Inductor

Abstract

An inductor (100) comprises a magnetic core (10) that includes a magnetic material, a coil element (20) that has a coil part (21) and a lead part (22), an electrode member (30) that is disposed on a side surface (13c) and a bottom surface (11), and a connection part (40) that connects the lead part (22) and the electrode member (30). The electrode member (30) has a bottom plate part (31) that is disposed along the bottom surface (11), a side plate part (35) that is provided along the side surface (13c), and a first protruding plate part (36) that is connected to the side plate part (35) and protrudes away from the side surface (13c). The lead part (22) extends along the side plate part (35) or the side surface (13c) outside the magnetic core (10). The first protruding plate part (36) has an edge part (E1) that contacts the lead part (22) along the extension direction of the lead part (22). The connection part (40) has a first connection part (41) at which the edge part (E1) of the first protruding plate part (26) is welded to the lead part (22).

Description

Technical Field

[0001] The present disclosure relates to an inductor.

Background Art

[0002] An inductor, which is a passive element that stores electrical energy as magnetic energy, is used for, for example, a DC-DC converter device or the like for the purpose of boosting and bucking a power supply voltage and smoothing a direct current. The inductor is mounted on the surface of, for example, a circuit board. For example, Patent Document 1 discloses an inductor including a main body portion containing a magnetic material, a coil element disposed inside the main body portion, and a terminal fitting connected to the coil element. In the inductor described in Patent Document 1, the tip of the coil element protrudes from the main body portion, and the terminal fitting is welded to the protruding tip of the coil element.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In a conventional inductor, the reliability of the connection between the electrode member, which is a terminal fitting, and the coil element is low, so the reliability of the inductor may be low. In view of the above, an object of the present disclosure is to improve the reliability of the inductor.

Means for Solving the Problems

[0005] An inductor according to an aspect of the present disclosure includes a magnetic core containing a magnetic material, having a bottom surface, a top surface, and side surfaces connecting the bottom surface and the top surface, a coil portion embedded in the magnetic core, and a coil element having an end portion connected to the coil portion and a lead-out portion drawn out from the side surface to the outside of the magnetic core, an electrode member disposed on the side surface and the bottom surface, and a connection portion connecting the lead-out portion and the electrode member. The electrode member has a bottom plate portion disposed along the bottom surface, a side plate portion connected to the bottom plate portion and disposed along the side surface, and a first protruding plate portion connected to the side plate portion and protruding in a direction away from the side surface. The lead-out portion extends along the side plate portion or the side surface outside the magnetic core, and at least a part of the first protruding plate portion contacts the lead-out portion along the extending direction of the lead-out portion. The connection portion has a first connection portion where the lead-out portion and the edge portion of the first protruding plate portion are welded. The protruding height of the first protruding plate portion from the side plate portion is lower than the outer diameter of the drawer portion, and it does not overlap with the drawer portion when viewed from a direction orthogonal to the side surface, and on the side opposite to the side plate portion It has an edge portion, and at least a part of the edge portion contacts the lead-out portion along the extending direction of the lead-out portion. of the first protruding plate portion The connection portion has a first connection portion where the lead-out portion and the edge portion of the first protruding plate portion are welded. and the first connecting portion is formed by connecting a plurality of weld marks along the extending direction of the drawer portion.

Advantages of the Invention

[0006] According to the present disclosure, the reliability of the inductor can be improved.

Brief Description of the Drawings

[0007]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Figure 15

DETAILED DESCRIPTION OF THE INVENTION

[0008] (BACKGROUND OF THE DISCLOSURE) In a structure in which an electrode member is welded to the tip of a coil element as in the above-described Patent Document 1, the cross-sectional area of the connection portion connecting the coil element and the electrode member becomes small, and the reliability regarding the connection between the coil element and the electrode member may decrease. Further, in a structure in which an electrode member is welded to the tip of a coil element, the cross-sectional area of the current path at the welding portion cannot be increased, and there is a problem that the DC resistance increases and the reliability of the inductor decreases. Further, if the cross-sectional area of the current path at the welding portion cannot be increased, a temperature rise occurs when the inductor is energized, and there is a problem that the reliability of the inductor decreases.

[0009] In order to improve the reliability of the inductor, the present disclosure has the following configuration. Hereinafter, embodiments will be described more specifically with reference to the drawings.

[0010] Note that all of the embodiments described below are specific examples of the present disclosure. The numerical values, shapes, materials, components, arrangement positions of the components, connection forms, steps, order of steps, etc. shown in the following embodiments are merely examples and are not intended to limit the present disclosure. Among the components in the following embodiments, components not described in the independent claims are described as optional components.

[0011] Also, in this specification, terms indicating the relationship between elements such as parallel, terms indicating the shape of elements such as a 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.

[0012] 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 duplicate descriptions may be omitted or simplified.

[0013] Also, 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 the axes are used for explanation as necessary. Note that each axis is for the purpose of explanation and does not limit the direction and posture in which the inductor is used.

[0014] 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 an absolute spatial recognition, but are used as terms defined by the relative positional relationship of the components of the inductor.

[0015] (Embodiment) [Configuration] The configuration of the inductor according to the embodiment will be described. An inductor is a passive element that stores electrical energy flowing through a coil element as magnetic energy.

[0016] FIG. 1 is a perspective view of an inductor 100 according to the embodiment. FIG. 2 is a view showing a state in which the electrode member 30 is separated from the inductor 100 shown in FIG. 1 except for the connection portion 40. FIG. 3 is a front view of the inductor 100. FIG. 4 is a side view of the inductor 100. FIG. 5 is a top view of the inductor 100. In FIGS. 3 to 5, the front view is X-axis a view seen from the plus side to the minus side of from the minus side to the plus side of the Y-axis and the side view is a view seen from

[0017] and the top view is a view seen from the plus side to the minus side of the Z axis. The same applies to the other figures in the following description. Also, a cross-sectional view taken along the V-V line of the inductor 100 shown in FIG. 4 is also shown in a part of FIG. 5. Further, in FIG. 5, the top view shape of the coil element 20 is shown by a solid line or a broken line.

[0018] As shown in FIGS. 1 to 5, the inductor 100 includes a magnetic core 10, a coil element 20 having a coil portion 21 and a lead portion 22, an electrode member 30 which is an external terminal, and a connection portion 40 that connects the lead portion 22 and the electrode member 30.

[0019] The outer shape of the inductor 100 is approximately determined by the shape of the magnetic core 10, which is, for example, a rectangular parallelepiped-shaped compacted powder magnetic core. Note that the magnetic core 10 can be molded into any shape by molding. That is, an inductor 100 of any shape can be realized depending on the shape at the time of molding the magnetic core 10. In the magnetic core 10 of the present embodiment, for example, the dimension in the X-axis direction is 17 mm or more, the dimension in the Y-axis direction is 17 mm or more, and the dimension in the Z-axis direction is 7 mm or more.

[0020] The magnetic core 10 is the outer shell portion of the inductor 100 and covers a part of the coil element 20. The magnetic core 10 contains a magnetic material and is, for example, a compacted powder magnetic core made of a metal magnetic material powder and a resin material or the like. Note that the magnetic core 10 only needs to be formed using a magnetic material. Ferrite may be used as the magnetic material, or other magnetic materials may be used. As the metal magnetic material 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. Further, 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 metal magnetic material powder and binding the particles of the metal magnetic material powder is selected.

[0021] The magnetic core 10 is, for example, rectangular parallelepiped-shaped. The magnetic core 10 has a bottom surface 11, a top surface 12 facing away from the bottom surface 11, and four side surfaces 13a, 13b, 13c, and 13d connecting the bottom surface 11 and the top surface 12. The side surface 13a and the side surface 13b are arranged in the X-axis direction and face away from each other. The side surface 13c and the side surface 13d are arranged in the Y-axis direction and face away from each other. The bottom surface 11, the top surface 12, and the side surfaces 13a, 13b, 13c, and 13d are each a flat plane. The pair of the bottom surface 11 and the top surface 12, the pair of the side surface 13a and the side surface 13b, and the pair of the side surface 13c and the side surface 13d are each a pair of surfaces in a parallel positional relationship. The bottom surface 11 and the top surface 12 and the side surfaces 13a, 13b, 13c, and 13d extend in intersecting directions, specifically, orthogonal directions. Further, the side surface 13a and the side surface 13b and the side surface 13c and the side surface 13d extend in intersecting directions, specifically, orthogonal directions.

[0022] The coil element 20 has a coil portion 21 embedded in the magnetic core 10 and a plurality of lead portions 22 exposed outside the magnetic core 10.

[0023] FIG. 6 is a perspective view of the coil element 20 provided in the inductor 100.

[0024] As shown in FIG. 6, the coil element 20 is composed of one coil portion 21 and two lead portions 22. In FIG. 6, the coil portion 21 is a portion on the plus side of the Y-axis with respect to the dashed line attached to the coil element 20, and the lead portion 22 is a portion on the minus side of the Y-axis with respect to the above-mentioned dashed line.

[0025] The coil element 20 is composed of, for example, a conducting wire. 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 other substances, and an insulating film covering the metal wire. Specifically, the conducting wire is, for example, a copper wire covered with an insulating film. The coil portion 21 and the lead portion 22 are, for example, designations given to each portion formed by processing one member made of the same material.

[0026] The coil portion 21 is a portion covered by the magnetic core 10. The coil portion 21 is composed of a wound conducting wire and functions as a coil. The number of turns of the coil portion 21 is not particularly limited and is appropriately selected in accordance with the performance required for the inductor 100, such as 0.5 turns to 10 turns, and the constraints such as the size of the magnetic core 10. The cross-section of the conducting wire constituting the coil portion 21 is, for example, circular with a diameter of 2 mm or more, and the aspect ratio of the cross-section is 1:1. The coil portion 21 is embedded in the magnetic core 10 such that the winding axis a1 of the coil portion 21 is along the direction (Z-axis direction) connecting the bottom surface 11 and the top surface 12.

[0027] The coil portion 21 has both end portions 21a and 21b that connect the wound portion to the side surface 13c of the magnetic core 10 (see FIG. 5). Among both end portions 21a and 21b of the coil portion 21, one end portion 21a is arranged on the plus side of the X-axis, which is more outward to the right than the winding axis a1, when viewed from a direction perpendicular to the side surface 13c, and the other end portion 21b is arranged on the minus side of the X-axis, which is more outward to the left than the winding axis a1. Also, both end portions 21a and 21b of the coil portion 21 are located at a height on the top surface 12 side than the center c1 of the side surface 13c, when viewed from a direction perpendicular to the side surface 13c, and have the same height from the bottom surface 11.

[0028] As shown in FIG. 4, the lead-out portion 22 is connected to the end portion 21a or 21b of the coil portion 21, is drawn out from the side surface 13c of the magnetic core 10, and extends along the side plate portion 35 or the side surface 13c. Specifically, the lead-out portion 22 is drawn out from a height on the top surface 12 side than the center c1 of the side surface 13c, bends so as to cover the side plate portion 35 of the electrode member 30, extends in the direction connecting the bottom surface 11 and the top surface 12 (Z-axis direction), and is interrupted before reaching the end on the bottom surface 11 side. The lead-out portion 22 of the present embodiment is drawn out from one of the four side surfaces, i.e., the side surface 13c.

[0029] As shown in FIGS. 1 to 5, the electrode member 30 is arranged outside the magnetic core 10 (for example, on the bottom surface 11 side and the side surface 13c side), and is electrically connected to the lead-out portion 22 via the connection portion 40. The electrode member 30 is provided corresponding to each of the two lead-out portions 22. The electrode member 30 includes a conductive material and is formed of, for example, a metal material plate. The metal material plate is formed of a metal material selected from metals such as aluminum, copper, silver, and gold, alloys containing one or more of these metals, and materials composed of a metal or an alloy and other substances.

[0030] The electrode member 30 has a bottom plate portion 31 arranged on the bottom surface 11 side of the magnetic core 10, a side plate portion 35 connected to the bottom plate portion 31, and a first protruding plate portion 36 connected to the side plate portion 35. The bottom plate portion 31, the side plate portion 35, and the first protruding plate portion 36 are, for example, names given to respective portions formed by processing a single member made of the same material.

[0031] The bottom plate portion 31 is disposed on the bottom surface 11 side of the magnetic core 10 so as to extend along the bottom surface 11. The bottom plate portion 31 is fixed to the magnetic core 10 via an adhesive. When the inductor 100 is mounted on a circuit board, the bottom plate portion 31 is joined to the circuit board by solder.

[0032] The side plate portion 35 is connected to the bottom plate portion 31 and is disposed along the side surface 13c of the magnetic core 10. The side plate portion 35 of the present embodiment extends from the bottom plate portion 31 toward the top surface 12 side and is disposed between the side surface 13c of the magnetic core 10 and the lead-out portion 22. When viewed from a direction perpendicular to the side surface 13c, the side plate portion 35 has an outer end portion 35h located outside the lead-out portion 22 and an inner end portion 35i located on the winding axis a1 side, which is inside the lead-out portion 22 (see FIG. 2). Note that the side plate portion 35 is disposed corresponding to one of the four side surfaces, i.e., the side surface 13c. The side plate portion 35 may be fixed to the magnetic core 10 via an adhesive.

[0033] The first protruding plate portion 36 is connected to the outer end portion 35h of the side plate portion 35 and protrudes in a direction away from the side surface 13c of the magnetic core 10. The first protruding plate portion 36 protrudes perpendicularly to the side plate portion 35. Further, the first protruding plate portion 36 has an edge portion E1 located on the side opposite to the side surface 13c and the outer end portion 35h. At least a part of the edge portion E1 is in contact with the lead-out portion 22 along the extending direction of the lead-out portion 22.

[0034] FIG. 7 is a cross-sectional view of the lead-out portion 22 and the electrode member 30 of the inductor 100 as viewed from line VII-VII in FIG. 4.

[0035] As shown in FIG. 7, the lead-out portion 22 has a coated region 23a having an insulating film 24 on the outer peripheral surface 23 of the lead-out portion 22, and an exposed region 23b where the lead wire is exposed without the insulating film 24. The exposed region 23b is formed at least in a region outside the axis a2 of the lead-out portion 22 when viewed from a direction perpendicular to the side surface 13c. That is, all or most of the exposed region 23b is provided on the side where the first protruding plate portion 36 is disposed. For example, the length of the exposed region 23b on the outer periphery of the lead-out portion 22 is 30% or more and 70% or less of the length of the outer periphery of the lead-out portion 22. Note that the length of the exposed region 23b is preferably longer than the length of the coated region 23a.

[0036] The edge E1 of the first protruding plate portion 36 contacts the exposed region 23b. A connecting portion 40 is formed at a location where the exposed region 23b and the edge E1 of the first protruding plate portion 36 are in contact.

[0037] As shown in FIGS. 1 and 3, the connecting portion 40 has a first connecting portion 41 where the lead-out portion 22 and the edge E1 of the first protruding plate portion 36 are welded. The first connecting portion 41 is formed along the extending direction of the lead-out portion 22. For example, the first connecting portion 41 is composed of a plurality of weld marks ws formed by laser seam welding, and the plurality of weld marks ws are connected along the extending direction of the lead-out portion 22. All of the plurality of weld marks ws may be continuously connected, or some of the weld marks ws may be continuously connected.

[0038] The length of the first connecting portion 41 in the extending direction of the lead-out portion 22 is, for example, 1.5 times or more and 5 times or less the diameter of the lead-out portion 22. Also, when the length of the first connecting portion 41 in the extending direction is L1, the thickness of the first protruding plate portion 36 is t1, and the cross-sectional area of the lead-out portion 22 is S (the region with diagonal upward hatching), it has a relationship of L1≧(S×0.2) / t1. In the above formula, L1×t1 corresponds to the cross-sectional area of the welding portion. Therefore, the longer the length L1 of the first connecting portion 41, the larger the cross-sectional area of the welding portion.

[0039] In the present embodiment, the edge E1 of the first protruding plate portion 36 is in contact along the extending direction of the drawer portion 22. Therefore, it is possible to increase the length of the connecting portion 40 formed by welding the edge E1 and the drawer portion 22. Thereby, the cross-sectional area of the connecting portion 40 that connects the coil element 20 and the electrode member 30 can be increased, and the reliability regarding the connection can be enhanced. Further, since the cross-sectional area of the current path in the connecting portion 40 can be increased, the DC resistance can be decreased, and the reliability of the inductor can be enhanced. Also, since the cross-sectional area of the current path in the connecting portion 40 can be increased, it is possible to suppress the occurrence of temperature rise when the inductor is energized, and the reliability of the inductor can be enhanced.

[0040] [Manufacturing Method] Next, the manufacturing method of the inductor 100 described above will be explained. FIG. 8 is a flowchart showing the manufacturing method of the inductor 100 according to the embodiment. Note that the manufacturing method described below is an example, and the manufacturing method of the inductor 100 is not limited to the following example. Also, in the following explanation, mainly, the plus-side half of the X-axis in the inductor 100 will be explained, but the minus-side half of the X-axis in the inductor 100 can also be manufactured in the same way, and the same explanation applies.

[0041] In the manufacturing method of the inductor 100, first, a step of pressure-molding the magnetic core 10 together with the coil element 20 is performed (step S11). The step of step S11 is executed by putting the coil element 20 having the coil portion 21 into a molding die and pressure-molding the powdered magnetic core. The pressure during pressure molding is, for example, 5 ton / cm 2 and the thermosetting temperature is, for example, 185°C. After pressure molding, the drawer portion 22 that is not covered by the magnetic core 10 and is exposed protrudes perpendicularly to the side surface 13c of the magnetic core 10, for example.

[0042] Next, a step of forming an exposed region 23b on the outer peripheral surface 23 of the drawer portion 22 is performed (step S12). The exposed region 23b is formed by removing a part of the insulating film 24 by laser irradiation or the like after step S11.

[0043] Next, a step of adhering an electrode member 30, which is formed in advance by cutting and bending a metal material plate, to the magnetic core 10 using an adhesive is performed (step S13). At this time, the electrode member 30 and the magnetic core 10 are arranged so as to have the positional relationship shown in FIG. 1, and the bottom plate portion 31 and the bottom surface 11 are adhered. Further, in step S13, a curing process of the adhesive such as heating is performed as necessary.

[0044] Next, a step of bending the drawer portion 22 exposed from the magnetic core 10 along the side surface 13c is performed (step S14). Specifically, the drawer portion 22 is bent so as to cover the side plate portion 35 of the electrode member 30 from the root located on the side surface 13c, and is formed into a shape extending in the direction connecting the bottom surface 11 and the top surface 12. Thereby, the drawer portion 22 comes into contact with the edge E1 of the first protruding plate portion 36.

[0045] Next, a step of welding the edge E1 of the first protruding plate portion 36 and the drawer portion 22 by laser beam welding or the like is performed (step S15). Thereby, a first connection portion 41 is formed along the extending direction of the drawer portion 22. The weld mark ws formed in the first connection portion 41 is circular, and is formed, for example, by rotating the spot of the laser beam at a predetermined radius.

[0046] Through steps S11 to S15 as described above, an inductor 100 in which the coil element 20 and the electrode member 30 are connected by a connection portion 40 is manufactured.

[0047] [Effects, etc.] As described above, the inductor 100 according to the present embodiment includes a magnetic core 10 containing a magnetic material and having a bottom surface 11, a top surface 12, and a side surface 13c connecting the bottom surface 11 and the top surface 12, a coil portion 21 embedded in the magnetic core 10, and a coil element 20 having a lead portion 22 connected to an end portion (for example, 21a) of the coil portion 21 and drawn out from the side surface 13c to the outside of the magnetic core 10, an electrode member 30 disposed on the side surface 13c and the bottom surface 11, and a connection portion 40 connecting the lead portion 22 and the electrode member 30. The electrode member 30 has a bottom plate portion 31 disposed along the bottom surface 11, a side plate portion 35 connected to the bottom plate portion 31 and disposed along the side surface 13c, and a first protruding plate portion 36 connected to the side plate portion 35 and protruding in a direction away from the side surface 13c. The lead portion 22 extends along the side plate portion 35 or the side surface 13c outside the magnetic core 10. The first protruding plate portion 36 has an edge portion E1 at least a part of which contacts the lead portion 22 along the extending direction of the lead portion 22. The connection portion 40 has a first connection portion 41 in which the lead portion 22 and the edge portion E1 of the first protruding plate portion 36 are welded together.

[0048] In the inductor 100 of the present embodiment, the edge portion E1 of the first protruding plate portion 36 is in contact along the extending direction of the lead portion 22. Therefore, it is possible to increase the length of the first connection portion 41 formed by welding the edge portion E1 and the lead portion 22. As a result, the cross-sectional area of the connection portion 40 connecting the coil element 20 and the electrode member 30 can be increased, and the reliability regarding the connection can be enhanced. Further, according to this configuration, since the cross-sectional area of the current path in the connection portion 40 can be increased, the DC resistance can be reduced, and the reliability of the inductor can be enhanced. Also, since the cross-sectional area of the current path in the connection portion 40 can be increased, an increase in temperature when the inductor is energized can be suppressed, and the reliability of the inductor can be enhanced.

[0049] Further, the first connection portion 41 may be formed along the extending direction of the lead portion 22.

[0050] According to this configuration, the length of the first connection portion 41 formed along the extending direction of the drawer portion 22 can be increased. As a result, the cross-sectional area of the connection portion 40 connecting the coil element 20 and the electrode member 30 can be increased, and the reliability regarding the connection can be enhanced. Further, according to this configuration, since the cross-sectional area of the current path in the connection portion 40 can be increased, the DC resistance can be decreased, and the reliability of the inductor can be enhanced. Also, since the cross-sectional area of the current path in the connection portion 40 can be increased, an increase in temperature when the inductor is energized can be suppressed, and the reliability of the inductor can be enhanced.

[0051] Further, the first connection portion 41 may be formed by connecting a plurality of welding marks ws.

[0052] According to this configuration, since the length of the first connection portion 41 can be increased, the cross-sectional area of the connection portion 40 can be increased. Thereby, the reliability of the inductor 100 can be enhanced.

[0053] Further, the drawer portion 22 has a coated region 23a having an insulating film 24 on the outer peripheral surface 23 of the drawer portion 22 and an exposed region 23b not having the insulating film 24, and the connection portion 40 may be formed in the exposed region 23b.

[0054] According to this configuration, the reliability of the connection between the drawer portion 22 and the electrode member 30 in the connection portion 40 can be enhanced. Thereby, the reliability of the inductor 100 can be enhanced.

[0055] Further, when the drawer portion 22 is viewed in cross section, the length of the exposed region 23b on the outer periphery of the drawer portion 22 may be 30% or more and 70% or less of the length of the outer periphery of the drawer portion 22.

[0056] According to this configuration, the exposed area 23b can be easily formed as compared with the case where the entire outer periphery of the lead-out portion 22 is the exposed area 23b. For example, when removing the insulating film 24 of the lead-out portion 22 by laser irradiation, the insulating film 24 can be removed by irradiating the laser from one direction, and the exposed area 23b can be easily formed.

[0057] Further, when the length of the first connection portion 41 in the extending direction of the lead-out portion 22 is L1, the thickness of the first protruding plate portion 36 is t1, and the cross-sectional area of the lead-out portion 22 is S, it may have a relationship of L1≧(S×0.2) / t1.

[0058] By having the above relationship, the length of the first connection portion 41 can be sufficiently ensured. Thereby, the reliability of the inductor 100 can be enhanced.

[0059] Further, the lead-out portion 22 may extend along the direction connecting the bottom surface 11 and the top surface 12.

[0060] According to this, the length of the first connection portion 41 can be sufficiently ensured. Thereby, the reliability of the inductor 100 can be enhanced.

[0061] (Modification of the embodiment) Hereinafter, an inductor according to a modification of the embodiment will be described. In the description of each of the following modifications, the description will be centered on the differences from the embodiment, and the description of the common points will be omitted or simplified.

[0062] [Modification 1] An inductor 100A according to Modification 1 of the embodiment will be described. In Modification 1, an example will be described in which the inductor 100A further includes a second connection portion 42 and the like in addition to the first connection portion 41.

[0063] FIG. 9 is a side view of an inductor according to Modification 1 of the embodiment. FIG. 10 is a cross-sectional view of the lead-out portion 22 and the electrode member 30A of the inductor 100A according to Modification 1 as seen from the X-X line in FIG. 9.

[0064] The inductor 100A of Modification 1 includes a magnetic core 10, a coil element 20 having a coil portion 21 and a lead portion 22, an electrode member 30A which is an external terminal, and a connection portion 40 that connects the lead portion 22 and the electrode member 30A. The configurations of the magnetic core 10 and the coil element 20 are substantially the same as those in the embodiment. In Modification 1, the outer peripheral surface 23 of the lead portion 22 is not covered with an insulating film and is an exposed region 23b.

[0065] The electrode member 30A has a bottom plate portion 31, a side plate portion 35A, and a first protruding plate portion 36, and further has a second protruding plate portion 37. The bottom plate portion 31 and the first protruding plate portion 36 are the same as those in the embodiment, and the side plate portion 35A is shorter in the X-axis direction than in the embodiment.

[0066] The second protruding plate portion 37 is connected to the inner end portion 35i of the side plate portion 35A and protrudes in a direction away from the side surface 13c of the magnetic core 10. The second protruding plate portion 37 protrudes perpendicularly to the side plate portion 35A and faces the first protruding plate portion 36 with the lead portion 22 therebetween. That is, the first protruding plate portion 36 and the second protruding plate portion 37 protrude from both ends of the side plate portion 35A and face each other when viewed from a direction perpendicular to the side surface 13c. The lead portion 22 is located between the first protruding plate portion 36 and the second protruding plate portion 37 and is sandwiched by the first protruding plate portion 36 and the second protruding plate portion 37.

[0067] Further, the second protruding plate portion 37 has an edge portion E2 located on the side opposite to the side surface 13c and the inner end portion 35i. At least a part of the edge portion E2 is in contact with the lead portion 22 along the extending direction of the lead portion 22. The edge portion E2 is in contact with the lead portion 22 in a region on the side opposite to the edge portion E1 when viewed from the lead portion 22.

[0068] The connection portion 40 has a first connection portion 41 in which the lead portion 22 and the edge portion E1 are welded, and a second connection portion 42 in which the lead portion 22 and the edge portion E2 are welded.

[0069] The second connection portion 42 of Modification 1 is also composed of a plurality of weld marks ws formed by laser seam welding, and the plurality of weld marks ws are connected along the extending direction of the lead-out portion 22. That is, the second connection portion 42 is formed along the extending direction of the lead-out portion 22. The length of the second connection portion 42 is, for example, not less than 1.5 times and not more than 5 times the diameter of the lead-out portion 22.

[0070] In Modification 1, the connection portion 40 is composed of two connection points, namely, the first connection portion 41 and the second connection portion 42. Therefore, the length of the connection portion 40, which is the sum of the lengths of the first connection portion 41 and the second connection portion 42, can be increased.

[0071] On the other hand, since Modification 1 has two connection points, the lengths of the first connection portion 41 and the second connection portion 42 in the extending direction can be made shorter than those in the embodiment. Therefore, in Modification 1, when the length of the first connection portion 41 in the extending direction is L1, the thickness of the first protruding plate portion 36 is t1, and the cross-sectional area of the lead-out portion 22 is S, it may have a relationship of L1≧(S×0.1) / t1, and when the length of the second connection portion 42 in the extending direction is L2 and the thickness of the second protruding plate portion 37 is t2, it may have a relationship of L2≧(S×0.1) / t2. In the above formula, the value obtained by adding L1×t1 and L2×t2 corresponds to the cross-sectional area of the welding portion.

[0072] Also in the inductor 100A of Modification 1, the edge portion E1 of the first protruding plate portion 36 is in contact along the extending direction of the lead-out portion 22. Therefore, it is possible to increase the length of the connection portion 40 formed by welding the edge portion E1 and the lead-out portion 22.

[0073] Further, in the inductor 100A of Modification 1, the electrode member 30A further has a second protruding plate portion 37 that faces the first protruding plate portion 36 with the lead-out portion 22 interposed therebetween and is connected to the side plate portion 35A and protrudes in a direction away from the side surface 13c. The second protruding plate portion 37 has an edge portion E2 at least a part of which is in contact with the lead-out portion 22 along the extending direction of the lead-out portion 22.

[0074] In the inductor 100A of Modification 1, the edge E2 of the second protruding plate portion 37 is in contact along the extending direction of the lead-out portion 22. Therefore, it is possible to increase the length of the connection portion formed by welding the edge E2 and the lead-out portion 22. Thereby, the reliability of the inductor 100A can be improved.

[0075] Further, the connecting portion 40 may further have a second connecting portion 42 in which the lead-out portion 22 and the edge E2 of the second protruding plate portion 37 are welded.

[0076] According to this, since the connecting portion 40 is composed of two connection portions, namely the first connection portion 41 and the second connection portion 42, it is possible to increase the length of the connecting portion 40 obtained by summing the lengths of the first connection portion 41 and the second connection portion 42. Thereby, the cross-sectional area of the connecting portion 40 can be increased. Thereby, the reliability of the inductor 100A can be improved.

[0077] Also, when the length of the first connection portion 41 in the extending direction of the lead-out portion 22 is L1, the thickness of the first protruding plate portion 36 is t1, and the cross-sectional area of the lead-out portion 22 is S, it has the relationship of L1≧(S×0.1) / t1. When the length of the second connection portion 42 in the extending direction of the lead-out portion 22 is L2 and the thickness of the second protruding plate portion 37 is t2, it may have the relationship of L2≧(S×0.1) / t2.

[0078] In this way, since the inductor 100A has two connection portions, it is possible to suppress the lengths of the first connection portion 41 and the second connection portion 42 in the extending direction of the lead-out portion 22 from becoming longer than necessary. Thereby, it is possible to miniaturize or reduce the height of the inductor 100A.

[0079] Further, the side plate portion 35A may be located between the side surface 13c and the lead-out portion 22, and the first protruding plate portion 36 and the second protruding plate portion 37 may protrude from both ends of the side plate portion 35A when viewed from a direction perpendicular to the side surface 13c.

[0080] According to this configuration, the drawer portion 22 can be sandwiched between the first protruding plate portion 36 and the second protruding plate portion 37, and the mechanical strength of the inductor 100A can be improved. Thereby, the reliability of the inductor 100A can be enhanced.

[0081] [Modification Example 2] The inductor 100B according to Modification Example 2 of the embodiment will be described. Also in Modification Example 2, an example in which the inductor 100B further includes a second connection portion 42 and the like in addition to the first connection portion 41 will be described.

[0082] FIG. 11 is a perspective view of the inductor 100B according to Modification Example 2 of the embodiment. FIG. 12 is a side view of the inductor 100B according to Modification Example 2. FIG. 13 is a cross-sectional view of the drawer portion 22B and the electrode member 30B of the inductor 100B according to Modification Example 2 as seen from the XIII-XIII line in FIG. 12.

[0083] The inductor 100B of Modification Example 2 includes a magnetic core 10, a coil element 20 having a coil portion 21 and a drawer portion 22B, an electrode member 30B which is an external terminal, and a connection portion 40 connecting the drawer portion 22B and the electrode member 30B. The configuration of the magnetic core 10 is substantially the same as that of the embodiment.

[0084] Both ends of the coil portion 21 of Modification Example 2 have both ends connecting the wound portion to the side surface 13c of the magnetic core 10. Both ends of the coil portion 21 are located at a height on the bottom surface 11 side rather than the center c1 of the side surface 13c when viewed from a direction perpendicular to the side surface 13c.

[0085] The drawer portion 22B is connected to the end of the coil portion 21, is drawn out from the side surface 13c of the magnetic core 10, and extends along the side surface 13c. Specifically, the drawer portion 22B is drawn out from a height on the bottom surface 11 side rather than the center c1 of the side surface 13c when viewed from a direction perpendicular to the side surface 13c, bends along the side surface 13c, extends in the direction connecting the bottom surface 11 and the top surface 12, and is interrupted before reaching the end on the top surface 12 side. The outer peripheral surface 23 of the drawer portion 22B is not covered with an insulating film 24 and is an exposed region 23b (not shown).

[0086] The electrode member 30B of Modification 2 has a bottom plate portion 31, a side plate portion 35B, a first protruding plate portion 36, and a second protruding plate portion 37.

[0087] The side plate portion 35B has an opening 35j along the extending direction of the lead-out portion 22B. The length of the opening 35j in the extending direction is longer than the length of the lead-out portion 22B, and the width of the opening 35j is the same as the diameter of the lead-out portion 22B. The opening 35j may be a rectangular through-hole or a slit.

[0088] Each of the first protruding plate portion 36 and the second protruding plate portion 37 is connected to a region located outside both sides of the opening 35j of the side plate portion 35B when viewed from a direction perpendicular to the side surface 13c, and protrudes in a direction away from the side surface 13c of the magnetic core 10. Each of the first protruding plate portion 36 and the second protruding plate portion 37 protrudes perpendicularly to the side plate portion 35B and faces each other with the lead-out portion 22B interposed therebetween. That is, the lead-out portion 22B is located between the first protruding plate portion 36 and the second protruding plate portion 37 and is sandwiched by the first protruding plate portion 36 and the second protruding plate portion 37.

[0089] The first protruding plate portion 36 has an edge portion E1 located on the side opposite to the side surface 13c. At least a part of the edge portion E1 is in contact with the lead-out portion 22B along the extending direction of the lead-out portion 22B. The second protruding plate portion 37 has an edge portion E2 located on the side opposite to the side surface 13c. At least a part of the edge portion E2 is in contact with the lead-out portion 22B along the extending direction of the lead-out portion 22B. The edge portion E1 and the edge portion E2 are in contact with the lead-out portion 22B at positions on opposite sides of each other when viewed from the lead-out portion 22B.

[0090] The connecting portion 40 has a first connecting portion 41 in which the lead-out portion 22B and the edge portion E1 are welded, and a second connecting portion 42 in which the lead-out portion 22B and the edge portion E2 are welded. The length of each of the first connecting portion 41 and the second connecting portion 42 is, for example, 1.5 times or more and 5 times or less the diameter of the lead-out portion 22B.

[0091] Even in Modification 2, the connection portion 40 is composed of two connection points, namely the first connection portion 41 and the second connection portion 42. Therefore, the length of the connection portion 40, which is the sum of the lengths of the first connection portion 41 and the second connection portion 42, can be increased.

[0092] On the other hand, in Modification 2, since there are two connection points, the length of each of the first connection portion 41 and the second connection portion 42 in the extending direction of the drawer portion 22B can be made shorter than in the embodiment. Even in Modification 2, when the length of the first connection portion 41 in the extending direction is L1, the thickness of the first protruding plate portion 36 is t1, and the cross-sectional area of the drawer portion 22B is S, it has the relationship of L1≧(S×0.1) / t1. When the length of the second connection portion 42 in the extending direction is L2 and the thickness of the second protruding plate portion 37 is t2, it has the relationship of L2≧(S×0.1) / t2. In the above formula, the value obtained by adding L1×t1 and L2×t2 corresponds to the cross-sectional area of the welding portion.

[0093] The inductor 100B of Modification 2 can also obtain the same effects as the inductor 100A of Modification 1.

[0094] In the inductor 100B of Modification 2, the side plate portion 35B has an opening 35j along the extending direction of the drawer portion 22B, and the first protruding plate portion 36 and the second protruding plate portion 37 protrude from regions located on both outer sides of the opening 35j of the side plate portion 35B when viewed from a direction perpendicular to the side surface 13c.

[0095] According to this configuration, the drawer portion 22B can be sandwiched between the first protruding plate portion 36 and the second protruding plate portion 37, and the mechanical strength of the inductor 100B can be improved. Thereby, the reliability of the inductor 100B can be enhanced.

[0096] [Modification 3] The inductor 100C according to Modification 3 of the embodiment will be described. In Modification 3, an example will be described in which the drawer portion 22C extends along a direction intersecting the direction connecting the bottom surface 11 and the top surface 12 of the magnetic core 10, and the connection portion 40C is formed along this extending direction.

[0097] FIG. 14 is a perspective view of the inductor 100C according to Modification 3 of the embodiment.

[0098] The inductor 100C of Modification 3 includes a magnetic core 10, a coil element 20 having a coil portion 21 and a lead portion 22C, an electrode member 30C which is an external terminal, and a connection portion 40C that connects the lead portion 22C and the electrode member 30C. The magnetic core 10 is the same as in the embodiment.

[0099] The coil portion 21 of Modification 3 has both ends that connect the wound portion to the side surface 13c of the magnetic core 10. One end of the coil portion 21 is located closer to the side surface 13a than the winding axis a1 when viewed from a direction perpendicular to the side surface 13c, and the other end is located closer to the side surface 13b than the winding axis a1.

[0100] In the following description, mainly, the plus-side half of the X-axis in the inductor 100C will be described. However, the minus-side half of the X-axis in the inductor 100C also has the same structure as the plus-side half of the X-axis in the inductor 100C, and the same description applies.

[0101] The lead portion 22C is connected to the end of the coil portion 21, is drawn out from the side surface 13c of the magnetic core 10, and extends along the side plate portion 35C. Specifically, the lead portion 22C is drawn out from the side surface 13c, bends so as to cover the side plate portion 35C of the electrode member 30C, extends in a direction (X-axis direction) intersecting the direction connecting the bottom surface 11 and the top surface 12, and breaks before reaching the center of the side surface 13c. Note that the lead portion 22C of Modification 3 is also drawn out from one of the four side surfaces, i.e., the side surface 13c.

[0102] The electrode member 30C is disposed outside the magnetic core 10 and is electrically connected to the lead portion 22C via the connection portion 40C. The electrode member 30C has a bottom plate portion 31 disposed on the bottom surface 11 side of the magnetic core 10, a side plate portion 35C connected to the bottom plate portion 31, and a first protruding plate portion 36C connected to the side plate portion 35C. The bottom plate portion 31 is the same as in the embodiment.

[0103] The side plate portion 35C is connected to the bottom plate portion 31 and is disposed along the side surface 13c of the magnetic core 10. The side plate portion 35C is located between the side surface 13c of the magnetic core 10 and the drawer portion 22C. The side plate portion 35C has a top surface side end portion 35k that is located on the top surface 12 side rather than the drawer portion 22C when viewed from a direction perpendicular to the side surface 13c. The side plate portion 35C of this modification is disposed corresponding to only one of the four side surfaces, i.e., the side surface 13c.

[0104] The first protruding plate portion 36C is connected to the top surface side end portion 35k of the side plate portion 35C and protrudes in a direction away from the side surface 13c of the magnetic core 10. The first protruding plate portion 36C protrudes perpendicularly to the side plate portion 35C. Further, the first protruding plate portion 36C has an edge portion E3 that is located on the side opposite to the side surface 13c and the top surface side end portion 35k. At least a part of the edge portion E3 is in contact with the drawer portion 22C along the extending direction (X-axis direction) of the drawer portion 22C.

[0105] The drawer portion 22C has a coated region 23a having an insulating film 24 on the outer peripheral surface 23 of the drawer portion 22C and an exposed region 23b having no insulating film 24. The exposed region 23b is formed in at least a region on the top surface 12 side rather than the axis a2 of the drawer portion 22C when viewed from a direction perpendicular to the side surface 13c. That is, the exposed region 23b is provided on the side where the first protruding plate portion 36C is disposed.

[0106] The edge portion E3 of the first protruding plate portion 36C contacts the exposed region 23b. A connecting portion 40C is formed at a location where the exposed region 23b and the edge portion E3 of the first protruding plate portion 36C are in contact.

[0107] The connecting portion 40C has a first connecting portion 41C where the lead-out portion 22C and the edge E3 of the first protruding plate portion 36C are welded. The first connecting portion 41C is formed along the extending direction of the lead-out portion 22C. For example, the first connecting portion 41C is composed of a plurality of welding marks ws formed by laser seam welding, and the plurality of welding marks ws are connected along the extending direction of the lead-out portion 22C. The length of the first connecting portion 41C in the extending direction of the lead-out portion 22C is, for example, 1.5 times or more and 5 times or less the diameter of the lead-out portion 22C.

[0108] Also in the inductor 100C of Modification 3, the same effects as those of the inductor 100 in the embodiment can be obtained.

[0109] In the inductor 100C of Modification 3, the lead-out portion 22C extends along a direction intersecting the direction connecting the bottom surface 11 and the top surface 12.

[0110] According to this, the length of the first connecting portion 41C can be sufficiently ensured. Thereby, the reliability of the inductor 100C can be enhanced.

[0111] [Modification 4] The inductor 100D according to Modification 4 of the embodiment will be described. In Modification 4, an example will be described in which the lead-out portion 22D is composed of a first lead-out portion 22d1 and a second lead-out portion 22d2, and each of the first lead-out portion 22d1 and the second lead-out portion 22d2 extends along a direction intersecting the direction connecting the bottom surface 11 and the top surface 12 of the magnetic core 10.

[0112] FIG. 15 is a perspective view of the inductor 100D according to Modification 4 of the embodiment. (a) in FIG. 15 is a perspective view of the inductor 100D viewed from a predetermined direction, and (b) is a perspective view of the inductor 100D viewed from a direction different from the predetermined direction.

[0113] The inductor 100D of Modification 4 includes a magnetic core 10, a coil element 20 having a coil portion 21 and a lead portion 22D, an electrode member 30D which is an external terminal, and a connection portion 40D that connects the lead portion 22D and the electrode member 30D.

[0114] The magnetic core 10 is, for example, in the shape of a rectangular parallelepiped and has a bottom surface 11, a top surface 12 facing away from the bottom surface 11, and four side surfaces 13a, 13b, 13c, and 13d connecting the bottom surface 11 and the top surface 12. In this modification, the side surface 13c is referred to as the first side surface 13c, and the side surface 13d is referred to as the second side surface 13d.

[0115] One end 21a of the coil portion 21 has a wound portion connected to the first side surface 13c of the magnetic core 10, and the other end 21b is connected to the second side surface 13d. One end 21a of the coil portion 21 is located closer to the side surface 13a than the winding axis a1 when viewed from a direction perpendicular to the first side surface 13c. The other end 21b of the coil portion 21 is located closer to the side surface 13a than the winding axis a1 when viewed from a direction perpendicular to the second side surface 13d.

[0116] The lead portion 22D is composed of a first lead portion 22d1 and a second lead portion 22d2.

[0117] The electrode member 30D is composed of one electrode member 30D and the other electrode member 30D. One electrode member 30D has a one bottom plate portion 31 disposed on the bottom surface 11 side of the magnetic core 10, a one side plate portion 35D connected to the one bottom plate portion 31 and disposed on the first side surface 13c side, and a one first protruding plate portion 36D connected to the one side plate portion 35D. The other electrode member 30D has another bottom plate portion 31 disposed on the bottom surface 11 side of the magnetic core 10, another side plate portion 35D connected to the other bottom plate portion 31 and disposed on the second side surface 13d, and another first protruding plate portion 36D connected to the other side plate portion 35D.

[0118] In Modification 4, the first lead-out portion 22d1 is connected to one end portion 21a of the coil portion 21, drawn out from the first side surface 13c of the magnetic core 10, and extends along one side plate portion 35D. Specifically, when viewed from a direction perpendicular to the first side surface 13c, the first lead-out portion 22d1 is drawn out from a position on the side surface 13a side of the winding axis a1, bends so as to cover one side plate portion 35D, and extends in a direction (X-axis direction) intersecting the direction connecting the bottom surface 11 and the top surface 12, and breaks before reaching the end on the side surface 13b side.

[0119] The second lead-out portion 22d2 is connected to the other end portion 21b of the coil portion 21, drawn out from the second side surface 13d of the magnetic core 10, and extends along the other side plate portion 35D. Specifically, when viewed from a direction perpendicular to the second side surface 13d, the second lead-out portion 22d2 is drawn out from a position on the side surface 13a side of the winding axis a1, bends so as to cover the other side plate portion 35D, and extends in a direction (X-axis direction) intersecting the direction connecting the bottom surface 11 and the top surface 12, and breaks before reaching the end on the side surface 13b side.

[0120] One electrode member 30D is electrically connected to the first lead-out portion 22d1 via one connection portion 40D. The other electrode member 30D is electrically connected to the second lead-out portion 22d2 via the other connection portion 40D.

[0121] In the following description, mainly, the minus-side half of the Y-axis in the inductor 100D will be described. However, the plus-side half of the Y-axis in the inductor 100D also has the same structure as the minus-side half of the Y-axis in the inductor 100D, and the same description applies.

[0122] As shown in Fig. 15(a), one side plate portion 35D is connected to one bottom plate portion 31 and is arranged along the first side surface 13c. One side plate portion 35D is located between the first side surface 13c and the first drawer portion 22d1. One side plate portion 35D has a top surface side end portion 35k that is located on the top surface 12 side of the first drawer portion 22d1 when viewed from a direction perpendicular to the first side surface 13c.

[0123] One first protruding plate portion 36D is connected to the top surface side end portion 35k of one side plate portion 35D and protrudes in a direction away from the first side surface 13c. One first protruding plate portion 36D protrudes perpendicularly to one side plate portion 35D. Also, one first protruding plate portion 36D has an edge portion E4 that is located on the side opposite to the first side surface 13c and the top surface side end portion 35k. At least a part of the edge portion E4 is in contact with the first drawer portion 22d1 along the extending direction of the first drawer portion 22d1.

[0124] The first drawer portion 22d1 has a coated region 23a having an insulating film 24 on the outer peripheral surface 23 of the first drawer portion 22d1 and an exposed region 23b having no insulating film 24. The exposed region 23b is formed at least in a region on the top surface 12 side of the axis a2 of the first drawer portion 22d1 when viewed from a direction perpendicular to the first side surface 13c. That is, the exposed region 23b is provided on the side where one first protruding plate portion 36D is arranged.

[0125] The edge portion E4 of one first protruding plate portion 36D is in contact with the exposed region 23b. A connecting portion 40D is formed at a location where the exposed region 23b and the edge portion E4 of one first protruding plate portion 36D are in contact.

[0126] The connecting portion 40D has a first connecting portion 41D where the first lead-out portion 22d1 and the edge E4 of the first protruding plate portion 36D are welded. The first connecting portion 41D is formed along the extending direction of the first lead-out portion 22d1. For example, the first connecting portion 41D is composed of a plurality of welding marks ws formed by laser seam welding, and the plurality of welding marks ws are connected along the extending direction of the first lead-out portion 22d1. The length of the first connecting portion 41D is, for example, 1.5 times or more and 10 times or less the diameter of the first lead-out portion 22d1.

[0127] Also, the connecting portion 40D of the inductor 100D has a first connecting portion 41D where the second lead-out portion 22d2 and the edge E4 of the other first protruding plate portion 36D are welded. The configurations of the second lead-out portion 22d2, the other first protruding plate portion 36D, and the first connecting portion 41D are the same as the configuration of the first connecting portion 41D described above.

[0128] In the inductor 100D of Modification 4 as well, the same effects as those of the inductor 100C of Modification 3 can be obtained.

[0129] In the inductor 100D, further, notches 19 are provided on the top surface 12 of the magnetic core 10, and locking portions 39 are provided on the electrode members 30D. The notches 19 are recesses that are recessed from the top surface 12 toward the bottom surface 11 side, and are formed at each of the four corners of the top surface 12. The locking portions 39 are portions that are locked to the notches 19 of the magnetic core 10, extend from the bottom plate portion 31 toward the notches 19 of the top surface 12, and have their tips bent toward the notches 19. Two locking portions 39 are provided for each electrode member 30D, and each locking portion 39 is locked to each notch 19. In the inductor 100D of Modification 4, by locking the locking portions 39 to the notches 19, the electrode members 30D are fixed to the magnetic core 10 in a state where the magnetic core 10 is sandwiched between the bottom plate portion 31 and the locking portions 39.

[0130] In the inductor 100D of Modification 4, the side surface has a first side surface 13c and a second side surface 13d facing away from each other. The lead-out portion 22D has a first lead-out portion 22d1 connected to one end portion 21a of the coil portion 21 and a second lead-out portion 22d2 connected to the other end portion 21b. The first lead-out portion 22d1 is drawn out from the first side surface 13c and extends along a direction intersecting the direction connecting the bottom surface 11 and the top surface 12. The second lead-out portion 22d2 is drawn out from the second side surface 13d and extends along a direction intersecting the direction connecting the bottom surface 11 and the top surface 12.

[0131] According to this, the length of the first connection portion 41D can be increased. Thereby, the reliability of the inductor 100D can be enhanced.

[0132] Further, the magnetic core 10 may have a notch portion 19 provided on the top surface 12, and the electrode member 30D may further have a locking portion 39 connected to the bottom plate portion 31 and locked to the notch portion 19.

[0133] According to this, since the electrode member 30D is locked to the magnetic core 10, the stress on the connection portion 40D is relaxed. Thereby, the reliability of the inductor 100D can be enhanced.

[0134] (Other embodiments, etc.) As described above, the inductor and the like according to the embodiments and each modification of the present disclosure have been described. However, the present disclosure is not limited to the above embodiments and each modification. As long as the gist of the present disclosure is not deviated from, various modifications conceived by those skilled in the art applied to the embodiments and each modification, and another form constructed by combining some components in the embodiments and each modification are also included in the scope of the present disclosure.

[0135] In the above-described embodiment, an example in which the bottom plate portion 31, the side plate portion 35, and the first protruding plate portion 36 of the electrode member 30 are formed by processing a single member made of the same material has been shown, but the present invention is not limited thereto. For example, the electrode member 30 may be formed by connecting the bottom plate portion 31, the side plate portion 35, and the first protruding plate portion 36, which are made of different members.

[0136] In the above-described embodiment, an example in which the coil portion 21 and the lead-out portion 22 of the coil element 20 are formed by processing a single member made of the same material has been shown, but the present invention is not limited thereto. The coil element 20 may be formed by connecting the coil portion 21 and the lead-out portion 22, which are made of different members.

[0137] In the above-described embodiment, an example in which the cross-section of the lead-out portion 22 is circular has been shown, but the present invention is not limited thereto. At least a part of the lead-out portion 22 may be extended in a flat plate shape in order to facilitate connection with the electrode member 30.

[0138] Also, for example, an electric product or an electric circuit using the above-described inductor is also included in the present disclosure. Examples of the electric product include a power supply device including the above-described inductor, various devices including the power supply device, and the like.

Industrial Applicability

[0139] The inductor according to the present disclosure is useful as an inductor used in various devices and equipment.

Explanation of Signs

[0140] 10 Core 11 Bottom Surface 12 Top Surface 13a, 13b, 13c, 13d Side Surfaces 19 Notch Portion 20 Coil Element 21 Coil Portion 21a, 21b End Portions 22, 22B, 22C, 22D Lead-Out Portions 22d1 First Lead-Out Portion 22d2 Second extraction part 23 Outer peripheral surface 23a Coated area 23b Exposed area 24 Insulating film 30, 30A, 30B, 30C, 30D Electrode member 31 Bottom plate part 35, 35A, 35B, 35C, 35D Side plate part 35h Outer end 35i Inner end 35j Opening 35k Top surface side end 36, 36C, 36D First protruding plate part 37 Second protruding plate part 39 Locking part 40, 40C, 40D Connection part 41, 41C, 41D First connection part 42 Second connection part 100, 100A, 100B, 100C, 100D Inductor a1 Winding axis of coil part a2 Axis of extraction part c1 Center of side surface E1, E2, E3, E4 Edge part L1 Length of first connection part L2 Length of second connection part t1 Thickness of first protruding plate part t2 Thickness of second protruding plate part S Cross-sectional area of extraction part ws Weld mark

Claims

1. A magnetic core including a magnetic material, having a bottom surface, a top surface, and side surfaces connecting the bottom surface and the top surface, a coil element including a coil portion embedded in the magnetic core and a lead portion connected to an end of the coil portion and drawn out from the side surface to the outside of the magnetic core, an electrode member disposed on the side surface and the bottom surface, a connection portion connecting the lead portion and the electrode member, and comprising: The electrode member has a bottom plate portion disposed along the bottom surface, a side plate portion connected to the bottom plate portion and disposed along the side surface, and a first protruding plate portion connected to the side plate portion and protruding in a direction away from the side surface. The lead portion extends along the side plate portion or the side surface outside the magnetic core. The first protruding plate portion has a protruding height from the side plate portion of the first protruding plate portion lower than the outer diameter of the lead portion, does not overlap the lead portion when viewed from a direction perpendicular to the side surface, and has an edge portion of the first protruding plate portion where at least a part on the side opposite to the side plate portion contacts the lead portion along the extending direction of the lead portion. The connection portion has a first connection portion where the lead portion and the edge portion of the first protruding plate portion are welded. The first connection portion is formed by connecting a plurality of weld marks along the extending direction of the lead portion. An inductor.

2. The lead portion has a coated region having an insulating film on the outer peripheral surface of the lead portion and an exposed region having no insulating film. The connection portion is formed in the exposed region. The inductor according to claim 1.

3. When the lead portion is viewed in a cross section, the length of the exposed region on the outer periphery of the lead portion is 30% or more and 70% or less of the length of the outer periphery of the lead portion. The inductor according to claim 2.

4. When the length of the first connection portion in the extending direction of the lead portion is L1, the thickness of the first protruding plate portion is t1, and the cross-sectional area of the lead portion is S, L1 ≧ (S × 0.2) / t1 has a relationship of The inductor according to any one of claims 1 to 3.

5. The electrode member further has a second protruding plate portion facing the first protruding plate portion with the lead portion interposed therebetween, connected to the side plate portion, and protruding in a direction away from the side surface. The second protruding plate portion has a protruding height from the side plate portion of the second protruding plate portion lower than the outer diameter of the drawer portion, does not overlap the drawer portion when viewed from a direction perpendicular to the side surface, and has an edge portion of the second protruding plate portion where at least a part on the side opposite to the side plate portion contacts the drawer portion along the extending direction of the drawer portion. The connecting portion further has a second connecting portion where the drawer portion and the edge portion of the second protruding plate portion are welded. The second connecting portion is formed by connecting a plurality of welding marks along the extending direction of the drawer portion. The inductor according to any one of claims 1 to 3.

6. When the length of the first connecting portion in the extending direction of the drawer portion is L1, the thickness of the first protruding plate portion is t1, and the cross-sectional area of the drawer portion is S. L1 ≥ (S × 0.1) / t1 has the relationship of When the length of the second connecting portion in the extending direction of the drawer portion is L2 and the thickness of the second protruding plate portion is t2. L2 ≥ (S × 0.1) / t2 has the relationship of The inductor according to claim 5.

7. The side plate portion is located between the side surface and the drawer portion. The first protruding plate portion and the second protruding plate portion protrude from both ends of the side plate portion when viewed from a direction perpendicular to the side surface. The inductor according to claim 5 or 6.

8. The side plate portion has an opening along the extending direction of the drawer portion. The first protruding plate portion and the second protruding plate portion protrude from regions located on both outer sides of the opening of the side plate portion when viewed from a direction perpendicular to the side surface. The inductor according to claim 5 or 6.

9. The drawer portion extends along a direction connecting the bottom surface and the top surface. The inductor according to any one of claims 1 to 8.

10. The drawer portion extends along a direction intersecting the direction connecting the bottom surface and the top surface. The inductor according to any one of claims 1 to 8.

11. The side surface has a first side surface and a second side surface facing away from each other. The drawer portion has a first drawer portion connected to one end of the coil portion and a second drawer portion connected to the other end of the coil portion. The first drawer portion is drawn out from the first side surface and extends along a direction intersecting the direction connecting the bottom surface and the top surface. The second drawer portion is drawn out from the second side surface and extends along a direction intersecting with a direction connecting the bottom surface and the top surface. The inductor according to claim 10.

12. The magnetic core has a notch provided on the top surface. The electrode member further has a locking portion connected to the bottom plate portion and locked to the notch. The inductor according to any one of claims 1 to 11.

Images