JP6090902B2 - Coil parts - Google Patents

Description

  The present invention relates to a coil component, and more particularly to a coil component including a high magnetic resistance member inside a magnetic core.

  As a technique for reducing the saturation of the inductance of the coil component in a high magnetic field by inserting a high magnetoresistive member into a part of the magnetic path, for example, there is one disclosed in Patent Document 1.

JP 2006-4957 A

  The technique disclosed in Patent Document 1 utilizes the property that magnetic flux travels so as to avoid a high magnetoresistive member and prevents the magnetic flux from concentrating near the coil, thereby making the magnetic flux uniform and inductance. Trying to prevent saturation.

  However, the configuration disclosed in Patent Document 1 has a problem that the AC copper loss is remarkably deteriorated even though the magnetic flux can be made uniform.

  It is an object of the present invention to provide a coil component that can achieve both uniform magnetic flux and prevention of deterioration of AC copper loss.

  The inventors of the present invention, as a cause of the deterioration of the AC copper loss, in order for the magnetic flux to proceed so as to avoid the high magnetic resistance member, a part of the magnetic flux enters the coil side and enters the coil constituting the coil. It was found that AC copper loss was aggravated by generating eddy currents. The present invention is based on such knowledge.

That is, according to the present invention, as the first coil component,
A coil formed by winding a winding around a winding shaft extending in the vertical direction; a high magnetic resistance member disposed on an inner peripheral side surface of the coil in a coil inner space surrounded by the coil; the coil and the high magnetism A coil component comprising a magnetic core surrounding the resistance member,
The high magnetic resistance member has a first surface extending from the upper edge of the inner peripheral side surface toward the winding shaft in the coil inner space, and from the lower edge of the inner peripheral side surface toward the winding shaft in the coil inner space. And a second surface extending
A coil component is obtained in which the first surface and the second surface extend below the upper end of the coil inner space and above the lower end of the coil inner space.

According to the present invention, the second coil component is a first coil component,
The coil inner space has an upper coil inner space and a lower coil inner space obtained by dividing the coil inner space into two equal parts in the vertical direction.
The high magnetic resistance member includes an upper high magnetic resistance member protruding from the inner peripheral side surface toward the winding shaft in the upper coil inner space, and a concave shape in a horizontal direction perpendicular to the upper high magnetic resistance member and the vertical direction. A lower high magnetic resistance member protruding from the inner peripheral side surface toward the winding shaft in the lower coil inner space so as to form a valley of
The first surface is formed on a part of the upper high magnetic resistance member,
On the second surface, a coil component formed on a part of the lower high magnetic resistance member is obtained.

According to the present invention, the third coil component is a second coil component,
An upper auxiliary high magnetic resistance member formed on the first surface and projecting from the first surface toward the winding shaft; and formed on the second surface and from the second surface toward the winding shaft. A coil component further including a projecting lower auxiliary high magnetic resistance member is obtained.

According to the present invention, the fourth coil component is a third coil component,
The upper auxiliary high magnetic resistance member is arranged so as to include the upper edge of the inner peripheral side surface,
The lower auxiliary high magnetic resistance member is disposed so as to include the lower edge of the inner peripheral side surface.
Coil parts are obtained.

Further, according to the present invention, the fifth coil component is a second coil component,
An upper auxiliary high magnetic resistance member that is formed at the top of the upper high magnetic resistance member in the horizontal direction and protrudes from the top of the upper high magnetic resistance member toward the winding shaft; and A coil component further comprising a lower auxiliary high magnetic resistance member formed at the top in the horizontal direction and projecting from the top of the lower high magnetic resistance member toward the winding shaft is obtained.

According to the present invention, as the sixth coil component, any one of the third to fifth coil components,
The upper auxiliary high magnetic resistance member protrudes obliquely upward from the upper high magnetic resistance member,
The lower auxiliary high magnetic resistance member is a coil component projecting obliquely downward from the lower high magnetic resistance member.

Further, according to the present invention, as the seventh coil component, any one of the third to sixth coil components,
A coil component in which the distance from the inner peripheral side surface to the tip of the high magnetic resistance member is 1/5 or more and 1/2 or less of the distance from the inner peripheral side surface to the tip of the auxiliary high magnetic resistance member is obtained. .

Further, according to the present invention, as the eighth coil component, any one of the third to seventh coil components ,
The upper auxiliary high magnetic resistance member and the lower auxiliary high magnetic resistance member are coil parts formed in a tapered shape.

Moreover, according to the present invention, as the ninth coil component,
A coil formed by winding a winding around a winding shaft extending in the vertical direction, an upper high magnetic resistance member projecting obliquely upward from the upper end of the coil toward the winding shaft, and the winding shaft from the lower end of the coil A coil component is obtained that includes a lower high magnetic resistance member projecting obliquely downward toward the surface, and a magnetic core that surrounds the coil, the upper high magnetic resistance member, and the lower high magnetic resistance member.

According to the present invention, the tenth coil component is a ninth coil component,
The upper high magnetic resistance member is disposed so as to include a boundary portion between the upper end of the coil and an inner peripheral side surface of the coil,
The lower high magnetic resistance member is a coil component arranged so as to include a boundary portion between the lower end of the coil and the inner peripheral side surface.

Moreover, according to the present invention, as the eleventh coil component, the ninth or tenth coil component,
As for the upper high magnetic resistance member and the lower high magnetic resistance member, a coil component having a tapered shape is obtained.

  According to the present invention, since the magnetic flux can be prevented from entering the coil by the first surface and the second surface of the high magnetic resistance member, AC copper loss in the coil component can be reduced. Furthermore, by further providing an auxiliary magnetoresistive member, the magnetic flux can be made uniform by preventing the magnetic flux from being concentrated around the coil. That is, according to the coil component of the present invention, both AC copper loss and iron loss can be reduced.

It is a perspective view which shows the coil used for the coil components by the 1st Embodiment of this invention, and a coil cover. It is sectional drawing along the II-II line of the coil cover of FIG. It is a perspective view which shows the composite_body | complex of the coil of FIG. 1, and a coil cover, and a case. It is a top view which shows the state which accommodated the composite_body | complex of FIG. 3 in the case, and was filled with the magnetic body. It is sectional drawing along the VV line of the coil components of FIG. It is sectional drawing of the coil components by the 2nd Embodiment of this invention. It is sectional drawing of the coil components by the 3rd Embodiment of this invention. It is sectional drawing of the coil components by the 4th Embodiment of this invention. It is sectional drawing of the coil components by the 5th Embodiment of this invention. It is sectional drawing showing the modification of the coil components of FIG. It is a figure showing the other modification of the coil components of FIG.

(First embodiment)
As shown in FIGS. 1, 3, 4, and 5, the coil component 1 (see FIGS. 4 and 5) according to the first embodiment of the present invention includes a coil 10, a coil cover 30, and a magnetic field. A core 40 and a case 60 for housing them are provided.

  As shown in FIG. 1, the coil 10 is formed by winding a winding (a flat conducting wire) 102 in a vertical winding around a winding axis T extending in the vertical direction. The drawing portion 104 (104a) of the winding 102 wound around the winding axis T is drawn along the outer surface of the coil 10 so as to be aligned with the other drawing portion 104 (104b).

  As shown in FIGS. 1 and 2, the coil cover 30 includes a housing portion 302 for housing the coil 10 and a cylindrical portion 304 disposed in the center of the housing portion 302. A drawer portion guide 306 is provided on the outer wall of the housing portion 302 to secure a space for routing the drawer portion 104 a of the coil 10. The coil cover 30 is formed of an insulator such as an epoxy resin.

  The high magnetic resistance member 20 is formed integrally with the coil cover 30 on the inner periphery of the cylindrical portion 304. As shown in detail in FIG. 2, the high magnetic resistance member 20 includes an upper high magnetic resistance member 202 and a lower high magnetic resistance member 204. The upper high magnetic resistance member 202 and the lower high magnetic resistance member 204 are each formed in a mountain shape from the inner periphery of the cylindrical portion 304 toward the winding axis T, and between these, a horizontal direction ( A concave recess (valley) 230 is formed in the radial direction of the coil 10. The high magnetoresistive member 20 according to the present embodiment is formed over the entire inner circumference of the cylindrical portion 304, but the high magnetoresistive member 20 should not be formed within 20% or less of the inner circumference of the cylindrical portion 304. (In this case, when the high magnetoresistive member 20 is viewed from above, a substantially C-shaped shape is exhibited).

  The high magnetic resistance member 20 according to the present embodiment will be described in more detail. As shown in FIG. 5, the coil 10 has a coil inner space 130 surrounded by the coil 10. The coil inner space 130 is divided into an upper coil inner space 136 and a lower coil inner space 136 which are divided into two equal parts. Side coil inner space 138. In the state in which the coil 10 is housed in the coil cover 30 (in the state shown in FIG. 5), the upper high magnetic resistance member 202 moves from the inner peripheral side surface 110 of the coil 10 toward the winding axis T in the upper coil inner space 136. It arrange | positions so that it may protrude along a horizontal direction. Similarly, the lower high magnetic resistance member 204 is disposed so as to protrude in the horizontal direction from the inner peripheral side surface 110 of the coil 10 toward the winding axis T in the lower coil inner space 138. Here, the upper high magnetic resistance member 202 has a first surface 210 extending from the upper edge 112 of the inner peripheral side surface 110 of the coil 10 toward the winding axis T, and the lower high magnetic resistance member 204 is The second surface 220 extends from the lower edge 112 of the inner peripheral side surface 110 of the coil 10 toward the winding axis T. The first surface 210 and the second surface 220 according to the present embodiment extend below the upper end 132 of the coil inner space 130 and above the lower end 134. In other words, the first surface 210 and the second surface 220 do not extend in a direction parallel to the upper end 132 and the lower end 134 (that is, the horizontal direction). As a result, as is apparent from the cross-sectional shape of the high magnetic resistance member 20 in FIG. 5, the thicknesses of the upper high magnetic resistance member 202 and the lower high magnetic resistance member 204 from the inner peripheral side surface 110 of the coil 10 (horizontal direction). (Thickness) is gradually larger than the edge 112 of the coil 10. Further, the concave portion 230 formed between the upper high magnetic resistance member 202 and the lower high magnetic resistance member 204 has a thickness from the inner peripheral side surface 110 (thickness in the horizontal direction) as it approaches the middle point in the vertical direction of the coil 10. Sa) is getting smaller.

  For the high magnetic resistance member 20 according to the present embodiment, a member having a low magnetic permeability (μ ≦ 10) is used. Specifically, a heat-resistant plastic such as epoxy resin, LCP, 6 nylon, PPS, or PBT can be used, and the thermal conductivity of the filler is 0.6 W / mK or more, preferably 0.8 W / mK. The above is suitable. In this embodiment, an epoxy resin with μ = 1 is used. In addition, although the coil cover 30 and the high magnetic resistance member 20 according to the present embodiment are integrally formed, they may be formed separately and bonded or the like later. The high magnetic resistance member 20 (the upper high magnetic resistance member 202 and the lower high magnetic resistance member 204) according to the present embodiment has a symmetrical shape with respect to the horizontal direction.

  The coil component 1 according to the first embodiment is manufactured as follows. First, as shown in FIG. 1, the coil 10 is accommodated in the coil cover 30. Here, an insulator such as an epoxy resin is filled between the coil 10 and the coil cover 30 in order to prevent the winding 102 from shifting, shaking, or the like. Since epoxy resins are required to be liquid and have low viscosity, additives, curing agents, compatibility with catalysts, and storage stability are also important characteristics that should be considered in selecting specific epoxy resins. In consideration of such matters, epoxy resins such as bisphenol A type, bisphenol F type, and polyfunctional type can be used as the main component of the insulator, and aromatic polyamine type, carboxylic acid anhydride type, latent type can be used as the curing agent. A hardener-based one can be used. In this example, a combination of a bisphenol A type epoxy resin and a solvent-free low viscosity liquid aromatic amine curing agent was used. As a result, the entire coil 10 excluding the lead-out portion 104 is embedded in the coil cover 30. The resin used may be another thermosetting resin such as a silicone resin, or may be cured without applying heat such as a chemically reactive curable resin, an ultraviolet curable resin, or a photocurable resin. A curable resin may be used.

  The composite body composed of the coil 10 and the coil cover 30 thus molded is accommodated in the case 60 as shown in FIG. 3 so that the space between the composite body and the case 60 is satisfied. A composite of resin and magnetic powder is poured into the case 60, and the resin is cured to obtain the magnetic core 40 according to the present embodiment.

  Here, the magnetic powder constituting the magnetic core 40 according to the present embodiment is a soft magnetic powder, specifically, an Fe-based soft magnetic metal powder. More specifically, the soft magnetic metal powder is a powder selected from the group consisting of Fe-Si powder, Fe-Si-Al powder, Fe-Ni powder, and Fe amorphous powder. Here, the average Si content in the Fe—Si based powder is preferably 0.0 wt% or more and 11.0 wt% or less. Further, the average Si content in the Fe—Si—Al-based powder is preferably 0.0 wt% or more and 11.0 wt% or less, and the average Al content is preferably 0.0 wt% or more and 7.0 wt%. It is as follows. Further, the average Ni content in the Fe—Ni-based powder is preferably 30.0 wt% or more and 85.0 wt% or less.

  Moreover, as resin mixed, it is good to use the thing similar to resin which can be filled between the coil 10 and the coil cover 30, as mentioned above.

  According to the above configuration, the high magnetoresistive member 20 acts so as to move away from the vicinity of the coil 10 with respect to the magnetic flux around the coil 10, thereby making the magnetic flux density B uniform and reducing the iron loss. be able to. Furthermore, the first surface 210 and the second surface 220 provided on the high magnetic resistance member 20 prevent the magnetic flux from entering between the windings 102 of the coil 10, thereby reducing the AC copper loss. That is, according to the coil component 1 according to the present embodiment, the characteristics of both the iron loss and the AC copper loss can be improved.

(Second Embodiment)
As shown in FIG. 6, the coil component 1 a according to the second embodiment of the present invention includes the high magnetic resistance member 20 a and the auxiliary high magnetic resistance member 50, according to the first embodiment. It is different from the coil component 1 (see FIG. 5), and the other members can be the same as those of the coil component 1 according to the first embodiment. In the following description, the difference from the coil component 1 according to the first embodiment will be particularly referred to.

  As shown in FIG. 6, the high magnetic resistance member 20a formed on the coil cover 30 includes an upper high magnetic resistance member 202a and a lower high magnetic resistance member 204a. The upper high magnetic resistance member 202a and the lower high magnetic resistance member 204a have substantially the same shape as that of the coil component 1 according to the first embodiment (see FIG. 5). The only difference is that the auxiliary high magnetic resistance member 502 and the lower auxiliary high magnetic resistance member 504 are formed. The upper auxiliary high magnetic resistance member 502 protrudes in the horizontal direction from the apex of the upper high magnetic resistance member 202a toward the winding axis T. On the other hand, the lower auxiliary high magnetic resistance member 504 protrudes in the horizontal direction from the apex of the lower high magnetic resistance member 204a toward the winding axis T. In the present embodiment, the distance L1 from the inner peripheral side surface 110 of the coil 10 to the tip of the high magnetic resistance member 20 is 1/2 of the distance L2 from the inner peripheral side surface 110 of the coil 10 to the tip of the auxiliary high magnetic resistance member 50. 5 or more and 1/2 or less. In particular, it is most desirable that the distance L1 is 1/4 of the distance L2.

(Third embodiment)
As shown in FIG. 7, the coil component 1b according to the third embodiment of the present invention is different from the coil component 1a according to the second embodiment (see FIG. 6) in the shape of the auxiliary high magnetic resistance member 50a and The protruding directions are different, and the other members can be the same as those of the coil component 1a according to the second embodiment. Hereinafter, the difference from the coil component 1a according to the second embodiment will be particularly referred to.

The auxiliary high magnetic resistance member 50a according to the present embodiment protrudes from the top in the horizontal direction of the high magnetic resistance member 20b. More specifically, the upper auxiliary high magnetic resistance member 502a protrudes obliquely upward from the apex of the upper high magnetic resistance member 202b toward the winding axis T. On the other hand, the lower auxiliary high magnetic resistance member 504a protrudes obliquely downward from the apex of the lower high magnetic resistance member 204b toward the winding axis T. The upper auxiliary high magnetic resistance member 502a and the lower auxiliary high magnetic resistance member 504a are formed in a tapered shape. In forming the taper, the thickness of the tip is preferably 0.3 mm or more in consideration of the strength of the member. Also in the present embodiment, the distance L3 from the inner peripheral side surface 110 of the coil 10 to the tip of the high magnetic resistance member 20b is the distance L4 from the inner peripheral side surface 110 of the coil 10 to the tip of the auxiliary high magnetic resistance member 50a. 1/5 or more and 1/2 or less. In particular, it is most desirable that the distance L3 is 1/4 of the distance L4.

(Fourth embodiment)
As shown in FIG. 8, the coil component 1c according to the fourth embodiment of the present invention includes the auxiliary high magnetic resistance member 50b, and thus the coil component 1 according to the first embodiment (see FIG. 5). The other members can be the same as those of the coil component 1 according to the first embodiment. Hereinafter, differences from the coil component 1 according to the first embodiment will be particularly referred to.

  The auxiliary high magnetic resistance member 50b according to the present embodiment is formed on each of the first surface 210c and the second surface 220c of the high magnetic resistance member 20c. More specifically, the upper auxiliary high magnetic resistance member 502 b is formed on the first surface 210 c and is disposed so as to include the upper edge 112 of the inner peripheral side surface 110 of the coil 10. The upper auxiliary high magnetic resistance member 502b protrudes toward the winding axis T along the upper end 132 of the coil inner space 130 (in the horizontal direction) and is formed in a tapered shape. On the other hand, the lower auxiliary high magnetic resistance member 504 b is formed on the second surface 220 c and is disposed so as to include the lower edge 112 of the inner peripheral side surface 110 of the coil 10. Further, the lower auxiliary high magnetic resistance member 504b protrudes toward the winding axis T along the lower end 134 of the coil inner space 130 (in the horizontal direction) and is formed in a tapered shape.

(Fifth embodiment)
As shown in FIG. 9, the coil component 1 d according to the fifth embodiment of the present invention includes the high magnetic resistance member 20 d at the upper end 12 and the lower end 14 of the coil 10. Specifically, the coil component 1d protrudes obliquely downward from the upper end 12 of the coil 10 toward the winding axis T and obliquely upward toward the winding axis T, and from the lower end 14 of the coil 10 toward the winding axis T. And a lower high magnetic resistance member 204d. In other words, the upper high magnetic resistance member 202d protrudes upward from the upper end 132 of the coil internal space 130, while the lower high magnetic resistance member 204d protrudes downward from the lower end 134 of the coil internal space 130. Yes. Thus, in the state where each high magnetic resistance member 20d protrudes diagonally upward (or diagonally downward), the magnetic core 40 is molded so that the high magnetic resistance member 20d is embedded. It is particularly larger in the vertical direction than the case 60 of the coil component 1 (see FIG. 5) according to the first embodiment. The high magnetoresistive member 20 d in the present embodiment is disposed so as to include the edge 112 of the inner peripheral side surface 110 of the coil 10. Moreover, the high magnetic resistance member 20d can be a coil component that is formed in a tapered shape. In the present embodiment, the upper high magnetic resistance member 202d is formed not on the coil cover 30 (see FIG. 1 etc.) but on the coil cap 32. The coil cap 32 is attached to the coil 10 so as to cover the upper end 12 and the lower end 14 of the coil 10. In the present embodiment, the coil 10 is surrounded by an insulator with the coil cap 32 attached.

  Hereinafter, the characteristics of the coil parts 1 and 1a to 1d according to the first to fifth embodiments described above were compared for the coil parts that do not use the high magnetoresistance member. For evaluation of the characteristics, Maxwell, which is a finite element method analysis software manufactured by Ansoft, was used and calculated from magnetic field analysis.

  As is clear from Table 1, when compared with the coil component that does not use the high magnetoresistive member, the AC copper loss and iron in any of the coil components 1 and 1a to 1d according to the first to fifth embodiments. It can be seen that both losses have been reduced.

  In addition, if it is the structure which has the 1st surface and the 2nd surface in the high magnetic resistance member mentioned above, as FIG. 10 shows, for example, the high magnetic resistance member 20e will be separated from the 1st surface 210e and the 2nd surface 220e. It is good also as forming in one mountain shape which becomes. Moreover, it is good also as a structure which filled the recessed part 230 of the high magnetoresistive member 20 (refer FIG. 5) by 1st Embodiment.

DESCRIPTION OF SYMBOLS 1, 1a-1d Coil components 10 Coil 12 Upper end 14 Lower end 102 Winding 104 Drawer part 110 Inner side surface 112 Edge part 120 End part 130 Coil inner space 132 Upper end 134 Lower end 136 Upper coil inner space 138 Lower coil inner space 20, 20a to 20f High magnetic resistance member 202, 202a to 202d Upper high magnetic resistance member 204, 204a to 204d Lower high magnetic resistance member 210 First surface 220 Second surface 230 Recess 30 Coil cover 32 Coil cap 302 Housing portion 304 Cylindrical portion 306 Drawer guide 40 Magnetic core 50, 50a, 50b Auxiliary high magnetic resistance member 502, 502a, 502b Upper auxiliary high magnetic resistance member 504, 504a, 504b Lower auxiliary high magnetic resistance member 60, 60a Case

Claims (8)

A coil formed by winding a winding around a winding shaft extending in the vertical direction; a high magnetic resistance member disposed on an inner peripheral side surface of the coil in a coil inner space surrounded by the coil; the coil and the high magnetism A coil component comprising a magnetic core surrounding the resistance member,
The high magnetic resistance member has a first surface extending from the upper edge of the inner peripheral side surface toward the winding shaft in the coil inner space, and from the lower edge of the inner peripheral side surface toward the winding shaft in the coil inner space. And a second surface extending
The first surface and the second surface are coil parts extending below the upper end of the coil inner space and above the lower end of the coil inner space. The coil component according to claim 1,
The coil inner space has an upper coil inner space and a lower coil inner space obtained by dividing the coil inner space into two equal parts in the vertical direction.
The high magnetic resistance member includes an upper high magnetic resistance member protruding from the inner peripheral side surface toward the winding shaft in the upper coil inner space, and a concave shape in a horizontal direction perpendicular to the upper high magnetic resistance member and the vertical direction. A lower high magnetic resistance member protruding from the inner peripheral side surface toward the winding shaft in the lower coil inner space so as to form a valley of
The first surface is formed on a part of the upper high magnetic resistance member,
The second surface is a coil component formed on a part of the lower high magnetic resistance member. The coil component according to claim 2,
An upper auxiliary high magnetic resistance member formed on the first surface and projecting from the first surface toward the winding shaft; and formed on the second surface and from the second surface toward the winding shaft. A coil component further comprising a projecting lower auxiliary high magnetic resistance member. The coil component according to claim 3,
The upper auxiliary high magnetic resistance member is arranged so as to include the upper edge of the inner peripheral side surface,
The lower auxiliary high magnetic resistance member is disposed so as to include the lower edge of the inner peripheral side surface.
Coil parts. The coil component according to claim 2,
An upper auxiliary high magnetic resistance member that is formed at the top of the upper high magnetic resistance member in the horizontal direction and protrudes from the top of the upper high magnetic resistance member toward the winding shaft; and A coil component further comprising: a lower auxiliary high magnetic resistance member formed at an apex in the horizontal direction and projecting from the apex of the lower high magnetic resistance member toward the winding shaft. A coil component according to any one of claims 3 to 5,
The upper auxiliary high magnetic resistance member protrudes obliquely upward from the upper high magnetic resistance member,
The lower auxiliary high magnetic resistance member protrudes obliquely downward from the lower high magnetic resistance member The coil component according to any one of claims 3 to 6,
The coil component, wherein a distance from the inner peripheral side surface to the tip of the high magnetic resistance member is 1/5 or more and 1/2 or less of a distance from the inner peripheral side surface to the tip of the auxiliary high magnetic resistance member. A coil component according to any one of claims 3 to 7,
The upper auxiliary high magnetic resistance member and the lower auxiliary high magnetic resistance member are coil parts formed in a tapered shape.

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