Electronic component

Abstract

[Problem] To provide an electronic component suitable for being used embedded in a substrate. [Solution] An electronic component 400 comprises a magnetic element body 430 and metal frames 410 and 420 embedded in the magnetic element body 430. The metal frame 410 includes sections 411-415. The metal frame 420 includes sections 421-425. A portion of the sections 414 and 415 of the metal frame 410 and a portion of the sections 424 and 425 of the metal frame 420 are exposed from the magnetic element 430. The sections 411 and 412 of the metal frame 410 are positioned so as to be sandwiched between the section 421 and the section 422 of the metal frame 420 from the X direction. The section 411 of the metal frame 410 and the section 421 of the metal frame 420 are stacked in the X direction so as to be insulated from each other. The section 412 of the metal frame 410 and the section 422 of the metal frame 420 are stacked in the X 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 base body and first and second metal frames embedded in the magnetic base body. The first metal frame includes first and second sections extending parallel to a 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 magnetic base body. A portion of the fifth section of the first metal frame is exposed from the magnetic base body. The second metal frame includes sixth and seventh sections extending parallel to the first direction. The first and second sections of the first metal frame are positioned between the sixth section of the second metal frame and the seventh section of the second metal frame so as to be sandwiched in a second direction perpendicular to the first direction. The sixth section of the second metal frame includes a fifth end which is one end in the first direction and a sixth end which is the other end in the first direction. The seventh section of the second metal frame includes 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. A portion of the ninth section of the second metal frame is exposed from the magnetic body. A portion of the tenth section of the second metal frame is exposed from the magnetic body. The first section of the first metal frame and the sixth section of the second metal frame are overlapped in the second direction so as 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 second direction so as 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 400 according to an embodiment of the technology disclosed herein. FIG. 1B is a schematic perspective view showing the appearance of the electronic component 400. FIG. 2A is a schematic see-through perspective view of the electronic component 400. FIG. 2B is a schematic see-through perspective view of the electronic component 400. FIG. 3A is a schematic perspective view for describing the structures of a metal frame 410 and an insulating member 440. FIG. 3B is a schematic perspective view for describing the structures of the metal frame 410 and the insulating member 440. FIG. 3C is a schematic perspective view for describing the structure of the metal frame 410. FIG. 3D is a schematic perspective view for describing the structure of the metal frame 410. FIG. 4A is a schematic perspective view for describing the structures of a metal frame 420 and an insulating member 440. FIG. 4B is a schematic perspective view for describing the structures of the metal frame 420 and the insulating member 440. FIG. 4C is a schematic perspective view for describing the structure of the metal frame 420. FIG. 4D is a schematic perspective view for describing the structure of the metal frame 420.

[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 400 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 400, 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 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 400 according to this embodiment includes a magnetic element 430 and metal frames 410 and 420 embedded in the magnetic element 430. The coil axis of the coil conductor formed by the metal frames 410 and 420 is in the Z direction. The magnetic element 430 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 metal frames 410 and 420 are coaxially arranged with the metal frame 410 on the inside and the metal frame 420 on the outside. The magnetic element 430 has main surfaces 401 and 402 that are opposite each other and form an XY plane, side surfaces 403 and 404 that are opposite each other and form an XZ plane, and side surfaces 405 and 406 that are opposite each other and form a YZ plane. In this disclosure, the main surfaces 401 and 402 may be referred to as the first and second surfaces, respectively.

[0012] In this embodiment, the folded metal frames 410, 420 are used as coil conductors, and therefore the electronic component 400 according to this embodiment can be used, for example, as an inductor for a power supply circuit. Furthermore, the metal frames 410, 420 are arranged coaxially, which further enhances the coupling between the coil conductors made of the metal frames 410 and 420. An insulating member 440 is provided between the metal frames 410 and 420, which ensures insulation between the metal frames 410 and 420.

[0013] The thickness of the metal frame 410 may be greater than the thickness of the metal frame 420. In other words, the cross-sectional area of ​​the metal frame 410 as viewed from the Z direction may be greater than the cross-sectional area of ​​the metal frame 420 as viewed from the Z direction. This reduces the resistance value of the coil conductor made of the metal frame 410 and makes it easier to bend the metal frame 420 along the outer periphery of the metal frame 410.

[0014] 3A and 3B are schematic perspective views illustrating the structure of the metal frame 410 and the insulating member 440, viewed from different directions, while FIGS. 3C and 3D are schematic perspective views illustrating the structure of the metal frame 410, viewed from different directions.

[0015] Metal frame 410 has sections 411 and 412 extending parallel to the Y direction, section 413 extending in the X direction and connecting the end of section 411 in the +Y direction with the end of section 412 in the +Y direction, section 414 connected to the end of section 411 in the -Y direction, section 415 connected to the end of section 412 in the -Y direction, and section 416 protruding from section 413 in the -Z direction.

[0016] Section 414 of metal frame 410 has a flat plate portion 414A connected to section 411, a flat plate portion 414B exposed from main surface 401 of magnetic body 430, and a bent portion 414C located between flat plate portions 414A and 414B and bent at approximately 90 degrees. The YZ plane of section 411 and the YZ plane of flat plate portion 414A of section 414 may be the same plane. A notch 418 is provided in metal frame 410, which forms a space between section 411 and bent portion 414C of section 414. Providing this notch 418 makes it easier to bend bent portion 414C of section 414.

[0017] Section 415 of metal frame 410 has a flat plate portion 415A connected to section 412, a flat plate portion 415B exposed from the main surface 402 of the magnetic body 430, and a bent portion 415C located between flat plate portions 415A and 415B and bent at approximately 90 degrees. The YZ plane of section 412 and the YZ plane of flat plate portion 415A of section 415 may be the same plane. A notch 419 is provided in metal frame 410, which forms a space between section 412 and bent portion 415C of section 415. Providing this notch 419 makes it easier to bend bent portion 415C of section 415.

[0018] The XY surfaces in the +Z direction of the plate portion 414B of section 414 are exposed from the main surface 401 of the magnetic element body 430, and the XZ surfaces in the −Y direction of the plate portions 414A, 414B and bent portions 414C of section 414 are exposed from the side surface 403 of the magnetic element body 430. The XY surfaces in the −Z direction of the plate portion 415B of section 415 are exposed from the main surface 402 of the magnetic element body 430, and the XZ surfaces in the −Y direction of the plate portions 415A, 415B and bent portions 415C of section 415 are exposed from the side surface 403 of the magnetic element body 430. The XY surfaces in the −Z direction of section 416 are exposed from the main surface 402 of the magnetic element body 430. In addition, a section protruding in the +Z direction may be provided in section 413 of metal frame 410 on the opposite side of section 416. The XY surface of this section (the XY surface on the +Z direction side) may be exposed from main surface 401 of the magnetic body 430.

[0019] The outer radial surfaces of sections 411 to 413 of metal frame 410, i.e., the surfaces facing metal frame 420, are covered with insulating member 440. Insulating member 440 may be a sheet- or film-shaped resin, or may be a resin applied to metal frame 410. If a material with a lower magnetic permeability than that of magnetic base body 430 is used as the material for insulating member 440, the coupling between the coil conductors made of metal frame 410 and the coil conductors made of metal frame 420 can be weakened. Note that a non-magnetic material can also be used as the material for insulating member 440, in which case the coupling between the coil conductors made of metal frame 410 and the coil conductors made of metal frame 420 can be enhanced. By using insulating member 440 formed using materials with various magnetic permeabilities, the coupling between the coil conductors made of metal frame 410 and the coil conductors made of metal frame 420 can be adjusted as appropriate. Furthermore, if a material having lower conductivity than the magnetic body 430 (for example, an electrically insulating material) is used as the material for the insulating member 440, higher electrical insulation can be obtained between the metal frames 410 and 420. Alternatively, the magnetic body 430 itself may be used as the insulating member 440.

[0020] 4A and 4B are schematic perspective views illustrating the structure of the metal frame 420 and the insulating member 440, viewed from different directions, while FIGS. 4C and 4D are schematic perspective views illustrating the structure of the metal frame 420, viewed from different directions.

[0021] Metal frame 420 has sections 421 and 422 extending parallel to the Y direction, section 423 extending in the X direction and connecting the end of section 421 in the +Y direction with the end of section 422 in the +Y direction, section 424 connected to the end of section 421 in the -Y direction, section 425 connected to the end of section 422 in the -Y direction, and section 426 protruding from section 423 in the -Z direction.

[0022] 4A to 4D, section 424 has a bent portion 424A connected to the end of section 421 in the −Y direction and bent by approximately 90 degrees, and a flat portion 424B connected to bent portion 424A and extending in the −X direction. Section 425 has a bent portion 425A connected to the end of section 422 in the −Y direction and bent by approximately 90 degrees, and a flat portion 425B connected to bent portion 425A and extending in the +X direction.

[0023] The XY surface in the -Z direction of the plate portion 424B of section 424 is exposed from the main surface 402 of the magnetic element body 430. The XZ surface in the -Y direction of the plate portion 424B of section 424 is exposed from the side surface 403 of the magnetic element body 430. The YZ surface in the -X direction of the plate portion 424B of section 424 is exposed from the side surface 405 of the magnetic element body 430. The XY surface in the -Z direction of the plate portion 425B of section 425 is exposed from the main surface 402 of the magnetic element body 430. The XZ surface in the -Y direction of the plate portion 425 of section 425 is exposed from the side surface 403 of the magnetic element body 430. The YZ surface in the +X direction of the plate portion 425 of section 425 is exposed from the side surface 406 of the magnetic element body 430. The XY surface of section 426 is exposed from the main surface 402 of the magnetic element body 430.

[0024] The surface of section 414 exposed from main surface 401 of magnetic body 430 constitutes one terminal electrode of the coil conductor made of metal frame 410. The surface of section 415 exposed from main surface 402 of magnetic body 430 constitutes the other terminal electrode of the coil conductor made of metal frame 410. The surface of section 424 exposed from main surface 402 of magnetic body 430 constitutes one terminal electrode of the coil conductor made of metal frame 420. The surface of section 425 exposed from main surface 402 of magnetic body 430 constitutes the other terminal electrode of the coil conductor made of metal frame 420. In this embodiment, sections 411 to 413 of metal frame 410 are not exposed from magnetic body 430, and sections 421 to 423 of metal frame 420 are not exposed from magnetic body 430. In this way, the small surface areas of metal frames 410 and 420 exposed from magnetic body 430 make it possible to obtain high inductance.

[0025] The surfaces of sections 416 and 426 exposed from the main surface 402 of the magnetic body 430 may be used as heat dissipation terminals. The wiring pattern connected to the heat dissipation terminals may terminate without being connected to power supply wiring, signal wiring, etc. The surfaces of sections 415, 416, 424, and 425 exposed from the main surface 402 of the magnetic body 430 may form the same plane. The surfaces of sections 414, 415, 424, and 425 exposed from the side surface 403 of the magnetic body 430 may form the same plane. Note that if section 413 of the metal frame 410 has a section protruding in the +Z direction on the opposite side to section 416, the XY surface of that section exposed from the main surface 401 of the magnetic body 430 and the XY surface of section 414 may form the same plane.

[0026] When manufacturing electronic component 400 having such a configuration, metal frames 410, 420 are bent, and then metal frames 410, 420 are placed on a support so that sections 415, 416 of metal frame 410 and sections 424-426 of metal frame 420 are in contact with the surface of the support, and then metal frames 410, 420 are embedded in magnetic base body 430. This allows metal frame 410 to be in contact with the surface of the support at two locations, and metal frame 420 to be in contact with the surface of the support at three locations, making it possible to stably support metal frames 410, 420 on the surface of the support, facilitating the manufacture of electronic component 400. Furthermore, if the surfaces of section 415 and section 416 exposed from main surface 402 of magnetic base body 430 form the same plane, metal frame 410 can be more stably placed on the support. Similarly, if the surfaces of sections 424 to 426 exposed from main surface 402 of magnetic element 430 form the same plane, metal frame 420 can be placed more stably on the support.

[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 base body and first and second metal frames embedded in the magnetic base body. The first metal frame includes first and second sections extending parallel to a 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 magnetic base body. A portion of the fifth section of the first metal frame is exposed from the magnetic base body. The second metal frame includes sixth and seventh sections extending parallel to the first direction. The first and second sections of the first metal frame are positioned between the sixth section of the second metal frame and the seventh section of the second metal frame so as to be sandwiched in a second direction perpendicular to the first direction. The sixth section of the second metal frame includes a fifth end which is one end in the first direction and a sixth end which is the other end in the first direction. The seventh section of the second metal frame includes 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. A portion of the ninth section of the second metal frame is exposed from the magnetic body. A portion of the tenth section of the second metal frame is exposed from the magnetic base body. The first section of the first metal frame and the sixth section of the second metal frame are overlapped in the second direction so as 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 second direction so as to be insulated from each other. This provides an electronic component suitable for use as an integrated part on a substrate.

[0030] In the electronic component, the third section of the first metal frame and the eighth section of the second metal frame may be overlapped in the first direction so as to be insulated from each other, thereby enhancing the coupling between the coil conductors formed by the first metal frame and the coil conductors formed by the second metal frame.

[0031] 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.

[0032] 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.

[0033] In the electronic component, the magnetic body has a first surface extending in the first and second directions 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 a fourth section of the first metal frame may be partially exposed from the first surface of the magnetic body, and a fifth section of the first metal frame may be partially exposed from the second surface of the magnetic body. This allows connection to both ends of the first metal frame from different directions.

[0034] In the electronic component, a part of the ninth section of the second metal frame and a part of the tenth section of the second metal frame may be exposed from the second surface of the magnetic body, thereby enabling connection to both ends of the second metal frame from the same direction.

[0035] 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.

[0036] In the electronic component, the second metal frame may further include a twelfth section that protrudes from the eighth section in the third direction, and a portion of the twelfth section of the second metal frame may be exposed from the second surface of the magnetic body. In this way, when the second metal frame is embedded in the magnetic body, the twelfth section is brought into contact with the surface of the support, thereby making it possible to more stably support the second metal frame.

[0037] In the electronic component described above, the cross-sectional area of ​​the first metal frame may be different from the cross-sectional area of ​​the second metal frame when viewed from a third direction perpendicular to the first and second directions, which makes it easier to bend the second metal frame along the outer periphery of the first metal frame.

[0038] 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.

[0039] 400 Electronic component 401 Main surface (first surface) 402 Main surface (second surface) 403 to 406 Side surfaces 410, 420 Metal frame 411 Section (first section) 412 Section (second section) 413 Section (third section) 414 Section (fourth section) 415 Section (fifth section) 416 Section (eleventh section) 414A, 414B, 415A, 415B Flat plate portion 414C, 415C Bent portion 418, 419 Notch 421 Section (sixth section) 422 Section (seventh section) 423 Section (eighth section) 424 Section (ninth section) 425 Section (tenth section) 426 Section (12th section) 424A, 425A: Bent portion 424B, 425B: Flat portion 430: Magnetic element 440: Insulating member

Claims

1. A magnetic element comprising: a magnetic element; and first and second metal frames embedded in the magnetic element; the first metal frame includes first and second sections extending parallel to a 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; 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 is exposed from the magnetic element; a portion of the fifth section of the first metal frame is exposed from the magnetic base body; the second metal frame includes sixth and seventh sections extending parallel to the first direction; the first and second sections of the first metal frame are positioned between the sixth section of the second metal frame and the seventh section of the second metal frame so as to be sandwiched in a second direction perpendicular to the first direction; the sixth section of the second metal frame includes 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 includes 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, a portion of the ninth section of the second metal frame being exposed from the magnetic body, and a portion of the tenth section of the second metal frame being exposed from 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 second 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 second direction so as to be insulated from each other.

2. The electronic component according to claim 1, wherein the third section of the first metal frame and the eighth section of the second metal frame are stacked in the first direction so as to be insulated from each other.

3. 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.

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

5. An electronic component as described in claim 1, wherein the magnetic base body has a first surface extending in the first and second directions and a second surface located on the opposite side of the first surface in a third direction perpendicular to the first and second directions, the portion of the fourth section of the first metal frame is exposed from the first surface of the magnetic base body, and the portion of the fifth section of the first metal frame is exposed from the second surface of the magnetic base body.

6. The electronic component according to claim 5, wherein the part of the ninth section of the second metal frame and the part of the tenth section of the second metal frame are exposed from the second surface of the magnetic base body.

7. The electronic component according to claim 6, 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.

8. The electronic component according to claim 7, wherein the second metal frame further includes a twelfth section that protrudes from the eighth section along the third direction, and a portion of the twelfth section of the second metal frame is exposed from the second surface of the magnetic base body.

9. The electronic component according to claim 1, wherein the cross-sectional area of the first metal frame is different from the cross-sectional area of the second metal frame when viewed from a third direction perpendicular to the first and second directions.

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