JP2003282342A - Coil sealed dust core - Google Patents
Coil sealed dust coreInfo
- Publication number
- JP2003282342A JP2003282342A JP2002086075A JP2002086075A JP2003282342A JP 2003282342 A JP2003282342 A JP 2003282342A JP 2002086075 A JP2002086075 A JP 2002086075A JP 2002086075 A JP2002086075 A JP 2002086075A JP 2003282342 A JP2003282342 A JP 2003282342A
- Authority
- JP
- Japan
- Prior art keywords
- coil
- dust core
- green compact
- powder
- compact
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Links
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Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、磁芯を一体化した
インダクタ、その他の電子機器に用いるコイル封入圧粉
磁芯に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an inductor in which a magnetic core is integrated and a coil-encapsulated dust core used in other electronic devices.
【０００２】[0002]
【従来の技術】近年、電気、電子機器の小型化が進み、
小型（低背）で大電流に対応した圧粉磁芯が要求されて
いる。圧粉磁芯の材料には、フェライト粉末や強磁性金
属粉末が用いられている。2. Description of the Related Art In recent years, miniaturization of electric and electronic devices has advanced,
There is demand for a compact (low profile) dust core that can handle large currents. Ferrite powder or ferromagnetic metal powder is used as the material of the dust core.
【０００３】強磁性金属粉末は、フェライト粉末に比較
して飽和磁束密度が大きいため、直流重畳特性が高磁界
まで保たれ、大電流を必要とする用途に適している。Since the ferromagnetic metal powder has a larger saturation magnetic flux density than the ferrite powder, the direct current superposition characteristic is maintained up to a high magnetic field, and it is suitable for applications requiring a large current.
【０００４】コアの小型化（低背）をさらに推進するた
め、コイルと磁性粉が一体になったコイルが提案されて
いる。この構造のインダクタを、本明細書では、コイル
封入圧粉磁芯と呼ぶ。In order to further promote the miniaturization (low profile) of the core, a coil in which a coil and magnetic powder are integrated has been proposed. In this specification, the inductor having this structure is referred to as a coil-encapsulated dust core.
【０００５】従来より表面実装型のインダクタの構造が
提案されている。例えば、特開平５−２９１０４６号公
報には、絶縁被覆した市販電線に外部電極を接続し、巻
線全体を絶縁被膜で覆い、さらにそれらを包み込むよう
に磁性粉末とともに成形することが開示されている。こ
の場合、導体と磁性粉末の間の絶縁、端子と磁性粉末間
の絶縁、及び磁性粉末を成形した磁性部表面に絶縁塗装
膜を形成する必要があり、製造工程が複雑となりコスト
アップとなっていた。Conventionally, a structure of a surface mount type inductor has been proposed. For example, JP-A-5-291046 discloses connecting an external electrode to a commercially available electric wire coated with insulation, covering the entire winding with an insulation coating, and molding the magnetic wire together with the magnetic powder so as to wrap them. . In this case, it is necessary to insulate between the conductor and the magnetic powder, insulate between the terminal and the magnetic powder, and to form an insulating coating film on the surface of the magnetic part formed by molding the magnetic powder, which complicates the manufacturing process and increases the cost. It was
【０００６】また、特開２００１−２６７１６０号公報
には、絶縁材をコーティングした強磁性金属粒子からな
る磁性粉末中に、平角導線をエッジワイズ巻きしたコイ
ルを埋め込んだ例が示されている（図１と同様の構
成）。このコイル封入圧粉磁芯は、圧粉体とコイルと圧
粉体に埋め込まれた端子電極のみから構成されているた
め、小型化ができ、かつ高飽和磁束密度の強磁性金属粒
子を使用しているため、良好な直流重畳特性が得られて
いる。Further, Japanese Patent Laid-Open No. 2001-267160 discloses an example in which a coil in which a rectangular conductor is edgewise wound is embedded in a magnetic powder composed of ferromagnetic metal particles coated with an insulating material (FIG. The same configuration as 1.). This coil-encapsulated dust core consists only of the compact and the coil and the terminal electrode embedded in the compact, so it can be downsized and uses ferromagnetic metal particles with high saturation magnetic flux density. Therefore, good DC superposition characteristics are obtained.
【０００７】[0007]
【発明が解決しようとする課題】従来のインダクタでは
端子電極とコアの間の絶縁は必須条件とされ、上記特開
平５−２９１０４６号公報のように絶縁されるか、また
はコアにＮｉ−Ｚｎフェライトのような絶縁抵抗が１０
５Ω・ｍと非常に大きなコアを用いることが一般的であ
った。In the conventional inductor, insulation between the terminal electrode and the core is an indispensable condition, and insulation is performed as in the above-mentioned JP-A-5-291046, or the core is made of Ni-Zn ferrite. Insulation resistance like 10
It was common to use a very large core of 5 Ω · m.
【０００８】しかし、前者の場合、絶縁材料が必要なた
め、コア体積をその分減らす必要があり、また後者の場
合、Ｎｉ−Ｚｎフェライトの飽和磁束密度が小さいた
め、どちらの場合も良好な直流重畳特性を得ることがで
きなかった。However, in the former case, an insulating material is required, so that the core volume needs to be reduced accordingly. In the latter case, the saturation magnetic flux density of Ni-Zn ferrite is small, and therefore in both cases, a good direct current is required. The superposition characteristic could not be obtained.
【０００９】一方、直流重畳特性を向上させるために、
上記特開２００１−２６７１６０号公報に開示されてい
るような絶縁材をコーティングした強磁性金属粒子から
なる磁性粉末中にコイルを埋め込んだコイル封入圧粉磁
芯が知られており、このコイル封入圧粉磁芯は、圧粉体
とコイルと圧粉体に埋め込まれた端子電極のみから構成
されているため、小型化ができ、かつ高飽和磁束密度の
強磁性金属粒子を使用しているため、良好な直流重畳特
性が得られている。しかし、強磁性金属粒子と絶縁材の
配合比、端子電極間の距離、及びコイル封入圧粉磁芯が
組み込まれたＤＣ／ＤＣコンバータの入力電圧によって
は、コイルの導線の抵抗及び圧粉体の磁気損失からは説
明できない損失分があることが判明した。この原因を調
査した結果、端子電極間に圧粉体を介して電流が流れ、
圧粉体の発熱を生じていることが分かった。その発熱量
が多い場合には、コイル損失による電源効率の低下が問
題となる。On the other hand, in order to improve the DC superposition characteristic,
There is known a coil-encapsulated dust core in which a coil is embedded in a magnetic powder composed of ferromagnetic metal particles coated with an insulating material as disclosed in JP-A-2001-267160. Since the powder magnetic core is composed only of the powder compact, the coil, and the terminal electrode embedded in the powder compact, it can be miniaturized and uses the ferromagnetic metal particles of high saturation magnetic flux density. Good DC superposition characteristics are obtained. However, depending on the mixing ratio of the ferromagnetic metal particles and the insulating material, the distance between the terminal electrodes, and the input voltage of the DC / DC converter incorporating the coil-encapsulated dust core, the resistance of the coil conductor and the It was revealed from the magnetic loss that there was a loss that could not be explained. As a result of investigating the cause, an electric current flows between the terminal electrodes through the green compact,
It was found that the green compact was generating heat. When the amount of heat generation is large, there is a problem that the power supply efficiency is lowered due to the coil loss.
【００１０】本発明は、上記の点に鑑み、２つの端子電
極を圧粉体に埋め込んだコイル封入圧粉磁芯において、
圧粉体を経由して端子電極間を流れる電流に起因する発
熱を防止したコイル封入圧粉磁芯を提供することを目的
とする。In view of the above points, the present invention provides a coil-encapsulated dust core in which two terminal electrodes are embedded in a compact.
An object of the present invention is to provide a coil-encapsulated dust core that prevents heat generation due to a current flowing between terminal electrodes via a dust compact.
【００１１】本発明のその他の目的や新規な特徴は後述
の実施の形態において明らかにする。Other objects and novel features of the present invention will be clarified in the embodiments described later.
【００１２】[0012]
【課題を解決するための手段】上記したように、絶縁材
をコーティングした強磁性金属粒子からなる磁性粉末中
に、コイルを埋め込んだコイル封入圧粉磁芯は、コイル
の導線の抵抗及び圧粉体の磁気損失からは説明できない
損失分があり、その原因は端子電極間に圧粉体を介して
電流が流れ、圧粉体が発熱するからであることが判っ
た。As described above, the coil-encapsulated dust core in which the coil is embedded in the magnetic powder made of the ferromagnetic metal particles coated with the insulating material is the resistance of the coil conductor and the dust. It has been found that there is a loss that cannot be explained from the magnetic loss of the body, and the cause is that current flows between the terminal electrodes through the green compact, causing the green compact to generate heat.
【００１３】本発明者等は、コイル封入圧粉磁芯の設計
に当たり、今までのインダクタではタブーとされてきた
端子電極間に圧粉体（コア）を介して電流が流れる場合
でも、２つの端子電極間に印加される電圧の最大値Ｖma
x（ボルト）と、その最大電圧が印加された時に前記圧
粉体を経由して端子電極間に流れる微小電流ｉ（アンペ
ア）と、当該コイル封入圧粉磁芯の体積Ｃ（cm３）との
間の関係が、
Ｖmax×ｉ／Ｃ＜０.０２ （Ｗ／cm３）
ならば、圧粉体に流れる電流による温度上昇は無視でき
る程度であり、実用上問題がないことを見いだした。The inventors of the present invention designed the coil-encapsulated powder magnetic core so that even if a current flows through the powder compact (core) between the terminal electrodes, which has been a taboo in the conventional inductors, there are two Maximum value Vma of voltage applied between terminal electrodes
x (volt), a minute current i (ampere) flowing between the terminal electrodes via the green compact when the maximum voltage is applied, and the volume C (cm 3 ) of the coil-enclosed dust core. It has been found that if the relationship between the two is Vmax × i / C <0.02 (W / cm 3 ), the temperature rise due to the current flowing through the green compact is negligible and there is no practical problem.
【００１４】そこで、本発明に係るコイル封入圧粉磁芯
は、重量比率で１〜８％の絶縁材をコーティングした強
磁性金属粒子からなる磁性粉末中に、コイルを埋め込ん
だ構成を持ち、前記磁性粉末の圧粉体に埋め込まれた２
つの端子電極間に印加される電圧の最大値Ｖmax（ボル
ト）と、その最大電圧が印加された時に前記圧粉体を経
由して端子電極間に流れる微小電流ｉ（アンペア）と、
前記コイル及び前記圧粉体の和の体積Ｃ（cm３）との間
の関係が、
Ｖmax×ｉ／Ｃ＜０.０２ （Ｗ／cm３）
を満足するものとしている。Therefore, the coil-embedded dust core according to the present invention has a structure in which a coil is embedded in a magnetic powder composed of ferromagnetic metal particles coated with an insulating material in a weight ratio of 1 to 8%. 2 embedded in a magnetic powder compact
A maximum value Vmax (volt) of a voltage applied between two terminal electrodes, and a minute current i (ampere) flowing between the terminal electrodes via the green compact when the maximum voltage is applied,
The relationship between the total volume C (cm 3 ) of the coil and the green compact is to satisfy Vmax × i / C <0.02 (W / cm 3 ).
【００１５】また、前記コイル封入圧粉磁芯において、
前記圧粉体に樹脂を含浸させた構成とし、圧粉体の端子
電極間の絶縁耐圧を向上させるようにしてもよい。In the above-mentioned coil-encapsulated dust core,
The powder compact may be impregnated with a resin to improve the dielectric strength between the terminal electrodes of the powder compact.
【００１６】[0016]
【発明の実施の形態】以下、本発明に係るコイル封入圧
粉磁芯の実施の形態を図面に従って説明する。BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of a coil-embedded dust core according to the present invention will be described below with reference to the drawings.
【００１７】図１は本発明に係るコイル封入圧粉磁芯の
第１の実施の形態であって、図１（Ａ）はコイル上側の
圧粉磁芯部を省略した平面図、（Ｂ）は正断面図であ
る。図において、１はコイル、２０は圧粉体（圧粉磁芯
部）であり、圧粉体２０はコイル１に継線された電極端
子５の外部導出部分を除き当該コイル１及び電極端子５
の周囲を覆っている。FIG. 1 shows a first embodiment of a coil-embedded dust core according to the present invention. FIG. 1A is a plan view in which the dust core on the upper side of the coil is omitted, and FIG. Is a front sectional view. In the figure, 1 is a coil, 20 is a powder compact (powder magnetic core portion), and the powder compact 20 is the coil 1 and the electrode terminal 5 except for the externally derived portion of the electrode terminal 5 connected to the coil 1.
Covering the perimeter of.
【００１８】前記コイル１は、絶縁被膜された平角導線
２（平角銅線）をエッジワイズ状に数ターン巻線したも
の、すなわち、厚さ方向に積層しかつ幅方向に湾曲状に
曲げて筒状に数ターン巻回したものである。コイル１の
両端部にはそれぞれ電極端子５（合計２個）が電気的に
接続されている。ここで２個の電極端子５は絶縁被覆を
設けないで用いる。なお、コイル１の端部の絶縁被覆を
除去して圧粉体２０の外部に導出して直接電極端子とし
て用いる継線レス構造としても差し支えない。The coil 1 is formed by winding an insulating coated flat conductor wire 2 (flat copper wire) for several turns in an edgewise manner, that is, by stacking in a thickness direction and bending in a width direction into a cylinder. It is wound several times in a shape. Electrode terminals 5 (two in total) are electrically connected to both ends of the coil 1. Here, the two electrode terminals 5 are used without providing an insulating coating. It should be noted that a wireless structure may be used in which the insulating coating on the end of the coil 1 is removed and the coil 1 is led to the outside of the powder compact 20 and used directly as an electrode terminal.
【００１９】前記圧粉体２０に用いる強磁性金属粒子と
しては、Ｆｅ、Ｆｅ−Ｎｉ合金、Ｆｅ−Ｓｉ合金等があ
り、これらから適宜選択すればよい。As the ferromagnetic metal particles used for the green compact 20, there are Fe, Fe-Ni alloys, Fe-Si alloys, etc., which may be appropriately selected.
【００２０】強磁性金属粒子をコーティングする絶縁材
としては、シリコーン（シリコン樹脂）、エポキシ樹脂
等があり、これらの絶縁材を用いて前記強磁性金属粒子
はコーティングされている。前記絶縁材の混合割合は、
当該絶縁材をコーティングした強磁性金属粒子からなる
磁性粉末に対する重量比率で１〜８％とする。なお、コ
ーティングに使用する絶縁材の重量比を８％より多くす
ると、成形して得た圧粉体２０の透磁率が低下し、大き
なインダクタンスを得ることができず、また絶縁材の重
量比を１％未満にすると各強磁性金属粒子相互間の絶縁
が不充分となり、磁芯としての特性が大幅に低下するた
め、コーティングに使用する絶縁材の重量比は１〜８％
が適している。As the insulating material for coating the ferromagnetic metal particles, there are silicone (silicon resin), epoxy resin and the like, and the ferromagnetic metal particles are coated with these insulating materials. The mixing ratio of the insulating material is
The weight ratio to the magnetic powder made of ferromagnetic metal particles coated with the insulating material is 1 to 8%. If the weight ratio of the insulating material used for the coating is more than 8%, the magnetic permeability of the green compact 20 obtained by molding is lowered, a large inductance cannot be obtained, and the weight ratio of the insulating material is reduced. If it is less than 1%, the insulation between the ferromagnetic metal particles will be insufficient and the characteristics as a magnetic core will be significantly reduced. Therefore, the weight ratio of the insulating material used for coating is 1 to 8%.
Is suitable.
【００２１】そして、上記のように重量比率で１〜８％
の絶縁材をコーティングした強磁性金属粒子からなる磁
性粉末中に、前記コイル１及び電極端子５の一部を設け
た状態で粉末成形機にて圧粉体２０を成形一体化する。
圧粉体２０の成形方法としては、例えば、前記磁性粉末
を成形金型内に充填して圧縮成形することで、図１
（Ａ）のように圧粉体２０の下部磁芯部２０ａを成形金
型内に作製しておき、その上にコイル１を載置した後、
コイル１が埋まるように再度磁性粉末を成形金型内に充
填して、下部磁芯部２０ａ及びコイル１が積層された方
向に加圧して圧縮成形（コイルを磁性粉末でインサート
成形）する方法（特開２００１−２６７１６０号公報に
開示された方法）等を採用可能である。And, as described above, the weight ratio is 1 to 8%.
In the magnetic powder made of ferromagnetic metal particles coated with the insulating material, the powder compact 20 is molded and integrated by a powder molding machine with the coil 1 and a part of the electrode terminal 5 provided.
As a method of molding the green compact 20, for example, the magnetic powder is filled in a molding die and compression-molded, as shown in FIG.
As shown in (A), the lower magnetic core portion 20a of the green compact 20 is prepared in a molding die, and the coil 1 is placed on the lower magnetic core portion 20a.
A method in which the magnetic powder is filled in the molding die again so that the coil 1 is filled, and is pressed in the direction in which the lower magnetic core portion 20a and the coil 1 are laminated to perform compression molding (coil insert molding with magnetic powder) ( The method disclosed in JP 2001-267160 A) can be adopted.
【００２２】本実施の形態では、２つの電極端子５には
絶縁被膜は設けておらず、コイル封入圧粉磁芯の設計に
当たり、今までのインダクタではタブーとされてきた端
子電極間にコアを介して電流が流れる場合でも、２つの
端子電極間に印加される電圧の最大値Ｖmax（ボルト）
と、その最大電圧が印加された時に前記圧粉体を経由し
て端子電極間に流れる微小電流ｉ（アンペア）と、当該
コイル封入圧粉磁芯の体積Ｃ（cm３）との間の関係が、
Ｖmax×ｉ／Ｃ＜０.０２ （Ｗ／cm３） …(1)
を満足するように設定する。In the present embodiment, no insulating coating is provided on the two electrode terminals 5, and when designing a coil-encapsulated dust core, a core is placed between the terminal electrodes, which has been a taboo in conventional inductors. Maximum value Vmax (volt) applied between two terminal electrodes even when current flows through
And the relationship between the minute current i (ampere) flowing between the terminal electrodes via the powder compact when the maximum voltage is applied and the volume C (cm 3 ) of the coil-encapsulated dust core. Is set so that Vmax × i / C <0.02 (W / cm 3 ) ... (1) is satisfied.
【００２３】上記(1)式のように設定する理由を以下の
表１及び図２乃至図６を用いて説明する。The reason for setting as in the above equation (1) will be described with reference to Table 1 below and FIGS. 2 to 6.
【００２４】[0024]
【表１】 [Table 1]
【００２５】上記表１は試料（コイル封入圧粉磁芯）の
温度上昇の測定結果を示すものであり、試料Ｎｏ.１〜
Ｎｏ.３は圧粉体、コイルの構成及び外形寸法は互いに
同一であるが、電極端子の構造が互いに異なる。試料Ｎ
ｏ.４〜Ｎｏ.６も圧粉体、コイルの構成及び外形寸法は
互いに同一であるが、電極端子の構造が互いに異なる。
試料Ｎｏ.７〜Ｎｏ.９も圧粉体、コイルの構成及び外形
寸法は互いに同一であるが、電極端子の構造が互いに異
なる。Table 1 above shows the measurement results of the temperature rise of the sample (powder magnetic core packed with coil).
No. 3 has the same structure and outer dimensions of the green compact and the coil, but has different electrode terminal structures. Sample N
o.4 to No. 6 also have the same configuration and outer dimensions of the green compact and the coil, but have different electrode terminal structures.
Samples No. 7 to No. 9 also have the same configuration and outer dimensions of the green compact and the coil, but have different electrode terminal structures.
【００２６】図２（Ａ）は表１中の圧粉体に流れる電流
（表１中ではコアに流れる電流ｉと表示）の測定方法を
示し、電極端子のみを圧粉体に埋め込んだ試料（本来の
試料Ｎｏ.１〜Ｎｏ.９からコイル部分を除去したもの）
を作製し、端子電極間に直流電源により電圧を印加し、
圧粉体に直列に挿入された電流計にて電流値を測定す
る。なお、図２（Ｂ）は前記試料の底面側を示す。FIG. 2A shows a method for measuring the current flowing through the green compact in Table 1 (indicated as the current i flowing through the core in Table 1), in which only the electrode terminals were embedded in the green compact ( Original sample No. 1 to No. 9 with the coil part removed)
And apply a voltage between the terminal electrodes with a DC power supply,
The current value is measured with an ammeter inserted in series in the green compact. Note that FIG. 2B shows the bottom surface side of the sample.
【００２７】図３はコイル封入圧粉磁芯の温度上昇測定
回路であり、入力電圧ＶinをＤＣ−ＤＣコンバータで降
圧し、試料となるインダクタンスＬのコイル封入圧粉磁
芯を平滑用チョークコイルとして用いたＬＣ平滑回路を
通して負荷Ｚに出力電圧Ｖoutを印加し、出力電流Ｉout
を流す構成である。ここで、ＤＣ−ＤＣコンバータのス
イッチング周波数は３００ｋＨｚである。FIG. 3 shows a temperature rise measuring circuit for a coil-embedded dust core, in which an input voltage Vin is stepped down by a DC-DC converter, and a coil-embedded dust core having an inductance L as a sample is used as a smoothing choke coil. The output voltage Vout is applied to the load Z through the used LC smoothing circuit, and the output current Iout is output.
It is a composition that flows. Here, the switching frequency of the DC-DC converter is 300 kHz.
【００２８】図４は試料Ｎｏ.１のときのコイル電流Ｉ
Ｌとコイル電圧（端子電極間電圧）ＶＬの波形図を示
す。この場合、コイル電流ＩＬの平均値が２２Ａ、コイ
ル電圧（端子電極間電圧）ＶＬの最大値Ｖmaxが３.４Ｖ
となっている。FIG. 4 shows the coil current I for sample No. 1.
The waveform diagram of L and coil voltage (voltage between terminal electrodes) VL is shown. In this case, the average value of the coil current I L is 22 A, and the maximum value Vmax of the coil voltage (terminal electrode voltage) V L is 3.4 V.
Has become.
【００２９】図５はコイル封入圧粉磁芯の圧粉体に流れ
る電流を変化させる方法を示し、２つの端子電極間の距
離を接近させて行くことによって、インダクタンスは同
じでも圧粉体に流れる平均電流を変えることができる。
例えば、表１の試料Ｎｏ.１〜Ｎｏ.３は、圧粉体が同一
であっても、試料Ｎｏ.１は図５（Ａ）のように端子電
極間の距離が大きく、試料Ｎｏ.２は図５（Ｂ）のよう
に端子電極間の距離が中位であり、試料Ｎｏ.３は図５
（Ｃ）のように端子電極同士が接近している。FIG. 5 shows a method of changing the current flowing through the powder compact of the coil-encapsulated powder magnetic core, by making the distance between the two terminal electrodes closer to each other, even if the inductance is the same, the current flows through the powder compact. The average current can be changed.
For example, in Samples No. 1 to No. 3 of Table 1, even if the green compacts are the same, the distance between the terminal electrodes is large in Sample No. 1 as shown in FIG. The distance between the terminal electrodes is medium as shown in FIG. 5B, and the sample No. 3 is shown in FIG.
The terminal electrodes are close to each other as shown in (C).
【００３０】図６（Ａ）は本実施の形態の場合で、コイ
ル１の両端部に継線された端子電極５の絶縁が無い構成
（表１の「試料温度上昇」の欄の「端子絶縁無」に対
応）、同図（Ｂ）は比較例であり、端子電極５を絶縁物
６で完全に覆って圧粉体２０に電流が流れないようにし
た場合（表１の「試料温度上昇」の欄の「端子絶縁有」
に対応）である。FIG. 6 (A) shows the case of this embodiment, in which the terminal electrodes 5 connected to both ends of the coil 1 are not insulated (see "Terminal Insulation" in the column "Sample temperature rise" in Table 1). (Corresponding to "no"), FIG. 6B is a comparative example, in which the terminal electrode 5 is completely covered with the insulator 6 so that the current does not flow to the green compact 20 ("Sample temperature rise in Table 1"). "With terminal insulation"
It corresponds to).
【００３１】上記表１で試料Ｎｏ.１〜Ｎｏ.９の温度上
昇の測定結果を見ると、上記式(1)の左辺（Ｖmax×ｉ／
Ｃ）の値を示す表１の係数が０.００９の試料Ｎｏ.１、
前記係数が０.０１８の試料Ｎｏ.４、及び前記係数が
０.００８の試料Ｎｏ.７が「端子絶縁有」、「端子絶縁
無」にかかわらず試料温度上昇が同じであり、いずれも
上記(1)式を満足する。これに反し、上記式(1)の左辺
（Ｖmax×ｉ／Ｃ）の値が０.０２を超える値となる試料
Ｎｏ.２，Ｎｏ.３，Ｎｏ.５，Ｎｏ.６，Ｎｏ.８，Ｎｏ.
９では「端子絶縁有」よりも「端子絶縁無」の温度上昇
が大きく、圧粉体に流れる電流による発熱を無視できな
くなっている。Looking at the measurement results of the temperature rise of samples No. 1 to No. 9 in Table 1, the left side of the above formula (1) (Vmax × i /
Sample No. 1 whose coefficient in Table 1 showing the value of C) is 0.009,
The sample No. 4 having the coefficient of 0.018 and the sample No. 7 having the coefficient of 0.008 have the same sample temperature rise regardless of “with terminal insulation” and “without terminal insulation”. (1) is satisfied. On the contrary, the sample No. 2, No. 3, No. 5, No. 6, No. 8, in which the value of the left side (Vmax × i / C) of the above formula (1) exceeds 0.02, No.
In No. 9, the temperature rise of "without terminal insulation" is larger than that of "with terminal insulation", and the heat generation due to the current flowing through the green compact cannot be ignored.
【００３２】従って、この表１より上記(1)を満足する
コイル封入圧粉磁芯であれば、圧粉体を経由して端子電
極間を流れる電流に起因する発熱を防止可能であると言
える。この場合、端部電極の表面絶縁処理が不要であ
り、コスト低減を図ることができる。Therefore, from Table 1, it can be said that the coil-encapsulated dust core satisfying the above (1) can prevent heat generation due to the current flowing between the terminal electrodes via the dust compact. . In this case, the surface insulation treatment of the end electrodes is unnecessary, and the cost can be reduced.
【００３３】本発明に係るコイル封入圧粉磁芯の第２の
実施の形態の構成も図１（Ａ）,（Ｂ）に示す通りであ
るが、絶縁材をコーティングした強磁性金属粒子からな
る磁性粉末を圧縮成形して圧粉体（圧粉磁芯部）２０を
作製した後、さらに、粘度の低い樹脂を圧粉体に含浸さ
せた点が第１の実施の形態と異なる。使用する樹脂は、
例えばエポキシ系２液型樹脂である。圧粉体への含浸を
確実に行うため、真空含浸とし、１２０℃、２時間の乾
燥硬化後、図２と同じ測定回路で、圧粉体に流れる電流
（表２中、コア電流ｉと表示）と、端子間耐電圧を測定
し、その結果を以下の表２に示す。The structure of the second embodiment of the coil-encapsulated dust core according to the present invention is also as shown in FIGS. 1 (A) and 1 (B), but is composed of ferromagnetic metal particles coated with an insulating material. This is different from the first embodiment in that a magnetic powder is compression-molded to produce a green compact (powder magnetic core portion) 20, and then a resin having a low viscosity is impregnated into the green compact. The resin used is
For example, it is an epoxy two-component resin. In order to ensure the impregnation of the green compact, vacuum impregnation was performed, and after drying and hardening at 120 ° C. for 2 hours, the current flowing through the green compact in the same measurement circuit as in FIG. 2 (indicated as core current i in Table 2). ) And the withstand voltage between terminals were measured, and the results are shown in Table 2 below.
【００３４】[0034]
【表２】 [Table 2]
【００３５】上記表２に示すように、コア電流は著しく
減少し、電流計では測定出来ないほど小さかった。ま
た、耐電圧は著しく向上し、カットオフカレントを０.
５ｍＡとしたときに、耐電圧は全てＤＣｌ００Ｖ以上の
値を示した。As shown in Table 2 above, the core current was remarkably reduced and was too small to be measured by an ammeter. In addition, the withstand voltage is remarkably improved and the cutoff current is reduced to 0.
When it was set to 5 mA, all the withstand voltages showed a value of DCl00V or more.
【００３６】この第２の実施の形態に係る樹脂含浸した
コイル封入圧粉磁芯の試料Ｎｏ.１〜Ｎｏ.９（第１の実
施の形態の試料の圧粉体にエポキシ樹脂を含浸したも
の）を作製し、図３の回路で各試料の温度上昇を調べた
結果を以下の表３に示す。Sample No. 1 to No. 9 of the resin-impregnated coil-encapsulated dust core according to the second embodiment (the compact of the sample of the first embodiment impregnated with epoxy resin) ) Was prepared and the temperature rise of each sample was examined by the circuit of FIG. 3 is shown in Table 3 below.
【００３７】[0037]
【表３】 [Table 3]
【００３８】表３中、試料Ｎｏ.１〜Ｎｏ.９の全てにお
いて温度上昇は、「端子絶縁無」であっても「端子絶縁
有」と同じ値を示し、圧粉体にはほとんど電流が流れて
いないことが確認された（表３中、コア平均電流が
０）。ちなみに、上記式(1)の左辺（Ｖmax×ｉ／Ｃ）の
値を示す表３の係数は試料Ｎｏ.１〜Ｎｏ.９の全てが０
となった。In Table 3, in all the samples No. 1 to No. 9, the temperature rise shows the same value as "with terminal insulation" even if "without terminal insulation", and almost no current flows through the green compact. It was confirmed that no current was flowing (in Table 3, the core average current was 0). By the way, the coefficient of Table 3 showing the value of the left side (Vmax × i / C) of the above formula (1) is 0 for all samples No. 1 to No. 9.
Became.
【００３９】この第２の実施の形態のように、圧粉体に
樹脂を含浸することで端子電極の絶縁処理が無くとも圧
粉体に流れる電流を無視できる程度に低減可能であり、
ひいては圧粉体発熱に起因する損失を回避でき、効率低
下を防止可能である。As in the second embodiment, by impregnating the green compact with resin, the current flowing through the green compact can be reduced to a negligible level without insulation treatment of the terminal electrodes.
As a result, it is possible to avoid the loss due to the heat generation of the powder compact, and it is possible to prevent the efficiency from decreasing.
【００４０】なお、各実施の形態の構造を示す図１では
平角導線を巻回してコイルを作製しているが、使用する
導線が平角導線に限定されないことは明らかである。In FIG. 1 showing the structure of each embodiment, the rectangular conductor wire is wound to form the coil, but it is clear that the conductor wire used is not limited to the rectangular conductor wire.
【００４１】以上本発明の実施の形態について説明して
きたが、本発明はこれに限定されることなく請求項の記
載の範囲内において各種の変形、変更が可能なことは当
業者には自明であろう。Although the embodiment of the present invention has been described above, it is obvious to those skilled in the art that the present invention is not limited to this and various modifications and changes can be made within the scope of the claims. Ah
【００４２】[0042]
【発明の効果】以上説明したように、本発明によれば、
重量比率で１〜８％の絶縁材をコーティングした強磁性
金属粒子からなる磁性粉末中に、コイルを埋め込んだコ
イル封入圧粉磁芯において、前記磁性粉末の圧粉体に埋
め込まれた２つの端子電極間に印加される電圧の最大値
Ｖmax（ボルト）と、その最大電圧が印加された時に前
記圧粉体を経由して端子電極間に流れる微小電流ｉ（ア
ンペア）と、当該コイル封入圧粉磁芯の体積Ｃ（cm３）
との間の関係が、
Ｖmax×ｉ／Ｃ＜０.０２ （Ｗ／cm３）
を満足するように設定したので、圧粉体に流れる電流に
起因する発熱を無視できる程度に低減し、損失低減を図
ることができる。また、コイル封入圧粉磁芯を電源装置
に使用した場合には電源効率の低下を防止できる。As described above, according to the present invention,
In a coil-embedded dust core in which a coil is embedded in a magnetic powder composed of ferromagnetic metal particles coated with an insulating material in a weight ratio of 1 to 8%, two terminals embedded in the powder compact of the magnetic powder. The maximum value Vmax (volt) of the voltage applied between the electrodes, the minute current i (ampere) flowing between the terminal electrodes via the powder compact when the maximum voltage is applied, and the coil-encapsulated powder compact Magnetic core volume C (cm 3 )
Is set so as to satisfy Vmax × i / C <0.02 (W / cm 3 ), heat generation due to the current flowing through the green compact can be reduced to a negligible level, and loss It can be reduced. Further, when the coil-encapsulated dust core is used in the power supply device, it is possible to prevent a decrease in power supply efficiency.
【図１】本発明に係るコイル封入圧粉磁芯の第１の実施
の形態であって、（Ａ）はコイル上側の圧粉磁芯部を省
略した平面図、（Ｂ）は正断面図である。FIG. 1 is a first embodiment of a coil-embedded powder magnetic core according to the present invention, in which (A) is a plan view in which the powder magnetic core portion on the upper side of the coil is omitted, and (B) is a front sectional view. Is.
【図２】コイル封入圧粉磁芯の圧粉体（圧粉磁芯部）に
流れる電流の測定方法であって、（Ａ）は回路図、
（Ｂ）は試料の電極端子配置を示す底面図である。FIG. 2 is a method for measuring an electric current flowing through a powder compact (powder magnetic core portion) of a coil-encapsulated powder magnetic core, in which (A) is a circuit diagram;
(B) is a bottom view showing the arrangement of the electrode terminals of the sample.
【図３】コイル封入圧粉磁芯の試料の温度上昇を測定す
る測定回路図である。FIG. 3 is a measurement circuit diagram for measuring a temperature increase of a sample of a coil-embedded dust core.
【図４】図３の測定回路におけるコイル電流及び電極端
子間電圧を示す波形図である。4 is a waveform diagram showing a coil current and a voltage between electrode terminals in the measurement circuit of FIG.
【図５】コイル封入圧粉磁芯の圧粉体に流れる電流を変
化させる方法を示し、（Ａ）は電極端子間距離が大きい
場合の底面図、（Ｂ）は電極端子間距離が中位の場合の
底面図、（Ｃ）は電極端子同士が接近している場合の底
面図である。FIG. 5 shows a method of changing the current flowing through the powder compact of the coil-encapsulated dust core, (A) is a bottom view when the distance between the electrode terminals is large, and (B) is a medium distance between the electrode terminals. And (C) is a bottom view when the electrode terminals are close to each other.
【図６】（Ａ）は本実施の形態の場合で、端子電極の絶
縁が無い構成（表１の「試料温度上昇」の欄の「端子絶
縁無」に対応）の断面図、（Ｂ）は比較例であり、端子
電極を絶縁物で完全に覆って圧粉体に電流が流れないよ
うにした場合（表１の「試料温度上昇」の欄の「端子絶
縁有無」に対応）の断面図である。FIG. 6A is a cross-sectional view of a configuration without terminal electrode insulation in the case of the present embodiment (corresponding to “without terminal insulation” in the column “Sample temperature rise” in Table 1); Is a comparative example, and is a cross section when the terminal electrode is completely covered with an insulator so that no current flows in the green compact (corresponding to "presence / absence of terminal insulation" in the "sample temperature rise" column of Table 1). It is a figure.
１ コイル ２ 平角導線 ５ 電極端子 ２０ 圧粉体 ２０ａ 下部磁芯部 1 coil 2 flat wire 5 electrode terminals 20 green compact 20a lower magnetic core
Claims (2)
ングした強磁性金属粒子からなる磁性粉末中に、コイル
を埋め込んだコイル封入圧粉磁芯において、前記磁性粉
末の圧粉体に埋め込まれた２つの端子電極間に印加され
る電圧の最大値Ｖmax（ボルト）と、その最大電圧が印
加された時に前記圧粉体を経由して端子電極間に流れる
微小電流ｉ（アンペア）と、当該コイル封入圧粉磁芯の
体積Ｃ（cm３）との間の関係が、 Ｖmax×ｉ／Ｃ＜０.０２ （Ｗ／cm３） を満足することを特徴とするコイル封入圧粉磁芯。1. A coil-embedded dust core in which a coil is embedded in a magnetic powder composed of ferromagnetic metal particles coated with an insulating material in a weight ratio of 1 to 8% and embedded in the powder compact of the magnetic powder. The maximum value Vmax (volt) of the voltage applied between the two terminal electrodes, and a minute current i (ampere) flowing between the terminal electrodes via the green compact when the maximum voltage is applied, The coil-encapsulated dust core has a relationship with the volume C (cm 3 ) of the coil-encapsulated dust core that satisfies Vmax × i / C <0.02 (W / cm 3 ). .
項１記載のコイル封入圧粉磁芯。2. The coil-embedded dust core according to claim 1, wherein the compact is impregnated with a resin.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2002086075A JP2003282342A (en) | 2002-03-26 | 2002-03-26 | Coil sealed dust core |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2002086075A JP2003282342A (en) | 2002-03-26 | 2002-03-26 | Coil sealed dust core |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JP2003282342A true JP2003282342A (en) | 2003-10-03 |
Family
ID=29232804
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2002086075A Withdrawn JP2003282342A (en) | 2002-03-26 | 2002-03-26 | Coil sealed dust core |
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| Country | Link |
|---|---|
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Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2007081120A (en) * | 2005-09-14 | 2007-03-29 | Nec Tokin Corp | Inductor |
| JP2015164173A (en) * | 2014-01-29 | 2015-09-10 | アルプス・グリーンデバイス株式会社 | Electronic component and electronic device |
| JP2015204337A (en) * | 2014-04-11 | 2015-11-16 | アルプス・グリーンデバイス株式会社 | Electronic component, method of manufacturing electronic component and electronic apparatus |
| JP2016076559A (en) * | 2014-10-03 | 2016-05-12 | アルプス・グリーンデバイス株式会社 | Inductance element and electronic apparatus |
| CN111986881A (en) * | 2019-05-23 | 2020-11-24 | 株式会社村田制作所 | Coil component and method for manufacturing same |
-
2002
- 2002-03-26 JP JP2002086075A patent/JP2003282342A/en not_active Withdrawn
Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2007081120A (en) * | 2005-09-14 | 2007-03-29 | Nec Tokin Corp | Inductor |
| JP2015164173A (en) * | 2014-01-29 | 2015-09-10 | アルプス・グリーンデバイス株式会社 | Electronic component and electronic device |
| JP2018022916A (en) * | 2014-01-29 | 2018-02-08 | アルプス電気株式会社 | Electronic component and electronic device |
| JP2018022917A (en) * | 2014-01-29 | 2018-02-08 | アルプス電気株式会社 | Inductance element and electronic device |
| JP2018022918A (en) * | 2014-01-29 | 2018-02-08 | アルプス電気株式会社 | Electronic component and electronic device |
| JP2015204337A (en) * | 2014-04-11 | 2015-11-16 | アルプス・グリーンデバイス株式会社 | Electronic component, method of manufacturing electronic component and electronic apparatus |
| JP2016076559A (en) * | 2014-10-03 | 2016-05-12 | アルプス・グリーンデバイス株式会社 | Inductance element and electronic apparatus |
| CN111986881A (en) * | 2019-05-23 | 2020-11-24 | 株式会社村田制作所 | Coil component and method for manufacturing same |
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