The present invention relates to a suitable multilayer inductor used as an inductor for a DC-DC converter particularly requiring a high bias, or the like.
Recently, with a request for reduction in a size and reduction in a thickness of a power circuit component, a chip inductor having a laminate structure is developed and put into use as a transformer or a choke coil used in a power supply circuit such as a DC-DC converter.
In such a multilayer inductor, electrically insulating magnetic layers and conductive body patterns are alternately laminated, and the above conductive body patterns are connected in the lamination direction in sequence, so that a coil that spirally circulates while being superimposed in the lamination direction is formed in a magnetic body, and each of the both ends of the coil is drawn out on the outer surface of a laminated body chip through a draw-out conductor. Herein, a ferrite is used as the magnetic body, the magnetic layers and the conductive body patterns are formed to be laminated by using, for example, a screen printing method.
On the other hand, in a mobile market where the reduction in a size is recently requested, a current value which flows in an inductor increases in accordance with rise in the switching frequency of a power supply to be used, and improvement in processing performance of the power supply. In the above ferrite, a loss at a high frequency (several MHz to several dozens MHz) is generally less, and therefore a laminated chip inductor using a ferrite material is optimized for a mobile power supply that operates at a high switching frequency. Additionally, in the mobile market, since the chip shape is excellent in mounting performance or mass productivity, a large number of laminated chip inductors have been employed.
However, the above ferrite generally tends to be low in magnetic flux saturation density, and to be bad in DC superposition characteristics, and therefore it is becoming difficult to follow the electric current increase in the recent mobile market.
In order to solve this, a measure for improving the DC superposition characteristics in the above multilayer inductor by increasing the size of the above coil, and reducing the density of a magnetic flux that flows in the coil, or using a metal material unlikely to be saturated as a magnetic material itself is considered. However, when the above coil size is increased, increase in the whole of the multilayer inductor is caused, which is against the market request. Additionally, a chip inductor, in which the chip shape having excellent mounting performance is maintained, and in which a metal material unlikely to cause magnetic saturation is used as a magnetic body, appears in the market. However, the chip inductor has disadvantage that the metal material generally has a large loss at a high frequency compared to the ferrite, and that conversion efficiency is reduced in a conversion usage.
The magnetic body used for the above multilayer inductor is saturated by a magnetic flux excited from a current flowing in the coil in the operation of a power supply. Accordingly, when the saturation of the above magnetic body can be suppressed, it becomes possible to improve the DC superposition characteristics.
Therefore, in the following Patent Literatures 1 and 2, as illustrated in
However, as illustrated in this figure, in a case where the permanent magnet 22 is disposed inside the coil 21, a leakage magnetic flux Z which does not act as a bias magnetic flux is emitted around the permanent magnet 22 inside the magnetic body 20, in addition to the magnetic flux Y whose direction is opposite to the direction of the magnetic flux X emitted from the permanent magnet 22 and excited by the coil 21. Therefore, there is a problem that the bias magnetic flux Y from the permanent magnet 22 does not effectively work, and the DC superposition characteristics can hardly be improved as expected.
[Patent Literature 1]
Japanese Patent Laid-Open No. 2002-170715
[Patent Literature 2]
Japanese Patent Laid-Open No. 3-101106
The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a multilayer inductor which can significantly improve DC superposition characteristics by a permanent magnet which generates a bias magnetic flux, and which can use a low-loss material as a magnetic material to also achieve the improvement of converter conversion efficiency.
In order to solve the problem, a multilayer inductor according to the invention recited in claim 1 includes: a plurality of electrically insulating magnetic layers that are laminated; and conductive patterns that are laminated, each of the conductive patterns being connected in sequence in the lamination direction to form a spirally circulating coil inside the magnetic layers, both ends of the coil being drawn out to an outer peripheral part, wherein an annular permanent magnet layer magnetized so as to emit a magnetic flux whose direction is opposite to a direction of a magnetic flux excited by the coil is disposed between an outer peripheral edge of the multilayer inductor and an outer peripheral edge of the coil so as not to overlap an inner peripheral part of the annular permanent magnet layer with the conductive patterns and so as to block a space between the conductive patterns and the annular permanent magnet layer, in axial view of the coil.
A multilayer inductor according to the invention recited in claim 2 has: a plurality of electrically insulating magnetic layers that are laminated; and conductive patterns that are laminated, each of the conductive patterns being connected in sequence in the lamination direction to form a spirally circulating coil inside the magnetic layers, both ends of the coil being drawn out to an outer peripheral part, wherein an annular permanent magnet layer magnetized so as to emit a magnetic flux whose direction is opposite to a direction of a magnetic flux excited by the coil is disposed over a whole surface of inside of the coil so as not to overlap an outer peripheral part of the annular permanent magnet layer with the conductive patterns and so as to block a space between the conductive patterns and the annular permanent magnet layer, in axial view of the coil.
According to the invention recited in claim 3, in the invention recited in claim 1 or 2, in the axial view, a clearance is formed between the permanent magnet layer and the conductive pattern, and the clearance is blocked by an annular electrically insulating nonmagnetic pattern interposed between the permanent magnet layer and the conductive pattern.
Furthermore, according to the invention recited in claim 4, in the invention recited in any of claims 1 to 3, the magnetic layer and the permanent magnet layer, or the magnetic layer, the permanent magnet layer, and the nonmagnetic pattern each are formed of a material which is capable of being collectively burned at a temperature of 940° C. or less.
According to the invention recited in claim 4, in the invention recited in claim 5, a Ni—Zn ferrite based material is used as the magnetic layer, a Zn ferrite based material is used as the nonmagnetic pattern, and a low-temperature sintered magnet material obtained by adding Bi2O3 and SiO2 to Ba ferrite powder or Sr ferrite powder is used as the permanent magnet layer.
In the invention recited in any of claims 1 to 5, the permanent magnet layer is disposed over the whole surface of the outside of the coil or the whole surface of the inside of the coil in axial view, and therefore a leakage magnetic flux Z which does not works as a bias magnetic flux Y and has an opposite direction, like a permanent magnet illustrated in
Furthermore, like the invention recited in claim 4, manufacture can be facilitated by using the material which is capable of being collectively baked at a temperature of 940° C. or less as the magnetic layer, the permanent magnet layer and the nonmagnetic pattern, sintering a laminated body at a low temperature of 940° C. or less to be integrated, and thereafter magnetizing the permanent magnet layer.
More specifically, like the invention recited in claim 5, it is suitable that the Ni—Zn ferrite based material is used as the magnetic layer, the Zn ferrite based material is used as the nonmagnetic pattern, the low-temperature sintered magnet material obtained by adding Bi2O3 and SiO2 to the Ba ferrite powder or the Sr ferrite powder is used as the permanent magnet layer.
As illustrated in
Herein, between the conductive patterns 2 adjacent in the lamination direction, an electrically insulating nonmagnetic pattern 4 having a shape corresponding to the shape of each of the conductive patterns 2 are disposed. Furthermore, at an intermediate position in the lamination direction, an electrically insulating nonmagnetic layer 5 that becomes a magnetic gap is disposed over a whole surface by one layer in place of the nonmagnetic pattern 4.
In the multilayer inductor according to this embodiment and multilayer inductors according to first to third modifications, in the axial view of each coil 2, each of magnetized permanent magnet layers 6 is disposed over the whole surface between the outer peripheral edge of this multilayer inductor (namely outer peripheral edge of each magnetic layer 1) and the outer peripheral edge of the coil 2 so as to emit a magnetic flux whose direction is opposite to the direction of a magnetic flux excited by the above coil 2.
That is, in the multilayer inductor of this embodiment, as illustrated in
In order to manufacture the multilayer inductor 1 having the above configuration, as illustrated in
Then, low-temperature sintered magnet material paste obtained by adding Bi2O3 and SiO2 to Ba ferrite powder or Sr ferrite powder is printed on this magnetic layers 1, so that a permanent magnet layers 6 is formed, and a magnetic layer 1 is printed at a part except this permanent magnet layer 6.
Then, a conductive pattern 2 is printed on a layer formed with this permanent magnet layers 6. Similarly, after a magnetic layer 1 is printed at a part except the conductive pattern 2, an electrically insulating Zn ferrite material is printed on the conductive pattern 2 so as to have a shape corresponding to the shape of the conductive pattern 2, so that a nonmagnetic pattern 4 is formed, and a magnetic layer 2 is formed at a part except the nonmagnetic pattern 4.
Thus, as illustrated in
Next, the obtained laminated body is collectively burned at a temperature of 940° C. or less, more specifically, at about 900° C. to be integrated, and thereafter the permanent magnet layers 6 are magnetized so as to emit a magnetic flux whose direction is opposite to the direction of the magnetic flux excited by the coil 2, so that it is possible to manufacture the multilayer inductor illustrated in
Additionally,
Furthermore,
In this multilayer inductor, a permanent magnet layer 6 is disposed over two layers of the whole surfaces of the outer peripheral edge of the multilayer inductor (namely, outer peripheral edge of each magnetic layer 1) and the outer peripheral edge of the coil 2. Herein, the permanent magnet layer 6 is disposed at a layer formed with the nonmagnetic pattern 4, and at a layer formed with the conductive pattern 2 located under, and adjacent to, the nonmagnetic pattern 4.
Then, the permanent magnet layer 6 is formed such that the inner peripheral edge of the permanent magnet layer 6 is in contact with the outer peripheral edge of the nonmagnetic pattern 4 at the layer formed with the nonmagnetic pattern 4, and the inner peripheral edge of the permanent magnet layer 6 is in contact with the outer peripheral edge of the conductive pattern 2 at the layer formed with the conductive pattern 2.
In each of these multilayer inductors, in axial view of a coil 2, a permanent magnet layer 6 magnetized so as to emit a magnetic flux whose direction is opposite to the direction of a magnetic flux excited by the coil 2 is disposed over the whole surface of the inside of the coil 2.
That is, in the multilayer inductor of the second embodiment, as illustrated in
Next,
Additionally, in the multilayer inductor according to the third modification illustrated in
According to the multilayer inductors shown and described in the first and second embodiments and the modifications of these, the permanent magnet layer 6 is disposed so as to block the outside of the coil 2 or the inside of the coil 2, in axial view, and therefore a leakage magnetic flux Z which does not work as a bias magnetic flux Y and has an opposite direction, like a permanent magnet illustrated in
Furthermore, a Ni—Zn ferrite based material is used as the magnetic layers 1, a Zn ferrite based material is used as each of the nonmagnetic patterns 4 and 7, and a low-temperature sintered magnet material obtained by adding Bi2O3 and SiO2 to Ba ferrite powder or Sr ferrite powder is used as the permanent magnet layer 6, and therefore collective burning is performed at a temperature of about 900° C. at the timing of manufacturing, and thereafter the permanent magnet layer 6 is magnetized, so that it is possible to easily manufacture the multilayer inductor.
In order to verify the effects of the multilayer inductors according to the present invention, the DC superposition characteristics of the multilayer inductors of the present invention, and the DC superposition characteristics of multilayer inductors of comparative examples were obtained to be compared by simulation.
In both the multilayer inductors of the present invention and the multilayer inductors of the comparative examples, chip size was 2.5×2.0×1.0 mm, the number of turns of the internal conductor was 5 turns, a film thickness of the internal conductor was 120 μm, and the thickness of an insulating layer between the internal conductors was 15 μm.
First,
Additionally, also in a case where a clearance is formed between the permanent magnet layer and the internal conductor, the multilayer inductor (2) which blocks the clearance by the nonmagnetic pattern can obtain DC superposition characteristics equivalent to the DC superposition characteristics of the above multilayer inductor (1).
It is possible to provide a multilayer inductor, in which it is possible to significantly improve DC superposition characteristics by a permanent magnet which emits a bias magnetic flux, and in which it is possible to use a low-loss material as a magnetic body so as to also achieve the improvement of converter conversion efficiency.
1 Magnetic layer
2 Conductive pattern (coil)
3 External electrode
4, 5, 7, 8 Nonmagnetic pattern
6 Permanent magnet layer
Number | Date | Country | Kind |
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2013-128372 | Jun 2013 | JP | national |
Filing Document | Filing Date | Country | Kind |
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PCT/JP2014/002577 | 5/16/2014 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
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WO2014/203447 | 12/24/2014 | WO | A |
Number | Date | Country |
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2-81410 | Mar 1990 | JP |
3-101106 | Apr 1991 | JP |
2002-170715 | Jun 2002 | JP |
2002-175917 | Jun 2002 | JP |
2002-175927 | Jun 2002 | JP |
2006-196591 | Jul 2006 | JP |
Entry |
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International Search Report issued Aug. 26, 2014 in corresponding International Application No. PCT/JP2014/002577 (with English translation). |
Number | Date | Country | |
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20160141089 A1 | May 2016 | US |