inductor

Abstract

To increase the reliability of an inductor.SOLUTION: An inductor 100 includes a magnetic core 10 with a side surface 13c, a coil element, and a plate-shaped electrode member 30 disposed on the side surface 13c and electrically connected to the coil element. A lead-out part 22 includes a bent part 22a whose extending direction is bent outside the magnetic core 10 and an extension part 22b extending from the bent part 22a. When the side surface 13c where the lead-out part 22 is led out among side surfaces 13a to 13d is a second side surface, the electrode member 30 includes a side plate part 35 disposed along the second side surface, a first protrusion plate part 36i connecting to the side plate part 35, protruding in a direction apart from the second side surface, and having an edge part on the opposite side of the second side surface welded to the extension part 22b, and a second protrusion plate part 36ii connecting to the side plate part 35, protruding in the direction apart from the second side surface, and having an edge part on the opposite side of the second side surface welded to the bent part 22a.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to inductors. [Background technology]

[0002] Inductors are passive elements that store electrical energy as magnetic energy and are used, for example, in DC-DC converter devices and the like for the purposes of increasing or decreasing power supply voltage and smoothing direct current. Inductors are mounted on the surface of, for example, a circuit board. For example, Patent Document 1 discloses an inductor that includes a main body containing a magnetic material, a coil element disposed inside the main body, and a terminal metal fitting connected to the coil element. In the inductor described in Patent Document 1, the terminal metal fitting is attached to the main body with an adhesive, and the terminal metal fitting is welded to the tip of the coil element exposed from the main body. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2011-243685 Summary of the Invention [Problem to be solved by the invention]

[0004] In conventional inductors, the reliability of the connection between the electrode member (terminal metal fitting) and the magnetic core may be low depending on the usage environment, resulting in low reliability of the inductor. In view of the above, an object of the present disclosure is to improve the reliability of inductors. [Means for solving the problem]

[0005] An inductor according to one embodiment of the present disclosure comprises a magnetic core containing a magnetic material and having a side surface, a coil element having a coil portion embedded in the magnetic core and a draw-out portion connected to an end of the coil portion and drawn out from the side surface to the outside of the magnetic core, and a plate-shaped electrode member arranged on the side surface and electrically connected to the coil element via the draw-out portion, wherein the draw-out portion has a bent portion whose extension direction is bent outside the magnetic core and an extension portion extending from the bent portion, and when the side surface from which the draw-out portion is drawn out is defined as a second side surface, the electrode member has a side plate portion arranged along the second side surface, a first protruding plate portion connected to the side plate portion and protruding in a direction away from the second side surface and having an edge portion located opposite the second side surface welded to the extension portion, and a second protruding plate portion connected to the side plate portion and protruding in a direction away from the second side surface and having an edge portion located opposite the second side surface welded to the bent portion. [Effects of the Invention]

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

[0007] [Figure 1] 1 is a first perspective view of an inductor according to an embodiment. [Figure 2] FIG. 2 is a second perspective view of the inductor according to the embodiment. [Figure 3] FIG. 1 is a first diagram for explaining connection points between lead portions and electrode members of an inductor according to an embodiment. [Figure 4] FIG. 2 is a second diagram for explaining the connection points between the lead-out portions and the electrode members of the inductor according to the embodiment. [Figure 5] FIG. 2 is a top view of a portion of an inductor according to an embodiment. [Figure 6] FIG. 2 is a side view of a portion of an inductor according to an embodiment. [Figure 7] FIG. 10 is another side view of a portion of the inductor according to the embodiment. [Figure 8] 10A and 10B are diagrams illustrating a convex portion of an inductor according to a modified example of the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0008] (Background to this disclosure) In a structure in which the terminal fittings are fixed to the main body only with adhesive, as in the aforementioned Patent Document 1, the relatively heavy magnetic core can be shaken by vibration, causing the magnetic core to come off from the electrode member soldered to the circuit board, and the welded portion can also come off.In particular, when an inductor is configured by bending the tip of a coil element, if the bent portion is used to weld the electrode member, the welding cannot be performed (or cannot be maintained) normally, and as a result, the electrode member and magnetic core can come off at this welded portion.

[0009] The present disclosure has the following configuration to improve the reliability of an inductor. Hereinafter, the embodiments will be described in more detail with reference to the drawings.

[0010] Note that the embodiments described below each illustrate a specific example of the present disclosure. The numerical values, shapes, materials, components, component placement positions, connection configurations, steps, and step sequences shown in the following embodiments are examples and are not intended to limit the present disclosure. Furthermore, among the components in the following embodiments, components that are not recited in independent claims are described as optional components.

[0011] Furthermore, in this specification, terms indicating the relationship between elements, such as parallelism, terms indicating the shape of elements, such as rectangular parallelepiped, and numerical ranges are not expressions that only express a strict meaning, but are expressions that also include a substantially equivalent range, for example, a difference of about a few percent.

[0012] In addition, each drawing is a schematic diagram in which emphasis, omission, or adjustment of proportions has been appropriately made to illustrate the present disclosure, and is not necessarily an exact illustration, and may differ from the actual shape, positional relationship, and proportion. In each drawing, substantially the same configuration is assigned the same reference numeral, and duplicated explanations may be omitted or simplified.

[0013] Each figure also shows an X-axis, a Y-axis, and a Z-axis, which represent three mutually orthogonal directions, and these axes and the axial directions along these axes are used as necessary for explanation. Note that each axis is added for explanation purposes only and does not limit the direction or posture in which the inductor is used.

[0014] Furthermore, in this specification, the terms "top surface" and "bottom surface" in the configuration of an inductor do not refer to the top surface (the surface on the vertically upper side) and bottom surface (the surface on the vertically lower side) in absolute spatial recognition, but are used as terms defined by the relative positional relationship of the components of the inductor.

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

[0016] Fig. 1 is a first perspective view of an inductor according to an embodiment as viewed from the top side, and Fig. 2 is a second perspective view of the inductor shown in Fig. 1 as viewed from the bottom side.

[0017] As shown in Figures 1 and 2, the inductor 100 comprises a magnetic core 10, a coil element having a coil portion 21 and an extension portion 22, an electrode member 30 which is an external terminal, and a connection portion which connects the extension portion 22 and the electrode member 30.

[0018] In the following explanation, the positive half of the X-axis in inductor 100 will be mainly described, but the negative half of the X-axis in inductor 100 has the same structure as the positive half of the X-axis in inductor 100, and the same explanation applies.

[0019] The approximate outer shape of inductor 100 is determined by the shape of magnetic core 10, which is, for example, a rectangular parallelepiped powder magnetic core. Magnetic core 10 can be molded into any shape. That is, depending on the shape of magnetic core 10 during molding, inductor 100 of any shape can be realized. Magnetic core 10 of this embodiment has, for example, dimensions in the X-axis direction of 17 mm or more, dimensions in the Y-axis direction of 17 mm or more, and dimensions in the Z-axis direction of 7 mm or more.

[0020] The magnetic core 10 is the outer shell of the inductor 100 and covers a portion of the coil element (coil portion 21). The magnetic core 10 includes a magnetic material, for example, a powder magnetic core made of a metal magnetic powder and a resin material. The magnetic core 10 may be formed using any magnetic material. The magnetic material may be ferrite or other magnetic materials. The metal magnetic powder is a particulate material having a predetermined element composition, such as an Fe-Si-Al-based, Fe-Si-based, Fe-Si-Cr-based, or Fe-Si-Cr-B-based material. The resin material is selected from materials such as silicone-based resins that can maintain a certain shape by binding the metal magnetic powder particles while insulating them from each other.

[0021] The magnetic core 10 has, for example, a rectangular parallelepiped shape. 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 connected to the bottom surface 11 and the top surface 12. The side surfaces 13a and 13b are aligned in the X-axis direction and face each other back to back. The side surfaces 13c (also referred to as the second side surface) and 13d (also referred to as the first side surface) are aligned in the Y-axis direction and face each other back to back. The bottom surface 11, the top surface 12, and the side surfaces 13a, 13b, 13c, and 13d are each substantially flat planes. The pair of the bottom surface 11 and the top surface 12, the pair of the side surfaces 13a and 13b, and the pair of the side surfaces 13c and 13d are each pairs of surfaces that are in a parallel positional relationship. The bottom surface 11 and the top surface 12 extend in directions that intersect with the side surfaces 13a, 13b, 13c, and 13d, specifically in directions that are perpendicular to each other. The side surfaces 13a and 13b extend in directions that intersect with the side surfaces 13c and 13d, specifically in directions that are perpendicular to each other.

[0022] The coil element has a coil portion 21 made of a single wire embedded in magnetic core 10, and multiple lead portions 22 that correspond to both ends of the wire and are exposed to the outside of magnetic core 10. In other words, the coil element according to the embodiment is composed of one coil portion 21 and two lead portions 22. In FIG. 1, the embedded coil portion 21 is indicated by a dashed line.

[0023] The coil element is composed of, for example, a conductor wire. The conductor wire is composed of a metal wire made of a metal material selected from metals such as aluminum, copper, silver, and gold, alloys containing one or more of these metals, and materials made of metals or alloys and other substances, and an insulating coating that covers the metal wire. Specifically, the conductor wire is, for example, a copper wire covered with an insulating coating. The coil portion 21 and the lead-out portion 22 are names given to respective portions formed, for example, by processing a single member made of the same material.

[0024] The coil portion 21 is a portion covered by the magnetic core 10. The coil portion 21 is made of a wound conductor and functions as a coil. There is no particular limitation on the number of turns of the coil portion 21, and it may be selected appropriately, for example, from 0.5 to 10 turns, depending on the performance required of the inductor 100 and constraints such as the size of the magnetic core 10. The cross section of the conductor constituting the coil portion 21 is, for example, a rectangular wire with each side measuring 3.2 mm x 2.4 mm. The coil portion 21 is wound vertically with the surfaces including the long sides of the cross section of the conductor overlapping. The coil portion 21 is embedded in the magnetic core 10 so that the winding axis of the coil portion 21 is aligned along the direction connecting the bottom surface 11 and the top surface 12 (the Z-axis direction).

[0025] Coil portion 21 has end portions (not shown) that connect from the wound portion to side surface 13c of magnetic core 10. One end of coil portion 21 is located on the positive side of the X axis, which is closer to the right of the winding axis, when viewed from a direction perpendicular to side surface 13c, and the other end is located on the negative side of the X axis, which is closer to the left of the winding axis. Furthermore, when viewed from a direction perpendicular to side surface 13c, the ends of coil portion 21 are located closer to bottom surface 11 than the center of side surface 13c, and are at the same height from bottom surface 11.

[0026] Lead-out portion 22 is connected to an end of coil portion 21, drawn out from side surface 13c of magnetic core 10, and extends along side plate portion 35 or side surface 13c. Specifically, lead-out portion 22 is drawn in a direction perpendicular to side surface 13c from a height closer to bottom surface 11 than the center of side surface 13c, and is bent so that a surface including the long side of the cross section of lead-out portion 22 faces side surface 13c and extends parallel to side plate portion 35 of electrode member 30. In other words, lead-out portion 22 has bent portion 22a whose extension direction is bent outside magnetic core 10, and extending portion 22b extending from the bent portion along side surface 13c. As a result, extending portion 22b of lead-out portion 22 extends in the direction connecting bottom surface 11 and top surface 12 (the Z-axis direction) at a tip end side of bent portion 22a in the extension direction and ends before reaching the end on the top surface 12 side. In this embodiment, the lead-out portion 22 is led out from one of the four side surfaces, ie, the side surface 13c.

[0027] As shown in FIGS. 1 and 2, the electrode members 30 are arranged outside the magnetic core 10 (for example, on the bottom surface 11 side, the side surface 13c (second side surface) side, and the other side surface 13d (first side surface) side), and are electrically connected to the lead portions 22 via connecting portions. The electrode members 30 are provided corresponding to each of the two lead portions 22. The electrode members 30 include a conductive material and are made of, for example, a metal material plate. The metal material plate is made of a metal material selected from metals such as aluminum, copper, silver, and gold, alloys containing one or more of these metals, and materials made of metals or alloys and other substances.

[0028] 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 arranged on the side surface 13c side of the magnetic core 10, and a locking portion 38 connected to the bottom plate portion 31 and arranged on the other side surface 13d side of the magnetic core 10. The side plate portion 35 has a first protruding plate portion 36i and a second protruding plate portion 36ii connected to the side plate portion 35. The bottom plate portion 31, the side plate portion 35, the locking portion 38, the first protruding plate portion 36i, and the second protruding plate portion 36ii are names given to respective portions formed, for example, by processing a single member made of the same material.

[0029] 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 may be fixed to the magnetic core 10 via an adhesive. When the inductor 100 is mounted on the circuit board, the bottom plate portion 31 is joined to the circuit board by soldering. Note that the bottom plate portion 31 may have a portion that protrudes outward from the magnetic core 10 when viewed from the top surface 12 side (when viewed in a plan view in the Z-axis direction). This is preferable because when soldering in a reflow furnace, the protruding portion can be easily heated by preheating the reflow furnace, improving solderability.

[0030] 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 in this embodiment extends from the bottom plate portion 31 toward the top surface 12. The side plate portion 35 has an opening that penetrates the thickness direction so that the lead-out portion 22 can pass through. The lead-out portion 22 passes through this opening and is disposed along the side surface 13c. When viewed from the X-axis direction, the side plate portion 35 is disposed between the side surface 13c of the magnetic core 10 and the lead-out portion 22, and when viewed from the Y-axis direction, the side plate portion 35 is disposed around the lead-out portion 22. The side plate portion 35 is disposed corresponding to one of the four side surfaces 13c. The side plate portion 35 may be fixed to the magnetic core 10 via an adhesive.

[0031] The first protruding plate portion 36i and the second protruding plate portion 36ii are connected to the opening edge of the side plate portion 35 and protrude in a direction away from the side surface 13c of the magnetic core 10. The first protruding plate portion 36i and the second protruding plate portion 36ii protrude perpendicular to the side plate portion 35 or from the opening edge of the side plate portion 35 so as to approach the lead-out portion 22. The first protruding plate portion 36i and the second protruding plate portion 36ii have edges located on the opposite side from the side surface 13c, and at least a portion of the edges contact the lead-out portion 22 along the extension direction of the lead-out portion 22.

[0032] Here, the connection points between the lead-out portion 22 and the electrode member 30 will be described with reference to Fig. 3 and Fig. 4. Fig. 3 is a first diagram for describing the connection points between the lead-out portion and the electrode member of the inductor according to the embodiment. Fig. 4 is a second diagram for describing the connection points between the lead-out portion and the electrode member of the inductor according to the embodiment.

[0033] 3(a) shows a part of the inductor 100 centered on one of the lead-out portions 22 when viewed from a direction perpendicular to the side surface 13c, and (b) shows a part of a cross section of the inductor 100 taken along line bb in (a) when viewed from a direction perpendicular to the top surface 12. Note that the welding marks ws at the connection portions are not shown in FIG.

[0034] 3(a), the first protruding plate portion 36i connected to the side plate portion 35 corresponds to the extending portion 22b at the bent tip end side of the drawn-out portion 22 as described above. The second protruding plate portion 36ii connected to the side plate portion 35 corresponds to the bent portion 22a of the drawn-out portion 22 as described above. As shown by the welding marks ws in FIG. 1, a portion of the first protruding plate portion 36i is welded to a portion of the extending portion 22b, and a portion of the second protruding plate portion 36ii is welded to a portion of the bent portion 22a.

[0035] The bent portion 22a is a bent portion formed when the wire of the coil element is bent by applying stress. The stress applied to the bulk portion differs between the outer side (the side of the extension portion 22b farther from the side surface 13c) and the inner side (the side of the extension portion 22b closer to the side surface 13c) during bending. Specifically, on the outer side during bending, the bulk portion is pulled in the direction in which the wire extends, making it unable to maintain its original wire width (here, the length in the X-axis direction), resulting in a change in the widthwise length. On the inner side during bending, the bulk portion is pushed in from the direction in which the wire extends, making it unable to maintain its original wire width (here, the length in the X-axis direction), resulting in a change in the widthwise length.

[0036] In this way, the bent portion 22a has a width different from the wire width. If the second protruding plate portion 36ii is provided to match the original wire width, the bent portion 22a and the second protruding plate portion 36ii may become separated from each other, or the second protruding plate portion 36ii may be pushed out by the bent portion 22a and not be able to maintain its designed position. As a result, defects may occur when welding the bent portion 22a and the second protruding plate portion 36ii. In this embodiment, to prevent such defects from occurring, an electrode member 30 is used in which the second protruding plate portion 36ii is provided in advance to correspond to the bent portion 22a.

[0037] In other words, the first protruding plate portion 36i and the second protruding plate portion 36ii, which contact the drawer portion 22 from the width direction (X-axis direction) of the drawer portion 22, have different positions in the width direction.

[0038] In this embodiment, as shown in FIG. 3 , the first protruding plate portions 36i are provided at two locations. Specifically, the first protruding plate portions 36i are provided at two locations that sandwich the extending portion 22b in the width direction. Similarly, the second protruding plate portions 36ii are provided at two locations that sandwich the bending portion 22a in the width direction. As described above, since the first protruding plate portions 36i and the second protruding plate portions 36ii are located at different widthwise positions, the separation distance D1 between the two first protruding plate portions 36i that sandwich the extending portion 22b is different from the separation distance D2 between the two second protruding plate portions 36ii that sandwich the bending portion 22a. More specifically, the separation distance D1 between the two first protruding plate portions 36i that sandwich the extending portion 22b is smaller than the separation distance D2 between the two second protruding plate portions 36ii that sandwich the bending portion 22a.

[0039] This is because the second protruding plate portion 36ii is provided to match the wire width that expands in the width direction when the wire is bent on the inside due to the bulk portion being pushed in the direction in which the wire extends and is unable to maintain its original width. Note that the second protruding plate portion 36ii may also be provided to match the wire width that contracts in the width direction when the wire is bent on the outside due to the bulk portion being pulled in the direction in which the wire extends and is unable to maintain its original width. In this case, the distance D1 between the two first protruding plate portions 36i that sandwich the extension portion 22b is greater than the distance D2 between the two second protruding plate portions 36ii that sandwich the bent portion 22a.

[0040] Furthermore, in order to maintain the connection reliability between the lead portion 22 and the electrode member 30 while maintaining the distance between the two first protruding plate portions 36i and the two second protruding plate portions 36ii, as well as to ensure the strength of the electrode member 30, the lead portion 22 is inserted into an opening 35a (a hole penetrating the side plate portion 35 in the thickness direction) provided in the side plate portion 35. This opening 35a is a single hole provided between the two first protruding plate portions 36i and between the two second protruding plate portions 36ii. The opening 35a is configured to have an inner periphery that is independent from the outer periphery of the side plate portion 35 (the outermost boundary of the side plate portion 35 when viewed from a direction perpendicular to the side surface 13c). Both the first protruding plate portion 36i and the second protruding plate portion 36ii are present on this inner periphery.

[0041] Therefore, the two first protruding plate portions 36i are connected to each other by the side plate portions 35 on the upper (top surface 12 side) and lower (bottom surface 11 side) sides of the inner periphery of the opening 35a. Similarly, the two second protruding plate portions 36ii are connected to each other by the side plate portions 35 on the upper (top surface 12 side) and lower (bottom surface 11 side) sides of the inner periphery of the opening 35a. In this way, by providing the two first protruding plate portions 36i on the inner periphery of the closed opening 35a, it is possible to ensure a resistance to a force that widens the separation distance D1 between the two first protruding plate portions 36i. Similarly, by providing the two second protruding plate portions 36ii on the inner periphery of the closed opening 35a, it is possible to ensure a resistance to a force that widens the separation distance D2 between the two second protruding plate portions 36ii.

[0042] 3(b), the second protruding plate portion 36ii has a two-stage bending structure including a third-direction bending portion 36f that bendingly extends in a third direction away from the side surface 13c via a third bending portion 36e connected to the side plate portion 35, and a fourth-direction bending portion 36h that bendingly extends in a fourth direction different from the third direction and away from the side surface 13c via a fourth bending portion 36g connected to the third-direction bending portion 36f. A similar two-stage bending structure is also present in the first protruding plate portion 36i. This two-stage bending structure will be described with reference to FIG. 4.

[0043] Fig. 4 shows a portion of the cross section of inductor 100 taken along line iv-iv in Fig. 3(a). Fig. 4(a) shows the inductor during manufacture before side plate portion 35 is aligned with side surface 13c, Fig. 4(b) shows the inductor during manufacture while side plate portion 35 is being aligned with side surface 13c, and Fig. 4(c) shows the inductor during manufacture after side plate portion 35 has been aligned with side surface 13c. Note that Fig. 4 does not show the welding marks ws at the connection portions, and does not show some of the configuration, such as bent portion 22a, which is located on the negative side of the cross section in the Z-axis direction.

[0044] As shown in FIG. 4, when attaching the first protruding plate portion 36i and the second protruding plate portion 36ii to the drawer portion 22, the side plate portion 35 is pressed against the side surface 13c using a press P having a flat pressing surface, thereby performing the attachment. At this time, as shown in FIG. 4(b), there is a timing when the press P and the drawer portion 22 are aligned in the width direction. At this time, the first side plate portion 36i (or the second side plate portion 36ii) extends between the press P and the drawer portion 22, intersecting the alignment direction thereof. Therefore, the press P presses the drawer portion 22 from a distance sufficient to allow the first side plate portion 36i (or the second side plate portion 36ii) to be present.

[0045] The first side plate portion 36i has a portion (first direction protruding portion 36b) that connects the side plate portion 35 that runs along the pressing surface of the press P and a portion (second direction protruding portion 36d) that runs along the surface in the width direction of the drawer portion 22, the portion being formed in accordance with the separation distance between the press P and the drawer portion 22. As a result, the first protruding plate portion 36i has a two-stage bent structure that includes the first direction protruding portion 36b that protrudes in a first direction away from the side surface 13c via a first bent portion 36a connected to the side plate portion 35, and the second direction protruding portion 36d that protrudes in a second direction different from the first direction and away from the side surface 13c via a second bent portion 36c connected to the first direction protruding portion 36b.

[0046] 1 and 2, the lead-out portion 22 has a covered region with an insulating coating on the outer circumferential surface of the lead-out portion 22, and a bare region where the conductor is exposed without the insulating coating. All or most of the bare region is provided on the side where the first protruding plate portion 36i and the second protruding plate portion 36ii are arranged.

[0047] The exposed regions are in contact with the edges of the first protruding plate portion 36i and the second protruding plate portion 36ii. Connections are formed at the locations where the exposed regions are in contact with the edges of the first protruding plate portion 36i and the second protruding plate portion 36ii.

[0048] 1, the connection portion is formed by welding the lead-out portion 22 to the edges of the first protruding plate portion 36i and the second protruding plate portion 36ii. For example, such a connection portion is configured by a plurality of weld marks ws formed by laser seam welding, and the plurality of weld marks ws are connected along the extension direction of the lead-out portion 22. All of the plurality of weld marks ws may be continuously connected, or only some of the weld marks ws may be continuously connected.

[0049] The length of the connection portion in the extension direction of the lead portion 22 is, for example, greater than the length of the long side of the cross section of the conductor in the lead portion 22, but not greater than five times the length of the long side. The longer the length of the connection portion, the larger the cross-sectional area of the welded portion.

[0050] In this embodiment, the edges of the first protruding plate portion 36i and the second protruding plate portion 36ii are in contact with each other along the extension direction of the lead-out portion 22. This allows the length of the connection portion formed by welding the edges to the lead-out portion 22 to be increased. This allows the cross-sectional area of the connection portion connecting the coil element 20 and the electrode member 30 to be increased, thereby improving the reliability of the connection. Furthermore, since the cross-sectional area of the current path in the connection portion can be increased, the DC resistance can be reduced and the reliability of the inductor can be improved. Furthermore, since the cross-sectional area of the current path in the connection portion can be increased, the temperature rise that occurs when current is applied to the inductor can be suppressed, thereby improving the reliability of the inductor.

[0051] In the following explanation, we will mainly explain the half of inductor 100 on the negative side of the X-axis, but the half of inductor 100 on the positive side of the X-axis has a similar structure to the half of inductor 100 on the negative side of the X-axis, and the same explanation applies.

[0052] As shown in FIG. 2 , the electrode member 30 has a locking portion 38 along the side surface 13d. More specifically, the locking portion 38 is connected to the bottom plate portion 31 and is arranged along the side surface 13d of the magnetic core 10. In this embodiment, the locking portion 38 extends from the bottom plate portion 31 toward the top surface 12 and is arranged between the outermost and innermost portions of the side surface 13d of the magnetic core 10 when viewed from the X-axis direction. The locking portion 38 is arranged to correspond to one of the four side surfaces 13d. An opening 38a is formed in the locking portion 38. The opening 38a is a rectangular through-hole that penetrates the electrode member 30 in the thickness direction (here, the Y-axis direction). The opening 38a corresponds to the protrusion 131d formed on the side surface 13d, and the locking portion 38 is arranged so that the protrusion 131d penetrates the opening 38a. The locking portion 38 may be fixed to the magnetic core 10 via an adhesive. Such locking portions 38 are used to fix the magnetic core 10 and the electrode member 30 by locking the side surface of the protrusion 131d on the top surface 12 side with the inner surface of the opening 38a on the top surface 12 side (facing the bottom surface 11 side). In other words, the electrode member 30 is fixed to the magnetic core 10 by locking the protrusion 131d with the locking portions 38, welding at the connection portions, and (in some cases, bonding the bottom plate portion 31, the side plate portion 35, and the locking portions 38 together). For example, as shown in the figure, such protrusion 131d is formed closer to the bottom surface 11 than the center of the magnetic core 10.

[0053] FIG. 5 is a top view of a portion of the inductor according to the embodiment. FIG. 5 shows a portion of the inductor 100 viewed from the top surface 12 side (in a plan view in the Z-axis direction) with the locking portion 38 at the center. As shown in FIG. 5, the protrusion 131d has a shape that protrudes vertically from the side surface 13d (here, toward the positive side in the Y-axis direction). A recess 132d is formed around the protrusion 131d so as to surround the protrusion 131d. The locking portion 38 is disposed inside the magnetic core 10 relative to the outermost surface of the protrusion 131d because the protrusion 131d penetrates the opening 38a. The locking portion 38 contacts the recess 132d and does not extend further inside the magnetic core 10. A portion 134d of the recess 132d is further recessed into the magnetic core 10 at a position corresponding to a locking surface 135d, which is the side surface of the protrusion 131d on the top surface 12 side to which the locking portion 38 is locked.

[0054] Therefore, recess 132d has portion 134d that is recessed further into magnetic core 10 than other portion 133d. Portion 134d of recess 132d has a curved surface whose depth into magnetic core 10 changes smoothly. Locking portion 38 has crimped portion 38b bent into a smooth curve along the curved surface. Crimped portion 38b is bent so as to enter portion 134d of recess 132d, improving the resistance of locking portion 38 to tension in the Z-axis direction. Furthermore, the provision of crimped portion 38b deforms the rectangular shape of opening 38a as shown in FIG. 6.

[0055] FIG. 6 is a side view of a portion of an inductor according to an embodiment. FIG. 6 illustrates a portion of inductor 100 as viewed from side surface 13d (in a plan view in the Y-axis direction) with locking portion 38 at the center. As shown in FIG. 6, one side of the rectangular shape of opening 38a corresponding to locking surface 135d is tightened and narrowed in the X-axis direction and is shorter than the opposite side. Specifically, when the length of the side corresponding to locking surface 135d is L5, L5 is shorter than the length L6 of the opposite side. Therefore, the rectangular shape of opening 38a is a so-called trapezoidal shape, and the inner surfaces of opening 38a on the side surfaces 13a and 13b contact protrusion 131d so as to sandwich it, improving the resistance of locking portion 38 to misalignment in the Y-axis direction.

[0056] To ensure reliable locking by the locking portion 38, the length of the locking surface 135d of the protrusion 131d in the direction along the plate surface of the electrode member 30 is sufficiently long. For example, the locking portion 38 is designed so that the length L5 of the side corresponding to the locking surface 135d is sufficiently large relative to the thickness L4 of the locking portion 38 (the thickness of the electrode member 30) shown in Fig. 5. L5 is, for example, at least twice the length of L4.

[0057] Returning to the explanation of FIG. 2, bottom plate portion 31 has bottom surface crimped portion 31a. Bottom surface crimped portion 31a tightens and narrows the length of bottom plate portion 31 in the Y-axis direction, thereby enabling locking portion 38 to more firmly lock onto protrusion 131d. In order to form bottom surface crimped portion 31a on bottom surface 11, magnetic core 10 is formed with bottom surface recess 11a, which is recessed into magnetic core 10 at a position on bottom surface 11 that overlaps with bottom plate portion 31 of electrode member 30. Bottom plate portion 31 then enters inside magnetic core 10 and curves along the recessed shape of bottom surface recess 11a, thereby forming bottom surface crimped portion 31a.

[0058] Regarding the width of the electrode member 30 at the bottom plate portion 31 (the length in the X-axis direction of the electrode member 30 extending in the Y-axis direction), for example, the width L2 at the position of the bottom surface crimped portion 31a is narrower than the other portions (for example, the length L1). This allows the bottom surface crimped portion 31a to be formed with less stress, and the narrowing of the length of the bottom plate portion 31 when the bottom surface crimped portion 31a is formed is efficiently transmitted to the crimped portion 38b and the like, making the electrode member 30 more firmly fixed to the magnetic core 10.

[0059] Here, Fig. 7 is another side view of a portion of the inductor according to the embodiment. Fig. 7 shows a portion of inductor 100 viewed from side surface 13b (in a plan view in the X-axis direction) with locking portion 38 and bottom plate portion 31 at the center. As shown in Fig. 7, magnetic core 10 has recessed void portion 11b formed inside magnetic core 10 at the boundary connecting bottom surface 11 and side surface 13d and at a position overlapping electrode member 30. Formation of void portion 11b provides play, making it less likely that the boundary will hinder the narrowing of bottom plate portion 31 by bottom surface crimping portion 31a, and therefore allowing the effect of bottom surface crimping portion 31a to be more efficiently applied to locking portion 38.

[0060] 2, the area of the bottom plate portion 31 on the side 13c side of the bottom crimped portion 31a (portion 31b in the figure) is larger than the area of the other side 13d side of the bottom crimped portion 31a (portion 31c in the figure). If the width of the bottom crimped portion 31a is narrowed, a portion with high electrical resistance will be formed between the portion 31b side and the portion 31c side. Therefore, by ensuring a portion 31b with a larger area closer to the lead-out portion 22 than this portion with high electrical resistance, it is possible to suppress deterioration of the electrical conductivity characteristics.

[0061] [Manufacturing method] Next, a description will be given of a method for manufacturing the above-described inductor 100. The inductor according to the embodiment is manufactured as follows. Note that the method for manufacturing the inductor 100 is not limited to the following example.

[0062] In the manufacturing method of the inductor 100, a step of pressure molding the magnetic core 10 together with the coil element is first carried out. This step is carried out by placing the coil element having the coil portion 21 in a molding die and pressure molding the powder magnetic core. The pressure during pressure molding is, for example, 5 ton / cm. 2 The thermosetting temperature is, for example, 185° C. After pressure molding, exposed lead portions 22 that are not covered by magnetic core 10 protrude perpendicularly to side surface 13c of magnetic core 10, for example.

[0063] Next, a step is performed to form a bare region on the outer peripheral surface of the lead portion 22. The bare region is formed by removing a part of the insulating coating by laser irradiation or the like after pressure molding.

[0064] Next, a step is performed in which lead-out portion 22 exposed from magnetic core 10 is bent along side surface 13c. Specifically, lead-out portion 22 is formed so as to have a shape extending from its base located on side surface 13c in a direction connecting bottom surface 11 and top surface 12, and so that a surface including a long side of the cross section of lead-out portion 22 faces side surface 13c.

[0065] Next, a process is performed in which the metal material plate is punched and bent to prepare the electrode member 30 having the bottom plate portion 31, the side plate portions 35, and the locking portion 38. In this process, the first protruding plate portion 36i and the second protruding plate portion 36ii of the side plate portion 35 are bent in advance in a direction away from the side surface 13c of the magnetic core 10. It is also advisable to pre-bend the boundary portion between the bottom plate portion 31 and the side plate portions 35 and the boundary portion between the bottom plate portion 31 and the locking portion 38 so that the interior angles are approximately 100° to 110°.

[0066] Next, the electrode member 30 is placed on the magnetic core 10 as shown in FIG. 1 . The bottom plate 31 is placed on the bottom surface 11 of the magnetic core 10, and the side plate 35 is bent to fit along the side surface 13c of the magnetic core 10, and the locking portion 38 is bent to fit along the other side surface 13d of the magnetic core 10. At this time, the lead-out portion 22 penetrates the opening of the side plate 35, so that the extension 22b of the lead-out portion 22 comes into contact with the edge of the first protruding plate portion 36i. The bent portion 22a of the lead-out portion 22 also comes into contact with the edge of the second protruding plate portion 36ii. In this step, the side plate 35 may be attached by pressing the side plate 35 against the side surface 13c using a press P with a flat pressing surface. The protrusion 131d also penetrates the opening 38a of the locking portion 38. Furthermore, when any or all of the bottom plate portion 31, side plate portion 35, and locking portion 38 of the electrode member 30 are to be bonded to the magnetic core 10, in this step, a thermosetting adhesive that is viscous when uncured is applied to the portion where the electrode member 30 contacts the magnetic core 10. The adhesive is not cured in this step, but will be cured in a later step described below.

[0067] Next, a process is performed in which the edges of the first protruding plate portion 36i and the second protruding plate portion 36ii are welded to the lead portion 22 by laser seam welding or the like. Specifically, a connection portion is formed along the extension direction of the lead portion 22. The weld marks ws formed at the connection portion are circular and are formed, for example, by rotating the laser beam spot at a predetermined radius. At this time, welding is performed while pressing the bottom plate portion 31 of the electrode member 30 against the bottom surface 11 of the magnetic core 10, the side plate portions 35 of the electrode member 30 against the side surface 13c of the magnetic core 10, and the locking portion 38 of the electrode member 30 against the other side surface 13d of the magnetic core 10. This electrically connects the lead portion 22 to the electrode member 30 and mechanically fixes the electrode member 30 to the magnetic core 10.

[0068] Next, a step is performed in which the locking portion 38 is bent so as to enter the part 134d of the recess 132d of the magnetic core 10. As a result, a crimped portion 38b is formed, and the opening 38a of the locking portion 38 is narrowed.

[0069] Next, a step is performed in which the bottom plate portion 31 is bent so as to fit into the bottom recess 11a of the magnetic core 10. This forms the bottom crimped portion 31a, narrowing the electrode member 30. By narrowing the electrode member 30 in this order, first the crimped portion 38b and then the bottom crimped portion 31a, the entire electrode member 30 is fastened to the magnetic core 10, firmly fixing the electrode member 30 and the magnetic core 10 together. Furthermore, when bonding the electrode member 30 and the magnetic core 10, this step is followed by a step of hardening the adhesive by heat treatment. By curing the adhesive after narrowing by the crimped portion 38b and the bottom crimped portion 31a, the viscosity of the uncured adhesive allows the crimped portion 38b and the bottom crimped portion 31a to efficiently fasten the electrode member 30 to the magnetic core 10, and after the adhesive hardens, the adhesive force of the adhesive can further strengthen the fixing force between the electrode member 30 and the magnetic core 10. In this way, the inductor 100 is manufactured.

[0070] [Effects, etc.] As described above, inductor 100 according to this embodiment includes magnetic core 10, which contains a magnetic material and has side surfaces 13a to 13d, a coil element having coil portion 21 embedded in magnetic core 10 and lead-out portion 22 connected to an end of coil portion 21 and led out from side surface 13c to the outside of magnetic core 10, and plate-shaped electrode member 30 disposed on side surface 13c and electrically connected to the coil element via lead-out portion 22, and lead-out portion 22 has bent portion 22a whose extension direction is bent outside magnetic core 10, and When side surface 13c from which lead-out portion 22 is drawn out among side surfaces 13a to 13d is defined as the second side surface, electrode member 30 has a side plate portion 35 arranged along the second side surface, a first protruding plate portion 36i connected to side plate portion 35 and protruding in a direction away from the second side surface, and having an edge portion located on the opposite side to the second side surface welded to extension portion 22b, and a second protruding plate portion 36ii connected to side plate portion 35 and protruding in a direction away from the second side surface, and having an edge portion located on the opposite side to the second side surface welded to bent portion 22a.

[0071] In this inductor 100, the bent portion 22a and the electrode member 30, and the extended portion 22b and the electrode member 30 can be welded separately. When forming the bent portion 22a, the line width of the bent portion 22a may differ from the line width of the wire. On the other hand, the line width of the extended portion 22b is equal to the line width of the wire. Therefore, when forming a protruding plate portion protruding from the side plate portion 35 and welding it to the lead-out portion 22, it is possible to reduce the possibility that the protruding plate portion formed to match the line width of the extended portion 22b will be poorly welded to the bent portion 22a, and the possibility that the protruding plate portion formed to match the line width of the bent portion 22a will be poorly welded to the extended portion 22b. This improves the reliability of the welding, thereby realizing a more reliable inductor 100.

[0072] Also, for example, the first protruding plate portions 36i may be provided at two locations on either side of the extending portion 22b, and the second protruding plate portions 36ii may be provided at two locations on either side of the bent portion 22a.

[0073] This allows welding to be performed by the two first protruding plate portions 36i that sandwich the extension portion 22b, and by the two second protruding plate portions 36ii that sandwich the bent portion 22a. Compared to using protruding plate portions provided in one location each, this allows for more welding points, thereby reducing electrical resistance at the welding points and improving physical connection stability.

[0074] Furthermore, for example, the side plate portion 35 may have side plate openings (openings 35a) that pull out the draw-out portion 22 to the outside of the side plate portion 35 between the first protruding plate portions 36i provided at two locations that sandwich the extension portion 22b, and between the second protruding plate portions 36ii provided at two locations that sandwich the bending portion 22a, and the side plate openings may have inner peripheries that are independent of the outer periphery of the side plate portion 35.

[0075] This provides high resistance to forces that pull apart the first protruding plate portions 36i provided at two locations and the second protruding plate portions 36ii provided at two locations in a configuration in which the draw-out portion 22 is drawn out further than the side plate portion 35 through the side plate opening and welded.

[0076] Furthermore, for example, the distance between the two first protruding plate portions 36i sandwiching the extending portion 22b may be different from the distance between the two second protruding plate portions 36ii sandwiching the bent portion 22a.

[0077] This allows two first protruding plate portions 36i and two second protruding plate portions 36ii to be provided on either side of the bent portion 22a and the extended portion 22b in accordance with the different line widths of the bent portion 22a and the extended portion 22b.

[0078] Furthermore, for example, the distance between the two first protruding plate portions 36i sandwiching the extending portion 22b may be smaller than the distance between the two second protruding plate portions 36ii sandwiching the bent portion 22a.

[0079] According to this, for the pull-out section 22 having the extension section 22b with a line width smaller than that of the bent section 22a, two first protruding plate sections 36i and two second protruding plate sections 36ii can be provided to sandwich the respective line widths in accordance with the respective line widths.

[0080] Furthermore, for example, the first protruding plate portion 36i may include a first direction protruding portion 36b that protrudes in a first direction away from the second side surface via a first bend portion 36a connected to the side plate portion 35, and a second direction protruding portion 36d that protrudes in a second direction different from the first direction and away from the second side surface via a second bend portion 36c connected to the first direction protruding portion 36b, and the second protruding plate portion 36ii may include a third direction protruding portion 36f that protrudes in a third direction away from the second side surface via a third bend portion 36e connected to the side plate portion 35, and a fourth direction protruding portion 36h that protrudes in a fourth direction different from the third direction and away from the second side surface via a fourth bend portion 36g connected to the third direction protruding portion 36f.

[0081] According to this, the first protruding plate portion 36i includes a first direction protruding portion 36b that protrudes in a first direction away from the second side surface via a first bent portion 36a connected to the side plate portion 35, and a second direction protruding portion 36d that protrudes in a second direction different from the first direction and away from the second side surface via a second bent portion 36c connected to the first direction protruding portion 36b, thereby reducing the possibility that the protruding plate portion formed to match the line width of the bent portion 22a will be defective when welded to the extension portion 22b. In addition, the second protruding plate portion 36ii includes a third direction protruding portion 36f that protrudes in a third direction away from the second side surface via a third bend portion 36e connected to the side plate portion 35, and a fourth direction protruding portion 36h that protrudes in a fourth direction different from the third direction and away from the second side surface via a fourth bend portion 36g connected to the third direction protruding portion 36f, thereby reducing the possibility that the protruding plate portion formed to match the line width of the extension portion 22b will be defective when welded to the bent portion 22a.

[0082] Furthermore, for example, magnetic core 10 may have top surface 12 connected to side surfaces 13a to 13d and bottom surface 11 connected to side surfaces 13a to 13d at a position different from top surface 12, and may have convex portion 131d protruding in a direction perpendicular to at least one of top surface 12 and another side surface 13d facing away from the second side surface among side surfaces 13a to 13d, and concave portion 132d surrounding convex portion 131d and recessed further into magnetic core 10 than convex portion 131d, and electrode member 30 may have locking portion 38 having opening 38a penetrating electrode member 30 in the thickness direction corresponding to convex portion 131d, and locking portion 38 which enters concave portion 132d and thereby locks to locking surface 135d which connects convex portion 131d and concave portion 132d.

[0083] With this, the locking portions 38 of the electrode member 30 are locked to the protrusions 131d of the magnetic core 10, thereby preventing the magnetic core 10 from falling off from the electrode member 30. In particular, the force acting in a direction in which the magnetic core 10 moves away from the electrode member 30 in the direction in which the locking surfaces 135d and the inner surface of the opening 38a overlap is suppressed by the locking, thereby realizing an inductor 100 that is highly resistant to the direction in which the locking surfaces 135d and the inner surface of the opening 38a overlap. In this way, the magnetic core 10 is prevented from falling off from the electrode member 30, which improves the connection reliability between the electrode member 30 and the coil element partially embedded in the magnetic core 10, thereby realizing an inductor with higher reliability.

[0084] Furthermore, for example, the protrusion 131d may protrude in a direction perpendicular to the other side surface 13d.

[0085] This makes it possible to realize an inductor 100 that is highly resistant to the direction parallel to the side surface 13d.

[0086] Furthermore, for example, the protrusion 131d may protrude in a direction perpendicular to the other side surface 13d and be formed closer to the bottom surface 11 than the center of the magnetic core 10 in the direction connecting the bottom surface 11 and the top surface 12.

[0087] This allows the electrode member 30 to be fixed closer to the bottom surface 11 than the center of gravity of the magnetic core 10, thereby increasing the self-resonant frequency for vibration of the inductor 100. Therefore, the magnetic core 10 is less likely to vibrate relative to the electrode member 30, and the magnetic core 10 is prevented from falling off the electrode member 30.

[0088] Furthermore, for example, the length of the locking surface 135d of the protrusion 131d in the direction along the plate surface of the electrode member 30 may be twice or more the length of the electrode member 30 in the thickness direction.

[0089] This provides the protrusions 131d on the side surface 13d with sufficient resistance to prevent breakage when the electrode member 30 and the magnetic core 10 are fixed to each other by engaging the protrusions 131d via the engaging portions 38.

[0090] Furthermore, for example, part 134d of recess 132d that is directly connected to locking surface 135d may be recessed further into magnetic core 10 than other part 133d, and locking part 38 may have a crimped part 38b bent to correspond to part 134d of recess 132d, and crimped part 38b may extend further into magnetic core 10 than other part 133d of recess 132d.

[0091] This allows the area of the inner surface of opening 38a, which engages with locking surface 135d, to be expanded in the depth direction of portion 134d. Furthermore, the end side of locking portion 38 relative to opening 38a is configured three-dimensionally, improving rigidity, thereby realizing an inductor that is resistant to a force that would cause magnetic core 10 to fall out.

[0092] Furthermore, for example, part 134d of recess 132d may have a curved surface where the depth of the recess into magnetic core 10 changes smoothly, and crimped portion 38b may have a smoothly curved shape that follows the curved surface.

[0093] This makes it less likely that the electrode member 30 will break at the crimped portion 38b than when the crimped portion 38b is formed by bending the electrode member 30.

[0094] Furthermore, for example, opening 38a may have a rectangular shape when viewed in the thickness direction, and the length of the side of the rectangular shape that corresponds to locking surface 135d may be shorter than the length of the side opposite to that side.

[0095] This allows for the formation of a trapezoidal opening 38a. The force applied when locking portion 38 is locked, in the direction in which locking surface 135d and the inner surface of opening 38a overlap, can be used to align opening 38a with protrusion 131d. Furthermore, because opening 38a can be tightened in the direction in which protrusion 131d is sandwiched, it is possible to prevent opening 38a from falling off protrusion 131d.

[0096] Furthermore, for example, the magnetic core 10 may have a bottom surface recess 11a that is recessed inside the magnetic core 10 at a position on the bottom surface 11 that overlaps with the electrode member 30, and the electrode member 30 may have a bottom surface crimped portion 31a that fits into the bottom surface recess 11a and is bent to correspond to the bottom surface recess 11a.

[0097] According to this, the bottom surface crimping portion 31a can reduce the length of the bottom plate portion 31 in the in-plane direction of the bottom surface 11. Therefore, the electrode member 30 can be tightened in a direction that reduces the distance between the locking portion 38 and the connection point with the lead-out portion 22, and therefore the locking portion 38 can be more firmly locked to the protrusion 131d.

[0098] Also, for example, the width of the portion of the electrode member 30 disposed on the bottom surface 11 at the position of the bottom surface crimped portion 31a may be narrowest.

[0099] This reduces the stress required to form the bottom crimped portion 31a.

[0100] Furthermore, for example, if the side 13d closest to the protrusion 131d among the side surfaces 13a to 13d is defined as the first side surface, the area of the portion of the electrode member 30 arranged on the bottom surface 11 from the position of the bottom surface crimping portion 31a to the second side surface side may be larger than the area of the portion from the position of the bottom surface crimping portion 31a to the first side surface side.

[0101] This allows an electrode portion with a large area to be provided on the lead-out portion 22 side without passing through a portion with a relatively high electrical resistance due to the narrow bottom surface crimped portion 31a.

[0102] Furthermore, for example, magnetic core 10 may have a cavity 11b that is recessed inside magnetic core 10 at the boundary connecting bottom surface 11 and side surface 13d and at the position where electrode member 30 overlaps.

[0103] This reduces the chance of the locking portion 38 getting caught when being pulled toward the bottom plate portion, compared to when the gap 11b is not provided. In other words, the force generated by the formation of the bottom crimping portion 31a, which tightens the electrode member 30 in a direction that reduces the distance between the locking portion 38 and the connection point with the lead-out portion 22, can be transmitted to the locking portion 38 with little loss.

[0104] (Modification of the embodiment) In the following, inductors according to modifications of the embodiment will be described. In the following description of each modification, differences from the embodiment will be mainly described, and descriptions of commonalities will be omitted or simplified.

[0105] [Variations] An inductor 100A according to a modification of the embodiment will be described below. In the modification, an example in which the inductor 100A has a protrusion on the top surface 12 side will be described.

[0106] Fig. 8 is a diagram illustrating a convex portion of an inductor according to a modified example of the embodiment, showing a perspective view of an end portion of an inductor 100A according to the modified example on the positive side in the X-axis direction and the positive side in the Y-axis direction.

[0107] The inductor 100A according to the modified example differs from the above embodiment in that a protrusion 121 is formed on the top surface 12 instead of the protrusion 131d formed on the side surface 13d. The protrusion 121 is surrounded by a recess 122 and penetrates an opening 38d formed in a locking portion 38c that extends along the side surface 13d to the top surface 12. The locking portion 38c is locked to the protrusion 121 by locking the inner surface of the opening 38d on the positive side of the Y axis with the negative side surface of the protrusion 121 in the Y axis direction. This makes it difficult for the locking portion 38c to come off the magnetic core 10, firmly fixing the electrode member 30 and the magnetic core 10 together. Note that the inductor 100A according to this modified example may also have a crimped portion 38e. A portion of the recess 122 is recessed further into the magnetic core 10 at a position corresponding to the locking surface, which is the side surface of the protrusion 121 on the side surface 13c of the side surface 13c where the locking portion 38c is locked. Therefore, recess 122 has a portion that is recessed further into magnetic core 10 than the other portions. A portion of recess 122 has a curved surface where the depth of the recess into magnetic core 10 changes smoothly. Crimping portion 38e is a portion of locking portion 38c that is bent into a smooth curved shape to fit the curved surface. Crimping portion 38e is bent so as to enter part of recess 122, improving the resistance of locking portion 38c to tension in the Y-axis direction. Furthermore, by providing crimping portion 38e, opening 38d has a trapezoidal shape when viewed from the top surface 12 side.

[0108] As described above, in the inductor 100A according to this embodiment, the protrusions protrude in a direction perpendicular to the top surface.

[0109] Such an inductor 100A can realize an inductor 100 that has high resistance to the direction parallel to the top surface 12.

[0110] (Other embodiments, etc.) While the inductors and the like according to the embodiments and modifications of the present disclosure have been described above, the present disclosure is not limited to the above-described embodiments and modifications. As long as they do not deviate from the gist of the present disclosure, various modifications that would occur to a person skilled in the art to the embodiments and modifications, as well as other forms constructed by combining some of the components of the embodiments and modifications, are also included within the scope of the present disclosure.

[0111] In the above embodiment, the bottom plate portion 31, the side plate portions 35, the first protruding plate portion 36i and the second protruding plate portion 36ii, and the locking portion 38 of the electrode member 30 are formed by processing a single member made of the same material, but this is not limiting. For example, the electrode member 30 may be formed by connecting the bottom plate portion 31, the side plate portions 35, the first protruding plate portion 36i and the second protruding plate portion 36ii, and the locking portion 38, which are made of different members.

[0112] In the above embodiment, the coil portion 21 and the lead-out portion 22 of the coil element are formed by processing a single member made of the same material, but this is not limiting. The coil element may be formed by connecting the coil portion 21 and the lead-out portion 22 made of different members.

[0113] In the above embodiment, the conductor wire has a rectangular cross section, but is not limited thereto. The conductor wire may have a circular cross section, and at least a portion of the lead portion 22 may be flattened to facilitate connection with the electrode member 30.

[0114] In the above embodiment, the lead-out portion 22 is drawn out from a position closer to the bottom surface 11 than the center of the side surface 13c and extends toward the top surface 12, but this is not limiting. The lead-out portion 22 may be drawn out from a position closer to the top surface 12 than the center of the side surface 13c and extend toward the bottom surface 11. In this case, the side plate portion 35 may be interposed between the lead-out portion 22 and the side surface 13c without an opening, and the first protruding plate portion 36i and the second protruding plate portion 36ii may be provided at the edge of the side plate portion 35.

[0115] In the above embodiment, the first protruding plate portion 36i and the second protruding plate portion 36ii are disposed on both sides of the extending direction of the drawing portion 22, but the present invention is not limited to this. The first protruding plate portion 36i and the second protruding plate portion 36ii may be disposed on only one side of the extending direction of the drawing portion 22.

[0116] The present disclosure also includes, for example, electrical appliances or electrical circuits using the above-described inductor. Examples of electrical appliances include power supply devices equipped with the above-described inductor and various devices equipped with such power supply devices. [Industrial Applicability]

[0117] INDUSTRIAL APPLICABILITY The inductor according to the present disclosure is useful as an inductor used in various devices and equipment. [Explanation of symbols]

[0118] 10 magnetic core 11 Bottom 11a Bottom recess 11b Cavity 12 Top 13a, 13b, 13c, 13d side 21 Coil section 22 Drawer section 22a Bending part 22b Extension part 30 Electrode material 31 Bottom plate part 31a Bottom caulking part 31b, 31c part 35 Side plate part 35a, 38a, 38d aperture 36i 1st protruding plate part 36ii 2nd protruding plate part 36a 1st bending part 36b First direction protrusion 36c 2nd bend 36d Second direction protrusion 36e 3rd bend 36f Third direction protrusion 36g 4th bending part 36h 4th direction protrusion 38, 38c locking part 38b, 38e Crimped part 100, 100A inductor 121, 131d convex part 122, 132d recess 133d other parts 134d part 135d Locking surface ws welding marks

Claims

1. a magnetic core including a magnetic material and having a side surface; a coil element having a coil portion embedded in the magnetic core and a lead portion connected to an end of the coil portion and led out from the side surface to the outside of the magnetic core; a plate-shaped electrode member disposed on the side surface and electrically connected to the coil element via the lead-out portion, the lead-out portion has a bent portion whose extension direction is bent outside the magnetic core, and an extension portion extending from the bent portion, The electrode member is When the side surface from which the drawer portion is drawn out is defined as a second side surface, a side plate portion is arranged along the second side surface; a first protruding plate portion connected to the side plate portion and protruding in a direction away from the second side surface, and an edge portion located on the opposite side from the second side surface is welded to the extension portion; a second protruding plate portion connected to the side plate portion and protruding in a direction away from the second side surface, and an edge portion located on the opposite side from the second side surface is welded to the bent portion, The first protruding plate portion and the second protruding plate portion are positioned differently in the line width direction of the lead-out portion. Inductor.

2. The first protruding plate portions are provided at two locations on either side of the extension portion, The second protruding plate portions are provided at two locations on either side of the bent portion.

10. The inductor of claim 1.

3. the side plate portions have side plate openings between the first protruding plate portions provided at two locations on either side of the extension portion and between the second protruding plate portions provided at two locations on either side of the bent portion, through which the draw-out portion is drawn outward from the side plate portions; The side plate opening has an inner periphery that is independent from the outer periphery of the side plate portion.

3. The inductor according to claim 2.

4. A distance between the two first protruding plate portions sandwiching the extending portion is different from a distance between the two second protruding plate portions sandwiching the bent portion.

4. The inductor according to claim 2 or 3.

5. The distance between the two first protruding plate portions sandwiching the extending portion is smaller than the distance between the two second protruding plate portions sandwiching the bent portion.

5. The inductor according to claim 4.

6. The first protruding plate portion is a first direction protruding portion that protrudes in a first direction away from the second side surface via a first bent portion that is connected to the side plate portion; a second direction protruding portion that protrudes in a second direction different from the first direction and away from the second side surface via a second bent portion connected to the first direction protruding portion, The second protruding plate portion is a third direction protruding portion protruding in a third direction away from the second side surface via a third bent portion connected to the side plate portion; a fourth direction protruding portion that protrudes in a fourth direction different from the third direction and away from the second side surface via a fourth bent portion that is connected to the third direction protruding portion, The inductor according to any one of claims 2 to 5.

7. The magnetic core is a top surface connected to the side surface and a bottom surface connected to the side surface at a position different from the top surface; a convex portion that protrudes in a direction perpendicular to at least one of the top surface and another side surface facing the second side surface among the side surfaces, and a concave portion that surrounds the convex portion and is recessed toward the inside of the magnetic core relative to the convex portion; The electrode member has a locking portion having an opening that penetrates the electrode member in the thickness direction in correspondence with the protrusion, and the locking portion is fitted into the recess to be locked to a locking surface that connects the protrusion and the recess. The inductor according to any one of claims 1 to 6.

8. The protrusion protrudes in a direction perpendicular to the other side surface.

8. The inductor of claim 7.

9. The convex portion protrudes in a direction perpendicular to the other side surface and is formed on the bottom surface side of the center of the magnetic core in a direction connecting the bottom surface and the top surface.

9. The inductor of claim 8.

10. The protrusion protrudes in a direction perpendicular to the top surface.

8. The inductor of claim 7.

11. The length of the engagement surface of the protrusion in a direction along the plate surface of the electrode member is at least twice the length of the electrode member in the thickness direction. The inductor according to any one of claims 7 to 10.

12. a portion of the recess that is directly connected to the locking surface is recessed more inwardly than the other portion of the recess, and the locking portion has a crimped portion bent to correspond to the part of the recess, The crimped portion is located closer to the interior of the magnetic core than the other portion of the recess. The inductor according to any one of claims 7 to 11.

13. the portion of the recess has a curved surface whose depth into the magnetic core in the recess shape changes smoothly, The crimped portion has a smoothly curved shape that follows the curved surface.

13. The inductor of claim 12.

14. The opening has a rectangular shape when viewed from the thickness direction, Of the four sides of the quadrilateral shape, the length of the side corresponding to the locking surface is shorter than the length of the side opposite to that side.

14. The inductor according to claim 12 or 13.

15. the magnetic core has a bottom surface recess that is recessed inside the magnetic core at a position on the bottom surface that overlaps with the electrode member, The electrode member has a bottom caulking portion that fits into the bottom recess and is bent to correspond to the bottom recess. The inductor according to any one of claims 7 to 13.

16. The width of the bottom surface crimping portion of the electrode member at the portion disposed on the bottom surface is narrowest.

16. The inductor of claim 15.

17. When the side surface closest to the protrusion among the side surfaces is defined as a first side surface, In the electrode member, the area of the portion disposed on the bottom surface from the position of the bottom surface crimping portion to the second side surface is larger than the area of the portion from the position of the bottom surface crimping portion to the first side surface.

17. An inductor according to claim 15 or 16.

18. The magnetic core has a cavity portion that is recessed inside the magnetic core at a boundary connecting the bottom surface and the side surface and at a position that overlaps with the electrode member. The inductor according to any one of claims 15 to 17.

Images