Coil component and coil device

Abstract

A coil component including a first conductive plate part formed with a first coil pattern having a first opening, and a second conductive plate part formed with a second coil pattern having a second opening and disposed at a predetermined interval in the laminating direction with respect to the first conductive plate part. The first conductive plate part and the second conductive plate part are made of the same single plate and are integrally formed by a bent joining segment.

Claims

1. A coil component having a laminating direction, comprising: a first conductive plate part formed with a first coil pattern having a first opening; a second conductive plate part formed with a second coil pattern having a second opening and disposed at a predetermined interval in the laminating direction with respect to the first conductive plate part; and a bent joining segment connecting the first conductive plate part and the second conductive plate part, wherein the first conductive plate part, the second conductive plate part and the bent joining segment are made of the same single plate, and the bent joining segment directly connects a part of a first outer edge of the first coil pattern contacting the first opening with a part of a second outer edge of the second coil pattern contacting the second opening, and wherein a recess for bending is formed on a bent inner surface or a bent outer surface of the bent joining segment, and a thickness of the bent joining segment is smaller than a first thickness of the first coil pattern and is smaller than a second thickness of the second coil pattern.

2. The coil component according to claim 1, wherein the bent joining segment is connected to the first coil pattern by a predetermined first end length extending from the first pattern end point of the first coil pattern along a periphery of the first opening, and the second coil pattern by a predetermined second end length extending from the second pattern end point of the second coil pattern along a periphery of the second opening, and wherein the first end length is longer than a first width of the first coil pattern, the second end length is longer than a second width of the second coil pattern, and the first end length and the second end length are substantially the same.

3. The coil component according to claim 1, wherein an insulating member is interposed between the first coil pattern and the second coil pattern.

4. A coil device comprising: the coil component according to claim 1; and a core member, made by compacting a magnetic material and mounting the coil component therein, wherein the core member comprises: a center leg which is inserted into an inside of the first opening and an inside of the second opening of the coil component; a planar base placed at an outer surface of the first coil pattern in the axial direction and an outer surface of the second coil pattern in the axial direction; and an outer leg placed at an outer side surface of the first coil pattern, an outer side surface of the second coil pattern, and an outer side surface of the bent joining segment.

5. A coil device comprising: the coil component according to claim 1; and a compressed powder body containing a magnetic material, integrally covering an inside of the first opening, an inside of the second opening, an outer surface of the first coil pattern, an outer surface of the second coil pattern, and an outer surface of the bent joining segment of the coil component.

6. A coil component having a laminating direction, comprising: a first conductive plate part formed with a first coil pattern having a first opening; a second conductive plate part formed with a second coil pattern having a second opening and disposed at a predetermined interval in the laminating direction with respect to the first conductive plate part; and a bent joining segment connecting the first conductive plate part and the second conductive plate part, wherein the first conductive plate part, the second conductive plate part and the bent joining segment are made of the same single plate, and the bent joining segment directly connects a part of a first outer edge of the first coil pattern contacting the first opening with a part of a second outer edge of the second coil pattern contacting the second opening, and wherein the bent joining segment is connected to the first coil pattern by a predetermined first end length extending from the first pattern end point of the first coil pattern along a periphery of the first opening, and the second coil pattern by a predetermined second end length extending from the second pattern end point of the second coil pattern along a periphery of the second opening, and wherein a first cutout recessed in the direction towards the first opening is formed on the first coil pattern at a position apart from the first pattern end point by the first end length, and a second cutout recessed in the direction towards the second opening is formed on the second coil pattern at a position apart from the second pattern end point by the second end length.

7. The coil component according to claim 6, wherein the first conductive plate part has a first lead part connected to the first coil pattern at a first start point by a predetermined first start length extending from the first pattern start point of the first coil pattern along the periphery of the first opening.

8. The coil component according to claim 7, wherein the first conductive plate part except a distal end of the first lead part is covered with an insulating layer.

9. The coil component according to claim 6, wherein the second conductive plate part has a second lead part connected to the second coil pattern at a second start point by a predetermined second start length extending from the second pattern start point of the second coil pattern along the periphery of the second opening, and the second lead part is bent from a plane of the second coil pattern toward the laminating direction and located outside the first coil pattern.

10. A coil device comprising: the coil component according to claim 6; and a compressed powder body containing a magnetic material, integrally covering an inside of the first opening, an inside of the second opening, an outer surface of the first coil pattern, an outer surface of the second coil pattern, and an outer surface of the bent joining segment of the coil component.

11. A coil component having a laminating direction, comprising: a first conductive plate part formed with a first coil pattern having a first opening; a second conductive plate part formed with a second coil pattern having a second opening and disposed at a predetermined interval in the laminating direction with respect to the first conductive plate part; and a bent joining segment connecting the first conductive plate part and the second conductive plate part, wherein the first conductive plate part, the second conductive plate part and the bent joining segment are made of the same single plate, and the bent joining segment directly connects a part of a first outer edge of the first coil pattern contacting the first opening with a part of a second outer edge of the second coil pattern contacting the second opening, and wherein an inner side surface positioned at an end in a longitudinal direction of the first opening has a first arcuate inner curved surface, an outer side surface of the first conductive plate part corresponding to the first arcuate inner curved surface has a first corner protrusion, an inner side surface positioned at an end in a longitudinal direction of the second opening has a second arcuate inner curved surface, and an outer side surface of the second conductive plate part corresponding to the second arcuate inner curved surface has a second corner protrusion.

12. A coil device comprising: the coil component according to claim 11; and a compressed powder body containing a magnetic material, integrally covering an inside of the first opening, an inside of the second opening, an outer surface of the first coil pattern, an outer surface of the second coil pattern, and an outer surface of the bent joining segment of the coil component.

13. The coil component according to claim 11, wherein the bent joining segment is connected to the first coil pattern by a predetermined first end length extending from the first pattern end point of the first coil pattern along a periphery of the first opening, and the second coil pattern by a predetermined second end length extending from the second pattern end point of the second coil pattern along a periphery of the second opening, and wherein the first end length is longer than a first width of the first coil pattern, the second end length is longer than a second width of the second coil pattern, and the first end length and the second end length are substantially the same.

14. A coil component having a laminating direction, comprising: a first conductive plate part formed with a first coil pattern having a first opening; a second conductive plate part formed with a second coil pattern having a second opening and disposed at a predetermined interval in the laminating direction with respect to the first conductive plate part; and a bent joining segment connecting the first conductive plate part and the second conductive plate part, wherein the first conductive plate part, the second conductive plate part and the bent joining segment are made of the same single plate, and the bent joining segment directly connects a part of a first outer edge of the first coil pattern contacting the first opening with a part of a second outer edge of the second coil pattern contacting the second opening, and wherein the first conductive plate part has a first lead part connected to the first coil pattern at a first start point by a predetermined first start length extending from the first pattern start point of the first coil pattern along the periphery of the first opening, and wherein the first lead part is bent from a plane of the first coil pattern toward the laminating direction, and a distal end of the first lead part has a taper having a narrower width toward the distal end.

15. The coil component according to claim 14, wherein the first conductive plate part except a distal end of the first lead part is covered with an insulating layer.

16. A coil device comprising: the coil component according to claim 8; and a compressed powder body containing a magnetic material, integrally covering an inside of the first opening, an inside of the second opening, an outer surface of the first coil pattern, an outer surface of the second coil pattern, and an outer surface of the bent joining segment of the coil component.

17. A coil component having a laminating direction, comprising: a first conductive plate part formed with a first coil pattern having a first opening; a second conductive plate part formed with a second coil pattern having a second opening and disposed at a predetermined interval in the laminating direction with respect to the first conductive plate part; and a bent joining segment connecting the first conductive plate part and the second conductive plate part, wherein the first conductive plate part, the second conductive plate part and the bent joining segment are made of the same single plate, and the bent joining segment directly connects a part of a first outer edge of the first coil pattern contacting the first opening with a part of a second outer edge of the second coil pattern contacting the second opening, and wherein the bent joining segment is connected to the first coil pattern by a predetermined first end length extending from the first pattern end point of the first coil pattern along a periphery of the first opening, and the second coil pattern by a predetermined second end length extending from the second pattern end point of the second coil pattern along a periphery of the second opening, and wherein the first end length is longer than a first width of the first coil pattern, the second end length is longer than a second width of the second coil pattern, and the first end length and the second end length are substantially the same, and wherein a first cutout recessed in the direction towards the first opening is formed on the first coil pattern at a position apart from the first pattern end point by the first end length, and a second cutout recessed in the direction towards the second opening is formed on the second coil pattern at a position apart from the second pattern end point by the second end length.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic perspective view of the coil device according to an embodiment of the invention.

(2) FIG. 2 is a perspective view of the coil component incorporated in the coil device shown in FIG. 1.

(3) FIG. 2A is a perspective view of the coil component showing a partial cross section of FIG. 2

(4) FIG. 3 is a cross-sectional view of the coil device along the line III-III shown in FIG. 2.

(5) FIG. 4A is a cross-sectional view of the coil device along the line IVA-IVA shown in FIG. 2.

(6) FIG. 4B is a cross-sectional view of the coil device along the line IVB-IVB shown in FIG. 2.

(7) FIG. 5A is a perspective view showing a producing process of the coil component shown in FIG. 2.

(8) FIG. 5B is a perspective view showing a subsequent step of FIG. 5A.

(9) FIG. 5C is a perspective view showing a subsequent step of FIG. 5B.

(10) FIG. 6 is an exploded perspective view of the coil device according to another embodiment of the invention.

(11) FIG. 7A is an enlarged perspective view of the coil component shown in FIG. 6.

(12) FIG. 7B is an enlarged perspective view of the upper core shown in FIG. 6, viewed from different angles.

DETAILED DESCRIPTION OF THE INVENTION

(13) Hereinafter, the invention will be described based on embodiments shown in the drawings.

First Embodiment

(14) As shown in FIG. 1, an inductor element 2 as the coil device in an embodiment of the invention has a core (sealing body) 4 as a powder compact. In the embodiment, the core 4 has an approximate hexahedral shape, and has an upper surface 4A, a lower surface 4B located on the opposite side of the upper surface 4A in the Z-axis direction, and four side surfaces 4C. In the embodiment, the lower surface 4B is a mounting surface for connection to such as a circuit board.

(15) The upper surface 4A of the core 4 is an outer surface opposite to the mounting side, substantially parallel to the lower surface 4B, and the four side surfaces 4C are substantially perpendicular to these upper and lower surfaces. However, the shape of the core 4 is not particularly limited, and it is not limited to a hexahedron but may be a cylindrical shape, an elliptical column, a polygonal column, etc.

(16) Further, in the embodiment, the core 4 is formed so as to be elongated in the X-axis direction rather than the Y-axis direction. And the lead parts 66 and 67 shown in FIG. 2 are formed and exposed on the side surface 4C in the X-axis direction. As shown in FIG. 3, the distal ends of the lead parts 66 and 67 are attached to the core 4 so as to protrude downward in the Z-axis direction lower than the lower surface 4B of the core 4. In the drawings, X-axis, Y-axis and Z-axis are substantially perpendicular to each other. And in the embodiment, Z-axis matches the vertical direction of the coil unit 2 and X-axis matches the longitudinal direction of the coil unit 2.

(17) As shown in FIG. 2, the coil component 6 is mounted inside the core 4. The main part of the coil component 6 is covered with the core 4. The main part of the coil component 6 is a part excluding a part of the lead parts 66 and 67 exposed from the core 4.

(18) As shown in FIG. 3, in the embodiment, it is preferable that most of the end faces in the X-axis direction of the lead parts 66 and 67 are exposed from the core 4. The lead parts 66 and 67 are however not always necessary to be exposed and may be embedded in the core 4. Since the lower ends of the respective lead parts 66 and 67 in the Z-axis direction become connections with the circuit board, it is preferable that they are exposed from the core 4 at least within a predetermined height Z1 in the Z-axis direction. The predetermined height Z1 is preferably 0.1 to 0.5 mm.

(19) In order to expose the lower end of each lead part 66 and 67 in the Z-axis direction in a range not less than the predetermined height Z1 not to contact the core 4, as shown in FIGS. 3 and 4B, a tapered concave 4D extending downward in the Z-axis direction is formed on the lead extraction part of the core 4. For the same reason, as shown in FIG. 4B, it is preferable that a taper is formed at the lower end in the Z-axis direction of each lead parts 66 and 67 in order to make the width in the Y-axis direction and/or the thickness in the X-axis direction toward the lower end in the Z-axis direction small.

(20) With the configuration, it is possible to easily connect the lower ends of each lead part 66 and 67 to the land parts of the circuit board with such as solder, and the solder becomes difficult to adhere to the lower surface 4B of the core 4. Note that the insulating layer 64 described later is peeled at the lower ends of each lead part 66 and 67, and the surfaces of the metals constituting the lead parts 66 and 67 are exposed.

(21) As shown in FIGS. 2 and 3, the coil component 6 has a multiple conductive plate parts laminated in the Z-axis direction (laminating direction). In the below-described embodiment, the two first and second conductive plate parts 61 and 62 are laminated in the Z-axis direction to form the coil component 6, but the invention is not limited thereto.

(22) As shown in FIG. 2, the first coil pattern 61b having the first opening 61a is formed on the first conductive plate part 61. The second conductive plate part 62 is disposed at a predetermined interval in the laminating (Z-axis) direction with respect to the first conductive plate part 61. The second coil pattern 62b having the second opening 62a is formed on the second conductive plate part 62. The second opening 62a communicates with the first opening 61a in the Z-axis direction and has substantially the same size with the first opening 61a.

(23) In the embodiment, the first coil pattern 61b has a pattern that surrounds the first opening slenderly elongated in the X-axis direction by approximately less than one round from the first pattern start point 61c to the first pattern end point 61d. A first cutout part is formed between the first pattern start point 61c and the first pattern end point 61d, and the first opening 61a is opened toward the outside at the first cutout. The cutout width of the first cutout part in the X-axis direction is not particularly limited as long as it is a width that maintains insulation between the first pattern start point 61c and the first pattern end point 61d.

(24) The second coil pattern 62b has a pattern that surrounds the second opening slenderly elongated in the X-axis direction by approximately less than one round from the second pattern starting point 62c to the second pattern end point 62d. A second cutout part is formed between the second pattern starting point 62c and the second pattern end point 62d, and the second opening 62a is opened toward the outside at the second cutout. The cutout width of the second cutout part in the X-axis direction is not particularly limited as long as it is a width that maintains insulation between the second pattern start point 62c and the second pattern end point 62d.

(25) In the embodiment, the first conductive plate part 61 and the second conductive plate part 62 are connected by a bent joining segment 63, made of the same single plate as the first conductive plate part 61 and the second conductive plate part 62. The bent joining segment 63 directly connect a part of the first outer edge of the first coil pattern 61b contacting (defining) the first opening 61a and a part of the second outer edge of the second coil pattern 62b contacting (defining) the second opening 62a.

(26) That is, the bent joining segment 63 is integrally connected to the first outer edge of the first coil pattern 61b by a predetermined first end length X1 (the length in the X-axis direction) along a periphery of the first opening 61a from the first pattern end point 61d of the first coil pattern 61b. Further, the bent joining segment 63 is integrally connected to the second outer edge of the second coil pattern 62b by a predetermined second end length X2 (the length in the X-axis direction) along a periphery of the second opening 62a from the second pattern end point 62d of the second coil pattern 62b.

(27) These end lengths X 1 and X 2 are preferably approximately the same but may be different. Further, in the embodiment, the X-axis direction position of the connection between the first coil pattern 61b and the bent joining segment 63, and the X-axis direction position of the connection between the second coil pattern 62 and the bent joining segment 63 are substantially the same but may be out of position in the X-axis direction.

(28) In the embodiment, the first cutout 61e is preferably formed on the first coil pattern 61b at a position apart from the first pattern end point 61d by a first end length X1. The first cutout 61e is recessed in the direction opposite to the bending direction of the bent joining segment 63 (the direction towards the first opening 61a). Further, the second cutout 62e is preferably formed on the second coil pattern 62b at a position apart from the second pattern end point 62d by a second end length X2. The second cutout 62e is recessed in the direction opposite to the bending direction of the bent joining segment 63 (the direction towards the second opening 62a).

(29) These cutouts 61e and 62e are not necessarily provided, but by being provided, it is possible to further reduce the protrusion amount of the bent joining segment 63 projecting in the Y-axis direction from the annular first coil pattern 61b and the annular second coil pattern 62b. Therefore, it is possible to further downsize the coil component 2.

(30) The width in the X-axis direction of each cutout 61e and 62e is not particularly limited, but it is preferably around 0.1 to 2 times the thickness (thickness in the Z-axis direction) of the first conductive plate part 61 or the same of the second conductive plate part 62. The depth in the Y-axis direction of each cutout 61e and 62e is not particularly limited, but it is preferably around 0.1 to 0.7 times the width (width in the Y-axis direction) of the first conductive plate part 61 or the same of the second conductive plate part 62.

(31) In addition, a recess 63a for bending is formed on the bent inner surface of the bent joining segment 63. As shown in FIG. 4A, at the recess 63a for bending, the thickness t0 of the bent joining segment 63 is smaller than the representative first thickness t1 of the first coil pattern 61b. The representative first thickness t1 of the first coil pattern 61b is substantially equal to the second thickness of the second coil pattern 62b and is equal to the thickness of the metal plate constituting these patterns. t0/t1 is 1 or less, preferably 0.3 or more and less than 1.

(32) The first end length X1 shown in FIG. 2 and FIG. 2A is longer than the representative first width W1 of the first coil pattern 61b shown in FIG. 4A and FIG. 2A. For example, W1/X1 (the same for W1/X2) is 1 or less, preferably 0.1 or more and less than 1. The representative first width W1 of the first coil pattern 61b is equivalent to the representative second width of the second coil pattern 62b. The representative first width W1 of the first coil pattern 61b is defined as a minimum value of the width in the Y-axis direction of the first coil pattern 61b in a portion where the bent joining segment 63 and the first cutout 61e are not formed. Similarly, the representative second width W2 of the second coil pattern 62b is defined as a minimum value of the width in the Y-axis direction of the second coil pattern 62b in a portion where the bent joining segment 63 and the second cutout 62e are not formed. The second width W2 is substantially the same as the first width W1.

(33) In the embodiment, the representative first width W1 of the first coil pattern 61b shown in FIG. 4A is not particularly limited, but in terms of the relationship with the width W0 of the first opening 61a in Y-axis direction, W1/W0 is preferably determined as 0.2 to 2. In addition, the first width W1 is determined so that t1/W1 is preferably 0.3 to 1 in relation to the representative first thickness t1 of the first coil pattern 61b. The first opening 61a and the second opening 62a are arranged to be aligned in the Y-axis direction and in the X-axis direction, and the width of the second opening 62a in the Y-axis direction is substantially the same with the width W0 of the first opening 61a in the Y-axis direction.

(34) As shown in FIG. 2, in the embodiment, the first conductive plate part 61 has a first lead part 66 connected to the first coil pattern 61b at a portion by a predetermined first starting length Y1 (the length in the Y-axis direction) extending from the first pattern start point 61c of the first coil pattern 61b along the periphery of the first opening 61a. The first lead part 66 is bent from a plane including the X-axis and the Y-axis of the first coil pattern 61b toward the laminating direction (downward of the Z-axis direction). As shown in FIG. 4B, at the distal end of the first lead part 66, a taper 66a having a narrower width toward the distal end is formed.

(35) As shown in FIG. 2, the second conductive plate part 62 has a second lead part 67 connected to the second coil pattern 62b at a portion by a predetermined second starting length Y2 (the length in the Y-axis direction) extending from the second pattern starting point 62c of the second coil pattern 62b along the periphery of the second opening 62a. The second lead part 67 is bent from a plane including the X-axis and the Y-axis of the second coil pattern 62b downwardly along Z-axis direction, and located outside the first coil pattern 61b. A taper 67a having a narrower width toward the distal end is formed at the distal end of the second lead part 67. As shown in FIG. 4B, the distal end of the second lead part 67 projecting downward from the lower surface 4B of the core 4, similarly to the distal end of the first lead part 66.

(36) The second starting length Y2 is preferably substantially the same as the first starting length Y1, but it is not always necessary to be the same. These lengths Y1 and Y2 are preferably equal to or greater than the representative first width W1 of the first coil pattern 61b shown in FIG. 4A, respectively, and Y1/W1 is preferably one or more, and more preferably 1.2 to 3.

(37) As shown in FIGS. 3, 4A and 4B, the first conductive plate part 61, the second conductive plate part 62, and the bent joining segment 63 are covered with an insulating layer 64 in areas other than the distal ends of the first lead part 66 and the second lead part 67. As will be described later, the first conductive plate part 61, the second conductive plate part 62, and the bent joining segment 63 are made of a single metal plate, and the thickness thereof is not particularly limited, but is preferably 0.1 to 2 mm. The thickness of the insulating layer 64 is not particularly limited, but is preferably 5 to 40 μm.

(38) The metal constituting the first conductive plate part 61, the second conductive plate part 62 and the bent joining segment 63 is not particularly limited, but examples thereof include Cu, Al, Fe, Ag, Au, and alloys thereof. The insulating layer 64 is not particularly limited, but is formed of a metal oxide, a resin, etc.

(39) The metal oxide constituting the insulating layer 64 is not particularly limited, but titanium oxide, alumite, etc. is exemplified. The resin constituting the insulating layer 64 is not particularly limited, but thermoplastic resins such as an epoxy resin, a urethane resin or a polyimide resin, thermosetting resins such as a melamine resin or a phenol resin, an ultraviolet curing resins such as epoxy resin, etc. are exemplified. Note that the method of applying the insulation coating or the oxide coating is not particularly limited, but an electrodeposition method, a vapor deposition method, a sputtering method, etc. are exemplified.

(40) As shown in FIG. 2, in the embodiment, the inner side surface positioned at an end in the longitudinal direction (X-axis direction) of the first opening 61a has a first arcuate inner curved surface 61f And the outer side surface of the first conductive plate part 61 corresponding to the first arcuate inner curved surface 61f has first corner protrusions 61g. Further, the inner side surface positioned at an end in the longitudinal direction (X-axis direction) of the second opening 62a has a second arcuate inner curved surface 62f. And the outer side surface of the second conductive plate part 62 corresponding to the second arcuate inner curved surface 62f has second corner protrusions 62g.

(41) With such configuration, it becomes possible to extend the magnetic flux to the core 4 as the compressed powder body located near the first corner protrusions 61g and the second corner protrusions 62g. Thus, it is possible to effectively use the corner part of the core 4 made of the compressed powder body. Further, at the first corner protrusions 61g, the cross sectional area of the first conductive plate part 61 is widened and the electric resistance is lowered, and at the second corner protrusions 62g, the cross sectional area of the second conductive plate part 62 is widened and the electric resistance is lowered.

(42) As shown in FIGS. 3 and 4A, in the coil component 6 of the embodiment, the inside of the first opening 61a, the inside of the second opening 62a, the outer surface of the first coil pattern 61b, the outer surface of the second coil pattern 62b and the outer surface of the bent joining segment 63 are integrally covered with the core 4 made of the compressed powder body containing a magnetic material. An adhesive 8 as an insulating member is filled between the first conductive plate part 61 and the second conductive plate part 62 that are bent at the bent joining segment 63 and laminated. Thereby an entry of the magnetic material powder constituting the core 4 between the first conductive plate part 61 and the second conductive plate part 62 is suppressed. The gap between the first conductive plate part 61 and the second conductive plate part 62 is not particularly limited but is preferably 10 to 500 μm.

(43) The core 4 is formed by compression compacting or injection molding of granules containing magnetic powder and binder. The magnetic powder is not particularly limited, but metal magnetic powder including Sendust (Fe—Si—Al; iron-silicon-aluminum), Fe—Si—Cr (iron-silicon-chromium), Permalloy (Fe—Ni), Carbonyl Iron type, Carbonyl Ni type, amorphous powder, nanocrystal powder, etc. are preferably used.

(44) The grain diameter of the magnetic powder is preferably 0.5 to 50 μm. In the embodiment, it is preferable that the magnetic powder is the metal magnetic grain and the grain periphery is coated with insulation. As the insulation coating, a metal oxide coating, a resin coating, a chemical treated film such as phosphorus, zinc, etc. are exemplified.

(45) However, as the magnetic powder, ferrite magnetic powder such as Mn—Zn, Ni—Cu—Zn, etc. may be used. The binder resin is not particularly limited, but examples thereof include an epoxy resin, a phenol resin, an acrylic resin, a polyester resin, a polyimide, a polyamideimide, a silicone resin, and a combination thereof.

(46) In the embodiment, the lower surface 4B of the core 4 shown in FIG. 1 is a mounting side outer surface to be connected to such as a circuit board. The lower surface 4B is formed substantially in parallel with a plane including X-axis and Y-axis, which are mutually perpendicular. And the winding axis of the coil component 6 is substantially parallel to the Z-axis perpendicular to the plane in which the X-axis and the Y-axis pass through.

(47) Although the size of the inductor element 2 of the embodiment is not particularly limited, for example, the width in X-axis direction is 1.0 to 20 mm, the width in Y-axis direction Y0 is 1.0 to 20 mm and the height Z0 is 1.0 to 10 mm. The inductor element 2 can be used as such as a transformer, a balun, a common mode filter (common mode choke), a circuit element such as a DC/DC converter, a choke coil in a power supply line, a decoupling element, an element for impedance matching, a component element for filter, an antenna element, etc.

(48) Next, a method of producing the inductor element 2 shown in FIGS. 1 to 4B will be described. First, a conductive plate such as a metal plate (e.g. a Sn-plated metal plate) is punched into a shape as shown in FIG. 5A (a stamping step). As shown in FIG. 5A, the multiple first conductive plate parts 61 connected to the lead frame 10 are formed via the lead parts 66 on the conductive plate part after punching.

(49) The second conductive plate part 62 is integrally formed with each first conductive plate part 61 via the bent joining segment 63. The first coil pattern 61b having the first opening 61a is formed on the first conductive plate part 61. The first lead part 66 is formed at the first pattern start point 61c of the first coil pattern 61b. The second coil pattern 62b having the second opening 62a is formed at the second conductive plate part 62. The second lead part 67 is formed at the second pattern starting point 62c of the second coil pattern 62b.

(50) The recess 63a for bending is formed on the surface of the bent joining segment 63, and only at the recess 63a for bending, the plate thickness is thinner than the other part. The thickness of the bent joining segment 63 at the recess 63a for bending corresponds to the thickness t0 shown in FIG. 4A. The thickness of the first conductive plate part 61 shown in FIG. 5A corresponds to the thickness t1 shown in FIG. 4A. In the state shown in FIG. 5A, the first conductive plate part 61 and the second conductive plate part 62 are substantially parallel to the plane including the X-axis and the Y-axis.

(51) Next, the second conductive plate part 62 shown in FIG. 5A is bent with respect to the first conductive plate part 61, with the bent joining segment 63 as a fulcrum. And as shown in FIG. 5B, the second conductive plate part 62 is bent substantially perpendicular to the first conductive plate part 61. In this state, the insulation coating is applied to the surfaces of the first conductive plate part 61, the second conductive plate part 62 and the bent joining segment 63 (the insulation coating process). In this process, an insulating resin layer is formed on the surfaces of the first conductive plate part 61, the second conductive plate part 62, and the bent joining segment 63 by electrodeposition, followed by drying and heat treatment as necessary. Then, an insulating layer 64 (see FIGS. 3 to 4B) covering the surfaces of the conductive plate parts 61 and 62 and the bent joining segment 63 is formed.

(52) As a polymer used for the electrodeposition solution for forming the insulating layer 64 by electrodeposition, various anionic or cationic synthetic polymer resins having electrodeposition properties can be mentioned. In order to impart adhesiveness to the polymer resins, an adhesive resin such as a rosin type, a terpene type, a petroleum resin, etc. may be added as required.

(53) In particular, from the viewpoint of insulation, strength, and chemical stability, it is preferable that the insulating layer 64 is a polyimide resin. For example, the insulating layer 64 may be an insulating resin layer which is formed by electrodeposing an electrodeposition coating composition including polyimide resin containing an ionic group, an organic solvent capable of dissolving the polyimide resin, water, an ionic compound having polarity different from that of the ionic group, followed by drying and heat treating. Note that the insulating layer 64 may also be formed by heating and melting the resin, applying the molten resin to each of the conductive plate parts 61 and 62, and then curing the resin. Before or after the processes thereof, the second lead part 67 may be bent in a substantially vertical direction from the plane of the first coil pattern 62b.

(54) Next, as shown in FIG. 5C, the second conductive plate part 62 is further bent with respect to the first conductive plate part 61 with the bent joining segment 63 as the fulcrum. The second conductive plate part 62 is laminated on the first conductive plate part 61 (a laminating step) in parallel to form the coil component 6. Before or after the laminating step, as shown in FIGS. 3 and 4A, the adhesive 8 as an insulating member is filled between the first conductive plate part 61 and the second conductive plate part 62.

(55) Next, the main part of the coil component 6 is inserted into a press mold, the distal ends of the lead parts 66 and 67 are exposed from the press mold, and the core 4 is formed by compression compacting in the press mold (a molding step). At the time of compression compacting, the mixture containing the magnetic powder and the binder resin is filled in the cavity of the press mold, and the whole is heat compressed, whereby the inductor element 2 shown in FIGS. 1 to 4B is obtained.

(56) The heating temperature during the heat compression is preferably 50 to 300° C. and a compression pressure is preferably 1 to 400 Pa. As a method for the compression compacting, the press mold may be used, or oil pressure or water pressure may be used. In compression compacting, instead of the above-mentioned mixture, only the resin may be filled in the cavity. Also, the molding step may be omitted, and the main part of the coil component 6 may simply put into an exterior packaging (a sealing body) and fixed.

(57) The lead frame 10 shown in FIG. 5C may be removed by cutting with a cutting tool after forming the core 4 by compression compacting, or it may be removed before forming the core 4. Although not shown in the drawing, it is preferable that the tapers 66a and 67a shown in FIG. 4B are formed in advance on the distal ends of the lead parts 66 and 67 protruding from the core 4. Further, in the core 4, it is preferable that the tapered concave 4D corresponding to the tapers 66a, 67a is formed. As shown in FIGS. 3 and 4B, the insulating layer 64 coated on the distal ends of the lead parts 66 and 67 is preferably removed before forming the core 4, but the insulating layer 64 may be removed after forming the core 4.

(58) As shown in FIG. 2, in the coil component 6 according to the embodiment, the bent joining segment 63 directly connects a part of the first outer edge of the first coil pattern 61b forming the first opening 61a and a part of the second outer edge of the second coil pattern 62b forming the second opening 62a. Therefore, it is possible to minimize the protruding amount in the Y-axis direction of the bent joining segment 63 protruding from the annular first coil pattern 61b and the annular second coil pattern 62b. Thus, it is easy to miniaturize the coil component 6.

(59) In addition, since it is easy to reduce the size of the coil component 6, it is also easy to reduce the size of the inductor element 2 having the coil component 6 and the core 4 including the compressed powder body in which the coil component 6 is integrally incorporated. Further, it is easy to make the first conductive plate part 61 defining the first coil pattern 61b and the second conductive plate part 62 defining the second coil pattern 62b to be relatively thick, and it becomes possible to increase the current flow flowing through the coil patterns 61b and 62b.

(60) In the embodiment, the width of the connection between the bent joining segment 63 and the first coil pattern 61b corresponds to the first end length X1, and the width of the connection between the bent joining segment 63 and the second coil pattern 62b corresponds to the second end length X2. And by keeping the lengths X1, X2 within the predetermined ranges, it is possible to suppress an increase in the electrical resistance at these connections.

(61) In the embodiment, by setting the end lengths X1 and X2 shown in FIG. 2 to be longer than the first width W1 of the first coil pattern shown in FIG. 4A, it becomes possible to suppress a decrease in the cross sectional area of the bent joining segment 63 and to suppress an increase in electrical resistance, even when the thickness t0 of the bent joining segment 63 is made thin. Although it is preferable that the width of the bent joining segment 63 is substantially the same along the bending direction, it is not necessarily arranged at the same position toward the laminating direction, and both edges in the width direction of the bent joining segment 63 in X axis direction may be inclined.

(62) Furthermore, in the embodiment, since the recess 63a for bending is formed on the bent inner surface of the bent joining segment 63, it is possible to further reduce the protruding amount of the bent joining segment 63 in the Y-axis direction, which protrudes from the annular first coil pattern 61b and the annular second coil pattern 62b. Therefore, it is possible to further reduce the size of the coil component 6.

(63) Further, by reducing the thickness t0 (see FIG. 4A) of the bent joining segment 63, it becomes easy to further reduce the gap in the Z-axis direction between the first coil pattern 61b and the second coil pattern 62b. As a result, it becomes possible to strengthen the magnetic coupling between these coil patterns 61b, 62b, and such as the metal magnetic powder contained in the core 4 becomes difficult to enter between the coil patterns 61b, 62b. Thus, it becomes difficult to generate such as a short-circuit failure.

(64) In the embodiment, as shown in FIG. 4B, by forming the tapers 66a, 67a at the distal ends of the first lead part 66 and the second lead part 67, for example, a contact between the core 4 including the metallic magnetic material and a metal exposed surface of the tapers 66a and 67a can be easily avoided. Thus, the short circuit of the lead parts with the metal magnetic body can be prevented.

(65) In the embodiment, since the conductive plate parts 61 and 62 are covered with the insulating layer 64 except for the distal ends of the lead parts 66 and 67, it is possible to easily avoid a contact of lead parts with the core 4 including such as the metal magnetic body. Thus, it is possible to effectively prevent a short circuit between the metal exposed surface of the conductive plate parts 61 and 62 and the metal magnetic body.

(66) Further, in the embodiment, the second conductive plate part 62 has a second lead part connected to the second coil pattern 62b by a predetermined second starting length Y2 extending from the second pattern starting point 62c of the second coil pattern along the periphery of the second opening 62a. The second lead part 67 is bent from a plane of the second coil pattern 62b toward the laminating direction, and located outside the first coil pattern 61b. With such configuration, the coil component 6 can be further reduced in size.

Second Embodiment

(67) Shown in FIG. 6, the inductor element 102 of the embodiment is similar to the inductor element 2 of the first embodiment, except the configuration of the coil component 106 is different and the configuration of the core (core members 41 and 42) is different. Hereinafter, parts different from the first embodiment will be described in detail, and description of common parts will be omitted. According to the members shown in the drawings, the common members are denoted by the similar reference numerals, and descriptions thereof will be partly omitted.

(68) As shown in FIG. 7A, the coil component 106 has two first and second conductive plate parts 161 and 162 laminated in the Z-axis direction (laminating direction). A first coil pattern 161b having a first opening 161a is formed on the first conductive plate part 161. The second conductive plate part 162 is disposed at a predetermined interval in the laminating (Z-axis) direction with respect to the first conductive plate part 161. A second coil pattern 162b having a second opening 162a is formed on the second conductive plate part 162. The second opening 162a communicates with the first opening 161a in the Z-axis direction and has substantially the same size with the first opening 161a.

(69) In the embodiment, the first conductive plate part 161 and the second conductive plate part 162 are connected by a bent joining segment 163, made of the same single plate as the first conductive plate part 61 and the second conductive plate part 62. The bent joining segment 163 directly connect a part of the first outer edge of the first coil pattern 161b forming the first opening 161a and a part of the second outer edge of the second coil pattern 162b forming the second opening 162a.

(70) That is, the bent joining segment 163 is integrally connected to the first outer edge of the first coil pattern 161b by the predetermined first end length X1 (see FIG. 2) extending from the first pattern end point 161d of the first coil pattern 161b along a periphery of the first opening 161a. Further, the bent joining segment 163 is integrally connected to the second outer edge of the second coil pattern 162b by the predetermined second end length X2 (see FIG. 2) extending from the second pattern end point 162d of the second coil pattern 162b along a periphery of the second opening 162a.

(71) In the embodiment, a recess 163a for bending is formed on the bent outer surface of the bent joining segment 63. At the recess 63a for bending, the thickness t0 (see FIG. 4A) of the bent joining segment 163 is smaller than the representative first thickness t1 (see FIG. 4A) of the first coil pattern 161b.

(72) In the embodiment, the core has a lower core member 41 and an upper core member 42, which are formed in advance as separate members and are combined with the coil component 106 in a later step. The lower core member 41 has a base 41a having a substantially square plate shape. The outer legs 41c1 and 41c2 are integrally formed around the base 41a. The outer legs 41c1 and 41c2 are formed to protrude from the base 41a so as to have a predetermined height in the Z-axis direction and are formed to be separated from each other by a pair of cutouts 41e for lead.

(73) The pair of cutouts 41e for lead are formed so as to allow the first lead part 66 and the second lead part 67, formed on both sides in the X-axis direction of the coil component 106, to extend outside of X-axis direction and downside of Z-axis direction from the base 41a. Also, the cutouts 41e make the outer legs 41c1 and 41c2 mutually separated.

(74) In the substantially central part in the X-axis and the Y-axis directions of the base 41a, a central leg 41b is integrally formed so as to protrude in the Z-axis direction. The central leg 41b has a shape which can be inserted inside the first opening 161a of the coil device 106 and has substantially the same shape but slightly smaller than the internal shape of the first opening 161a.

(75) As shown in FIG. 7B, the upper core member 42 has a base 42a having a substantially square plate shape. In the substantially central part in the X-axis and the Y-axis directions of the base 42a, a central leg 42b is integrally formed so as to protrude in the Z-axis direction. The central leg 42b has a shape which can be inserted into the the second opening 162a of the coil device 106 and has substantially the same shape but slightly smaller than the internal shape of the second opening 162a.

(76) Further, the outer legs 42c1 and 42c2 are integrally formed around the base 42a. The outer legs 42c1 and 42c2 are formed to protrude from the base 42a so as to have a predetermined height in the Z-axis direction and are formed to be separated from each other by a pair of cutouts 42e for lead.

(77) The pair of cutouts 42e1 and 42e2 for lead are formed so as to allow the first lead part 66 and the second lead part 67, formed on both sides in the X-axis direction of the coil component 106 shown in FIG. 7A, to extend outside of X-axis direction from the base 42a. Also, the cutouts 42e1 and 42e2 make the outer legs 42c1 and 42c2 mutually separated.

(78) The first lead part 66 of the coil component 106 is taken out from the first conductive plate part 161, a second lead part 67 is taken out from the second conductive plate part 162. Thus, taken out positions thereof in the Z-axis direction are different from each other. Therefore, the cutout 42e1 for lead corresponding to the first lead part 66 is not necessarily provided, and even if it is provided, the depth of the cutout 42e1 in the Z-axis direction may be set to be shallow compared to that of the other cutout 42e2 for lead.

(79) In the embodiment, the central leg 41b of the lower core member 41 enters the first opening 161a of the coil component 106, the central leg 42b of the upper core member 42 enters the second opening 162a. And distal ends of the central legs 41b and 42b mutually abut to contact each other or face each other with a predetermined gap, in order to make a part of the magnetic circuit.

(80) Further, the outer leg 41c1 of the core member 41 and the outer leg 42c1 of the core member 42 abut to contact each other in Z-axis direction at an outside of the bent joining segment 163 of the coil component 106, in order to constitute a part of the magnetic circuit. In addition, the outer leg 41c2 of the core member 41 and the outer leg 42c2 of the core member 42 face each other in Z-axis direction at the opposite outside of the bent joining segment 163 of the coil component 106 in order to constitute a part of the magnetic circuit.

(81) As shown in FIG. 6, a step 41d may be formed on one of the outer legs 41c2 (and/or 42c2), and the height in Z-axis direction may be smaller than the same of the other outer leg 41c1 (and/or 42c1). The step 41d is formed on the outer leg 41c2 (and/or 42c2) along the X-axis direction so as to correspond to the position at the opposite side in the Y-axis direction from the bent joining segment 163 of the coil component 106.

(82) The length of the stepped part 41d in the X-axis direction is preferably substantially the same as the length of the bent joining segment 163 of the coil device 106 in the X-axis direction. In the coil component 106, as compared with a portion where the bent joining segment 163 is formed, the magnetic property as a coil becomes stronger in a portion of the coil component 106 positioned on the opposite side of the bent joining segment 163 in the Y-axis direction. Therefore, by providing the step 41d in the outer leg 41c2 (and/or 42c2) of the core member 41 or 42 and providing a gap in the facing part thereof, it becomes easy to balance the magnetic property on both sides of the coil device 106 in the Y-axis direction.

(83) The core members 41 and 42 may bond at least at four corners with such as an adhesive. The core members 41 and 42 may bond between the outer leg 41c1 and the outer leg 42c1 and between the outer leg 41c2 and the outer leg 42c2. The core members 41 and 42 will surround main parts of the coil component 106 other than the lead parts 66 and 67. That is, bases 41a, 42a of the core members 41, 42 cover the outer surface of the first coil pattern 161b in the axial direction and the outer surface of the second coil pattern 162b in the axial core direction, respectively. The outer side surface of the first coil pattern 161b, the outer side surface of the second coil pattern 162b, and the outer side surface of the bent joining segment 163 are covered with the outer legs 41c1, 41c2, 42c1, and 42c2.

(84) In the embodiment, the core members 41 and 42 can each be made of the magnetic material or the resin which are the same material as the core 4 of the first embodiment. Unlike the core 4, the core members 41 and 42 can also be made of a magnetic material of a sintered body not including the resin, since it is not necessary to integrally form with coil component 106 including metals. In the embodiment, unlike the core 4, the core members 41 and 42 can be made of magnetic materials such as Ni—Zn based ferrite, Mn—Zn based ferrite, Fe based powder, Fe-based sintered body, etc.

(85) The coil component 106 and the inductor element 102 according to the embodiment have the same configurations as the coil component 6 and the inductor element 2 of the first embodiment and exhibit similar operational effects, except the descriptions above.

(86) The invention is not limited to the above-described embodiments and can be variously modified within the scope of the invention.

(87) For example, the coil component 6 includes two conductive plate parts 61 and 62 and a single bent joining segment 63 in the above embodiment, however, it may include three or more conductive plate parts and two or more bent joining segments.

DESCRIPTION OF THE REFERENCE NUMERALS

(88) 2, 102 . . . Inductor element (Coil device)

(89) 4 . . . Core (Compressed powder body)

(90) 4A . . . Upper surface

(91) 4B . . . Lower surface

(92) 4C . . . Side surface

(93) 4D . . . Tapered concave

(94) 41 . . . Lower core member 41a . . . Base 41b . . . Central leg 41c1, 41c2 . . . Outer leg 41d . . . Step 41e . . . Cutout for lead

(95) 42 . . . Upper core member 42a . . . Base 42b . . . Central leg 42c1, 42c2 . . . Outer leg 42e . . . Cutout for lead

(96) 6, 106 . . . Coil component

(97) 61, 161 . . . First conductive plate part 61a, 161a . . . First opening 61b, 161b . . . First coil pattern 61c . . . First pattern start point 61d . . . First pattern end point 61e . . . First cutout 61f . . . First arcuate inner curved surface 61g . . . First corner protrusion

(98) 62, 162 . . . Second conductive plate part 62a, 162a . . . Second opening 62b, 162b . . . Second coil pattern 62c . . . Second pattern start point 62d . . . Second pattern end point 62e . . . Second cutout 62f . . . Second arcuate inner curved surface 62g . . . Second corner protrusion

(99) 63, 163 . . . Bent joining segment 63a, 163a . . . Recess for bending

(100) 64 . . . Insulating layer

(101) 66 . . . First lead part 66a . . . Taper

(102) 67 . . . Second lead part 67a . . . Taper

(103) 8 . . . Adhesive (Insulating member)

(104) 10 . . . Lead frame