate-shaped cores having a flat plate shape are formed as the green body.

[0109] Each split core has a shape obtained by equally dividing a portion of core 10 in Fig. 1B, which is made up of magnetic body 11 and magnetic body 12, into upper and lower portions along axial direction X1 shown in Fig. 1B. Each split core is formed using granulated powder containing metal magnetic powder 31. Each split core has a bottom plate portion including magnetic body 12, and three legs including magnetic body 11 and protruding from the bottom plate portion.

[0110] Each plate-shaped core has a shape corresponding to the magnetic body 13. Each plate-shaped core is formed using granulated powder containing magnetic metal powder 41.

[0111] In the core manufacturing step ST32, the obtained green body is heated in an inert gas atmosphere or in the air to remove the resin contained in the green body as a binder (degreasing).

[0112] In the core manufacturing process ST32, the degreased compact is heat-treated (high-temperature annealing). The heat treatment relieves the distortion of the metal magnetic powders 31, 41 that have been subjected to stress by compaction, thereby reducing hysteresis loss.

[0113] In the core manufacturing process ST32, an impregnating resin is injected (impregnation) into the molded body (split core) after the heat treatment. In the impregnation process, the resin is impregnated and injected into the spaces around each of the metal magnetic powders 31, 41 of the molded body whose binding strength has been reduced by removing the resin through the heat treatment, and then the impregnating resin is hardened. This improves the mechanical strength of the molded body.

[0114] In the assembly process ST33, the obtained compact (split cores and plate-like cores) is polished as necessary. In the assembly process ST33, the sets of split cores and plate-like cores are bonded, for example, by adhesion, to obtain two combined bodies having an E-shaped cross section. The two combined bodies are then assembled with the coil 2 to form the inductor 200.

[0115] Even in core 10 (magnetic component 1) manufactured by such a method, by providing magnetic body 11, magnetic body 12, and magnetic body 13, it is possible to reduce magnetic loss.

[0116] (3.2) Other Modifications In one variation, the electric device 100 is not limited to the inductor 200 but may be, for example, a transformer or the like.

[0117] In one modified example, at least one of the magnetic bodies 11 and 12 may be made of an anisotropic magnetic material instead of an isotropic magnetic material. That is, as long as the magnetic anisotropy of the magnetic body 13 is larger than both the magnetic anisotropy of the magnetic body 11 and the magnetic body, at least one of the magnetic bodies 11 and 12 may be made of an anisotropic magnetic material. It is preferable that the magnetic anisotropy of the magnetic body 12 is larger than that of the magnetic body 11. In other words, it is preferable that the magnetic anisotropy of the magnetic body 11, the magnetic body 12, and the magnetic body 13 increases in this order, that is, the magnetization easy direction becomes prominent in this order.

[0118] In one variation, in the sheet molding method, the magnetic body 11 may be formed from a separate member from the magnetic sheet that forms the magnetic body 12 .

[0119] In one modified example, the shape of the boundary between magnetic body 12 and magnetic body 13 is not limited to a flat shape. For example, when inductor 200 is manufactured by a sheet molding method, a step may occur in magnetic body 12 and magnetic body 13 near the portion corresponding to the boundary between central space 21 of coil 2 and winding 20. Magnetic component 1 of the present disclosure also includes magnetic components having such a step.

[0120] In one modification, the easy magnetization direction of the magnetic body 13 does not have to be parallel to a plane perpendicular to the axial direction X1, and some deviation and curvature are permitted.

[0121] In one modified example, in the metal composite type inductor 200, the coil 2 may be an integrally molded part integrally formed with at least a part of the core 10, for example, the magnetic body 11.

[0122] In one variant, the magnetic body 11 may not comprise the portion 112 .

[0123] In one modified example, winding 20 is not limited to a two-layer structure having a portion in the same layer as electrode 201 and a portion in the same layer as electrode 202, but may have a single layer or three or more layers.

[0124] (4) Description The following aspects are disclosed from the above-described embodiment and modified examples.

[0125] The magnetic component (1) of the first aspect includes a magnetic body (11), a magnetic body (12), and a magnetic body (13). The magnetic body (11) is arranged in the same layer as the coil (2) in the axial direction (X1). The magnetic body (12) is arranged outside the coil (2) in the axial direction (X1). The magnetic body (13) is arranged outside the magnetic body (12) in the axial direction (X1). The magnetic body (13) has a larger magnetic anisotropy than both the magnetic body (11) and the magnetic body (12). The easy magnetization direction of the magnetic body (13) is along a plane perpendicular to the axial direction (X1).

[0126] According to this aspect, it is possible to reduce magnetic loss.

[0127] In the magnetic component (1) of the second embodiment, the magnetic body (11) in the first embodiment is made of an isotropic magnetic material, and the magnetic body (13) is made of an anisotropic magnetic material.

[0128] According to this aspect, it is possible to reduce magnetic loss.

[0129] In the magnetic component (1) of the third aspect, in the first or second aspect, the magnetic body (11) and the magnetic body (12) are formed from the same material.

[0130] According to this aspect, it is possible to reduce magnetic loss.

[0131] In the magnetic part (1) of the fourth aspect, in any one of the first to third aspects, the dimension (D2) of the magnetic body (12) in the axial direction (X1) is within a range of 30% to 65% of the total dimension of the dimension (D2) of the magnetic body (12) and the dimension (D3) of the magnetic body (13).

[0132] According to this aspect, it is possible to reduce magnetic loss while improving inductance.

[0133] In the magnetic component (1) of the fifth aspect, in any one of the first to fourth aspects, the dimension (D1) of the magnetic body (11) in the axial direction (X1) is within the range of 50% to 100% of the total dimension of the dimension (D2) of the magnetic body (12) located on one side of the coil (2) in the axial direction (X1) and the dimension (D3) of the magnetic body (13).

[0134] According to this aspect, it is possible to reduce magnetic loss while improving inductance.

[0135] The magnetic component (1) of the sixth aspect is an integrally molded product in any one of the first to fifth aspects, which is integrally molded with the coil (2) so as to incorporate the coil (2).

[0136] According to this embodiment, it is possible to reduce magnetic loss in the magnetic component (1) integrally formed with the coil (2).

[0137] An electric device (100) of a seventh aspect includes the magnetic component (1) of any one of the first to sixth aspects, and a coil (2).

[0138] According to this aspect, it is possible to reduce magnetic loss. [Explanation of symbols]

[0139] 1 Magnetic components 100 Electrical Equipment 2 Coil 11 Magnetic body (first magnetic body) 12 Magnetic material (second magnetic material, fourth magnetic material) 13 Magnetic material (3rd magnetic material, 5th magnetic material) 121 Magnetic material (second magnetic material) 122 Magnetic material (4th magnetic material) 131 Magnetic material (third magnetic material) 132 Magnetic material (5th magnetic material) A1 center axis X1 Axial direction

Claims

1. 1. A magnetic component configured for use with a coil wound around an axially extending central axis, comprising: a first magnetic body configured to pass magnetic flux generated by the coil, extending in the axial direction, having both ends along the axial direction, and having a portion overlapping with the coil when viewed in a direction perpendicular to the axial direction; a second magnetic body disposed on an opposite side of the coil with respect to one of the ends of the first magnetic body in the axial direction; a third magnetic body disposed on an opposite side of the coil with respect to the second magnetic body in the axial direction; a fourth magnetic body disposed on an opposite side of the coil with respect to the other of the two ends of the first magnetic body in the axial direction; a fifth magnetic body disposed on an opposite side of the coil with respect to the fourth magnetic body in the axial direction; Equipped with The coil is wound so as to surround an internal space through which the central axis passes, The first magnetic body is a first portion extending in the axial direction, passing through the internal space of the coil, and connecting to the second magnetic body and the fourth magnetic body; a second portion extending in the axial direction, passing through a space outside the coil, and connecting to the second magnetic body and the fourth magnetic body; having the third magnetic body has a larger magnetic anisotropy than either the first magnetic body or the second magnetic body, and has a direction of easy magnetization that is a direction in which it is easier to be magnetized than other directions; the easy magnetization direction of the third magnetic body is perpendicular to the axial direction; the fifth magnetic body has a larger magnetic anisotropy than any of the first magnetic body, the second magnetic body, and the fourth magnetic body, and has a direction of easy magnetization that is a direction in which magnetization is easier than other directions; the easy magnetization direction of the fifth magnetic body is perpendicular to the axial direction; a dimension of the second magnetic body in the axial direction is 30 to 60% of a sum of a dimension of the second magnetic body in the axial direction and a dimension of the third magnetic body in the axial direction; A dimension of the first magnetic body in the axial direction is 50 to 100% of a sum of a dimension of the second magnetic body in the axial direction and a dimension of the third magnetic body in the axial direction. Magnetic parts.

2. the first magnetic body is made of an isotropic magnetic material; The third magnetic body is made of an anisotropic magnetic material. The magnetic component according to claim 1 .

3. The first magnetic body and the second magnetic body are formed from the same material. The magnetic component according to claim 1 or 2.

4. the second magnetic body is directly connected to one of the two ends of the first magnetic body, The third magnetic body is directly connected to the second magnetic body. The magnetic component according to any one of claims 1 to 3.

5. The second magnetic body is directly connected to one of the two ends of the first magnetic body, the third magnetic body is directly connected to the second magnetic body, the fourth magnetic body is directly connected to the other of the two ends of the first magnetic body, The fifth magnetic body is directly connected to the fourth magnetic body. The magnetic component according to any one of claims 1 to 4.

6. The magnetic component is an integrally molded product integrally molded with the coil so as to incorporate the coil. The magnetic component according to any one of claims 1 to 5.

7. A magnetic component according to any one of claims 1 to 6, The coil; Equipped with Electrical equipment.

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