Electronic component

Abstract

[Problem] To provide an electronic component suitable for being built in a substrate for use. [Solution] An electronic component 300 comprises: a magnetic element body 330; and metal frames 310, 320 embedded in the magnetic element body 330. The metal frame 310 includes sections 311-315. The metal frame 320 includes sections 321-325. Portions of the sections 314, 315 of the metal frame 310 are exposed from respective main surfaces 301, 302 of the magnetic element body 330. Portions of the sections 324, 325 of the metal frame 320 are exposed from the respective main surfaces 301, 302 of the magnetic element body 330. The section 311 of the metal frame 310 and the section 321 of the metal frame 320 are laminated in a Z direction so as to be insulated from each other. The section 312 of the metal frame 310 and the section 322 of the metal frame 320 are laminated in a Z direction so as to be insulated from each other.

Description

Electronic Components

[0001] The present disclosure relates to electronic components, and more particularly to electronic components having a structure in which a metal frame is embedded in a magnetic body.

[0002] Patent Document 1 discloses an electronic component having a structure in which a bent metal frame is embedded in an element body.

[0003] Japanese Patent Application Laid-Open No. 2022-151206

[0004] The inductor disclosed in Patent Document 1 is a surface-mount electronic component.

[0005] In this disclosure, electronic components suitable for use within a substrate are described.

[0006] An electronic component according to one aspect of the present disclosure includes a magnetic body having a first surface extending in a first direction and a second direction perpendicular to the first direction, and a second surface located on the opposite side of the first surface in a third direction perpendicular to the first and second directions, and first and second metal frames embedded in the magnetic body. The first metal frame includes first and second sections extending parallel to the first direction. The first section of the first metal frame includes a first end that is one end in the first direction and a second end that is the other end in the first direction. The second section of the first metal frame includes a third end that is one end in the first direction and a fourth end that is the other end in the first direction. The first metal frame further includes a third section connecting the first end of the first section and the third end of the second section, a fourth section connected to the second end of the first section, and a fifth section connected to the fourth end of the second section. A portion of the fourth section of the first metal frame is exposed from the first surface of the magnetic body. A portion of the fifth section of the first metal frame is exposed from the second surface of the magnetic body. The second metal frame includes sixth and seventh sections extending parallel to the first direction. The sixth section of the second metal frame includes a fifth end that is one end in the first direction and a sixth end that is the other end in the first direction. The seventh section of the second metal frame includes a seventh end that is one end in the first direction and an eighth end that is the other end in the first direction. The second metal frame further includes an eighth section connecting the fifth end of the sixth section and the seventh end of the seventh section, a ninth section connected to the sixth end of the sixth section, and a tenth section connected to the eighth end of the seventh section. A portion of the ninth section of the second metal frame is exposed from the first surface of the magnetic body. A portion of the tenth section of the second metal frame is exposed from the second surface of the magnetic body. The first section of the first metal frame and the sixth section of the second metal frame are overlapped in the third direction to be insulated from each other. The second section of the first metal frame and the seventh section of the second metal frame are overlapped in the third direction to be insulated from each other.

[0007] According to the present disclosure, an electronic component suitable for use within a substrate is provided.

[0008] FIG. 1A is a schematic perspective view showing the appearance of an electronic component 300 according to an embodiment of the technology disclosed herein. FIG. 1B is a schematic perspective view showing the appearance of electronic component 300. FIG. 2A is a schematic see-through perspective view of electronic component 300. FIG. 2B is a schematic see-through perspective view of electronic component 300. FIG. 3A is a schematic perspective view for describing the structure of metal frame 310. FIG. 3B is a schematic perspective view for describing the structure of metal frame 310. FIG. 3C is a schematic perspective view showing an example in which insulating member 340 has a ring-shaped planar shape. FIG. 4A is a schematic perspective view for describing the structure of metal frame 320. FIG. 4B is a schematic perspective view for describing the structure of metal frame 320.

[0009] Hereinafter, embodiments of the technology according to the present disclosure will be described in detail with reference to the accompanying drawings.

[0010] FIGS. 1A and 1B are schematic perspective views showing the appearance of an electronic component 300 according to an embodiment of the technology disclosed herein, viewed from different directions. FIGS. 2A and 2B are schematic perspective perspective views of the electronic component 300, viewed from different directions. For ease of explanation, FIGS. 1A, 1B, 2A, and 2B tentatively illustrate X, Y, and Z axes. Hereinafter, the direction of the arrow on each axis will be referred to as the + (plus) direction, and the opposite direction will be referred to as the - (minus) direction (the same applies to the other drawings). In this disclosure, the Y direction may be referred to as the first direction, the X direction as the second direction, and the Z direction as the third direction. Furthermore, a surface extending in the X and Y directions may be referred to as the XY plane, a surface extending in the X and Z directions as the XZ plane, and a surface extending in the Y and Z directions as the YZ plane.

[0011] The electronic component 300 according to this embodiment includes a magnetic element 330 and metal frames 310 and 320 embedded in the magnetic element 330. The metal frames 310 and 320 are stacked in the Z direction within the magnetic element 330. The coil axis of the coil conductor formed by the metal frames 310 and 320 is in the Z direction. The magnetic element 330 may be made of a composite magnetic material in which a magnetic filler made of a high-permeability material such as ferrite or permalloy is solidified with a resin binder. The magnetic element 330 has main surfaces 301 and 302 that form an XY plane and are located opposite each other, side surfaces 303 and 304 that form an XZ plane and are located opposite each other, and side surfaces 305 and 306 that form a YZ plane and are located opposite each other. In this disclosure, the main surfaces 301 and 302 may be referred to as the first and second surfaces, respectively.

[0012] The metal frames 310 and 320 are members made of a metal (e.g., copper (Cu)) and function as coil conductors. The metal frames 310 and 320 may be manufactured by, for example, casting or cutting. Furthermore, the metal frames 310 and 320 may each be an integral metal member without any joints or the like. Thus, in this embodiment, the metal frames 310 and 320 are used as coil conductors, and therefore the electronic component 300 according to this embodiment can be used, for example, as an inductor for a power supply circuit. Furthermore, the metal frames 310 and 320 are arranged in the Z direction, which is the coil axis direction, thereby enhancing the coupling between the coil conductors made of the metal frame 310 and the coil conductors made of the metal frame 320. An insulating member 340 is provided between the metal frames 310 and 320, thereby ensuring insulation between the metal frames 310 and 320.

[0013] 3A and 3B are schematic perspective views for explaining the structure of the metal frame 310, showing the state as viewed from different directions.

[0014] Metal frame 310 has sections 311 and 312 extending parallel to the Y direction, section 313 extending in the X direction and connecting the end of section 311 in the +Y direction with the end of section 312 in the +Y direction, section 314 connected to the end of section 311 in the -Y direction, section 315 connected to the end of section 312 in the -Y direction, section 316 protruding from section 313 in the -Z direction, and section 317 protruding from section 311 in the -Z direction.

[0015] 3A and 3B, section 314 may include a flat plate portion 314A connected to the end of section 311 in the −Y direction and extending in the +Z direction, and a flat plate portion 314B connected to flat plate portion 314A and extending in the +X direction. Section 315 may include a flat plate portion 315A connected to the end of section 312 in the −Y direction and extending in the −Z direction, and a flat plate portion 315B connected to flat plate portion 315A and extending in the −X direction.

[0016] The XY surfaces in the +Z direction of the plate portion 314B of the section 314 may be exposed from the main surface 301 of the magnetic element body 330. The XZ surfaces in the −Y direction of the plate portions 314A, 314B of the section 314 may be exposed from the side surface 303 of the magnetic element body 330. The YZ surfaces in the +X direction of the plate portion 314B of the section 314 may be exposed from the side surface 306 of the magnetic element body 330. The XY surfaces in the −Z direction of the plate portion 315B of the section 315 may be exposed from the main surface 302 of the magnetic element body 330. The XZ surfaces in the −Y direction of the plate portions 315A, 315B of the section 315 may be exposed from the side surface 303 of the magnetic element body 330. The YZ surfaces in the −X direction of the plate portion 315B of the section 315 may be exposed from the side surface 305 of the magnetic element body 330. The XY surface of the section 316 in the −Z direction and the XY surface of the section 317 in the −Z direction are exposed from the main surface 302 of the magnetic body 330 .

[0017] The XY surfaces of sections 311 to 313 of metal frame 310 that face metal frame 320 are covered with insulating member 340. Insulating member 340 may be a sheet- or film-shaped resin, or may be a resin applied to metal frame 310. If a material with a lower magnetic permeability than magnetic base body 330 is used as the material for insulating member 340, the coupling between the coil conductors made of metal frame 310 and the coil conductors made of metal frame 320 can be weakened. Note that a non-magnetic material may also be used as the material for insulating member 340, in which case the coupling between the coil conductors made of metal frame 310 and the coil conductors made of metal frame 320 can be further enhanced. By using insulating member 340 formed using materials with various magnetic permeabilities, the coupling between the coil conductors made of metal frame 310 and the coil conductors made of metal frame 320 may be adjusted as appropriate. Furthermore, if a material having lower conductivity than the magnetic base body 330 (for example, an electrically insulating material) is used as the material for the insulating member 340, higher electrical insulation can be obtained between the metal frames 310 and 320. Alternatively, the magnetic base body 330 itself may be used as the insulating member 340. The planar shape of the insulating member 340 may be a substantially U-shape as shown in FIG. 3A or a ring shape as shown in FIG. 3C. In either example, by not disposing the insulating member 340 in the inner diameter region sandwiched between the sections 311 and 312, it is possible to increase inductance.

[0018] 4A and 4B are schematic perspective views for explaining the structure of the metal frame 320, showing the state as viewed from different directions.

[0019] Metal frame 320 has sections 321 and 322 extending parallel to the Y direction, section 323 extending in the X direction and connecting the end of section 321 in the -Y direction with the end of section 322 in the -Y direction, section 324 connected to the end of section 321 in the +Y direction, and section 325 connected to the end of section 322 in the +Y direction.

[0020] 4A and 4B, section 324 may include a flat plate portion 324A connected to the end of section 321 in the +Y direction and extending in the +Z direction, and a flat plate portion 324B connected to flat plate portion 324A and extending in the +X direction. Section 325 may include a flat plate portion 325A connected to the end of section 322 in the +Y direction and extending in the −Z direction, and a flat plate portion 325B connected to flat plate portion 325A and extending in the −X direction.

[0021] The XY surfaces in the +Z direction of the flat plate portion 324B of the section 324 may be exposed from the main surface 301 of the magnetic element body 330. The XZ surfaces in the +Y direction of the flat plate portions 324A, 324B of the section 324 may be exposed from the side surface 304 of the magnetic element body 330. The YZ surfaces in the +X direction of the flat plate portion 324B of the section 324 may be exposed from the side surface 306 of the magnetic element body 330. The XY surfaces in the -Z direction of the flat plate portion 325B of the section 325 may be exposed from the main surface 302 of the magnetic element body 330. The XZ surfaces in the +Y direction of the flat plate portions 325A, 325B of the section 325 may be exposed from the side surface 304 of the magnetic element body 330. The YZ surface in the −X direction of the flat plate portion 325 B of the section 325 may be exposed from the side surface 305 of the magnetic body 330 .

[0022] As described above, in this embodiment, section 313 of metal frame 310 is located at the end in the +Y direction, while section 323 of metal frame 320 is located at the end in the -Y direction. Section 313 of metal frame 310 is located between sections 324 and 325 of metal frame 320 in a plan view seen from the Z direction. Section 323 of metal frame 320 is located between sections 314 and 315 of metal frame 310 in a plan view seen from the Z direction. The widths of metal frame 310 and metal frame 320 may be the same as or different from each other. The thicknesses of metal frame 310 and metal frame 320 may be the same as or different from each other.

[0023] The surface of section 314 exposed from main surface 301 of magnetic body 330 constitutes one terminal electrode of the coil conductor made of metal frame 310. The surface of section 315 exposed from main surface 302 of magnetic body 330 constitutes the other terminal electrode of the coil conductor made of metal frame 310. The surface of section 324 exposed from main surface 301 of magnetic body 330 constitutes one terminal electrode of the coil conductor made of metal frame 320. The surface of section 325 exposed from main surface 302 of magnetic body 330 constitutes the other terminal electrode of the coil conductor made of metal frame 320. In this embodiment, sections 311 to 313 of metal frame 310 are not exposed from magnetic body 330, and sections 321 to 323 of metal frame 320 are not exposed from magnetic body 330. In this way, the small surface areas of metal frames 310 and 320 exposed from magnetic body 330 make it possible to obtain high inductance.

[0024] In electronic component 300 according to this embodiment, the surfaces of sections 314 and 324 exposed from main surface 301 of magnetic body 330 can be used as a pair of input terminals, and the surfaces of sections 315 and 325 exposed from main surface 302 of magnetic body 330 can be used as a pair of output terminals. In this case, the magnetic flux generated by the coil conductor made of metal frame 310 and the magnetic flux generated by the coil conductor made of metal frame 320 cancel each other out.

[0025] The surfaces of sections 316 and 317 exposed from main surface 302 of magnetic body 330 may be used as heat dissipation terminals. The wiring pattern connected to the heat dissipation terminal may terminate without being connected to power supply wiring, signal wiring, etc. The surfaces of sections 314 and 324 exposed from main surface 301 of magnetic body 330 may be flush with each other. The surfaces of sections 315 to 317 and 325 exposed from main surface 302 of magnetic body 330 may be flush with each other. The surfaces of sections 314 and 315 exposed from side surface 303 of magnetic body 330 may be flush with each other. The surfaces of sections 324 and 325 exposed from side surface 304 of magnetic body 330 may be flush with each other. The surfaces of sections 315 and 325 exposed from side surface 305 of magnetic body 330 may be flush with each other. The surfaces of the sections 314 and 324 exposed from the side surface 306 of the magnetic element 330 may be flush with each other.

[0026] When manufacturing electronic component 300 having such a configuration, metal frame 310 is placed on a support body, and metal frame 320 is then placed on metal frame 310 via insulating member 340 so that sections 316 and 317 of metal frame 310 are in contact with the surface of the support body. Metal frames 310, 320 are then embedded in magnetic base body 330. This allows metal frame 310 to be in contact with the surface of the support body at three points, making it possible for metal frame 310 to be stably supported on the surface of the support body, facilitating the manufacture of electronic component 300. Furthermore, if the surfaces of sections 315 to 317 exposed from main surface 302 of magnetic base body 330 form the same plane, metal frame 310 can be placed more stably on the support body.

[0027] The above describes embodiments of the technology according to the present disclosure, but the technology according to the present disclosure is not limited to the above embodiments, and various modifications are possible within the scope of the gist of the technology, and it goes without saying that these modifications are also included within the scope of the technology according to the present disclosure.

[0028] The technology according to the present disclosure includes, but is not limited to, the following configuration examples.

[0029] An electronic component according to one aspect of the present disclosure includes a magnetic body having a first surface extending in a first direction and a second direction perpendicular to the first direction, and a second surface located on the opposite side of the first surface in a third direction perpendicular to the first and second directions, and first and second metal frames embedded in the magnetic body. The first metal frame includes first and second sections extending parallel to the first direction. The first section of the first metal frame includes a first end that is one end in the first direction and a second end that is the other end in the first direction. The second section of the first metal frame includes a third end that is one end in the first direction and a fourth end that is the other end in the first direction. The first metal frame further includes a third section connecting the first end of the first section and the third end of the second section, a fourth section connected to the second end of the first section, and a fifth section connected to the fourth end of the second section. A portion of the fourth section of the first metal frame is exposed from the first surface of the magnetic body. A portion of the fifth section of the first metal frame is exposed from the second surface of the magnetic body. The second metal frame includes sixth and seventh sections extending parallel to the first direction. The sixth section of the second metal frame includes a fifth end that is one end in the first direction and a sixth end that is the other end in the first direction. The seventh section of the second metal frame includes a seventh end that is one end in the first direction and an eighth end that is the other end in the first direction. The second metal frame further includes an eighth section connecting the fifth end of the sixth section and the seventh end of the seventh section, a ninth section connected to the sixth end of the sixth section, and a tenth section connected to the eighth end of the seventh section. A portion of the ninth section of the second metal frame is exposed from the first surface of the magnetic body. A portion of the tenth section of the second metal frame is exposed from the second surface of the magnetic body. The first section of the first metal frame and the sixth section of the second metal frame are overlapped in the third direction to be insulated from each other. The second section of the first metal frame and the seventh section of the second metal frame are overlapped in the third direction to be insulated from each other. This provides an electronic component suitable for use as an integrated part on a substrate.

[0030] The electronic component further includes insulating members disposed between the first section of the first metal frame and the sixth section of the second metal frame, and between the second section of the first metal frame and the seventh section of the second metal frame, and the insulating members may have a lower magnetic permeability than the magnetic body, thereby enhancing coupling between the coil conductor formed by the first metal frame and the coil conductor formed by the second metal frame.

[0031] In the electronic component, the electrical conductivity of the insulating member may be lower than the electrical conductivity of the magnetic body, thereby improving the insulation between the first metal frame and the second metal frame.

[0032] In the electronic component, the first metal frame may further include an eleventh section protruding from the third section in the third direction, and a portion of the eleventh section of the first metal frame may be exposed from the second surface of the magnetic body. In this way, when the first metal frame is embedded in the magnetic body, the eleventh section is brought into contact with the surface of the support, thereby making it possible to more stably support the first metal frame.

[0033] In the electronic component, the first metal frame may further include a twelfth section protruding from the first section in the third direction, and a portion of the twelfth section of the first metal frame may be exposed from the second surface of the magnetic body. In this way, when the first metal frame is embedded in the magnetic body, the twelfth section is brought into contact with the surface of the support, thereby enabling the first metal frame to be supported more stably.

[0034] This application claims the benefit of U.S. Provisional Application No. 63 / 626,699, filed January 30, 2024, the entire disclosure of which is incorporated herein by reference.

[0035] 300 Electronic component 301 Main surface (first surface) 302 Main surface (second surface) 303 to 306 Side surfaces 310, 320 Metal frame 311 Section (first section) 312 Section (second section) 313 Section (third section) 314 Section (fourth section) 315 Section (fifth section) 316 Section (eleventh section) 317 Section (twelfth section) 314A, 314B, 315A, 315B Flat plate portion 321 Section (sixth section) 322 Section (seventh section) 323 Section (eighth section) 324 Section (ninth section) 325 Section (tenth section) 324A, 324B, 325A, 325B Plate portion 330 Magnetic element 340 Insulating member

Claims

1. A magnetic element comprising: a magnetic body having a first surface extending in a first direction and a second direction perpendicular to the first direction, and a second surface located on the opposite side of the first surface in a third direction perpendicular to the first and second directions; and first and second metal frames embedded in the magnetic body, wherein the first metal frame includes first and second sections extending parallel to the first direction, the first section of the first metal frame includes a first end which is one end in the first direction and a second end which is the other end in the first direction, and the second section of the first metal frame includes a third end which is one end in the first direction and a fourth end which is the other end in the first direction, the first metal frame further includes a third section connecting the first end of the first section and the third end of the second section, a fourth section connected to the second end of the first section, and a fifth section connected to the fourth end of the second section, a portion of the fourth section of the first metal frame being exposed from the first surface of the magnetic body, and a portion of the fifth section of the first metal frame being exposed from the second surface of the magnetic body, the second metal frame including sixth and seventh sections extending parallel to the first direction, the sixth section of the second metal frame including a fifth end which is one end in the first direction and a sixth end which is the other end in the first direction, and the seventh section of the second metal frame including a seventh end which is one end in the first direction and an eighth end which is the other end in the first direction, the second metal frame further includes an eighth section connecting the fifth end of the sixth section and the seventh end of the seventh section, a ninth section connected to the sixth end of the sixth section, and a tenth section connected to the eighth end of the seventh section, wherein a portion of the ninth section of the second metal frame is exposed from the first surface of the magnetic body, and a portion of the tenth section of the second metal frame is exposed from the second surface of the magnetic body,An electronic component, wherein the first section of the first metal frame and the sixth section of the second metal frame are stacked in the third direction so as to be insulated from each other, and the second section of the first metal frame and the seventh section of the second metal frame are stacked in the third direction so as to be insulated from each other.

2. The electronic component according to claim 1, further comprising insulating members arranged between the first section of the first metal frame and the sixth section of the second metal frame, and between the second section of the first metal frame and the seventh section of the second metal frame, wherein the magnetic permeability of the insulating members is lower than the magnetic permeability of the magnetic base body.

3. The electronic component according to claim 2, wherein the electrical conductivity of the insulating member is lower than the electrical conductivity of the magnetic base body.

4. The electronic component according to claim 1, wherein the first metal frame further includes an eleventh section that protrudes from the third section along the third direction, and a portion of the eleventh section of the first metal frame is exposed from the second surface of the magnetic base body.

5. The electronic component according to claim 4, wherein the first metal frame further includes a twelfth section that protrudes from the first section along the third direction, and a portion of the twelfth section of the first metal frame is exposed from the second surface of the magnetic base body.

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