JP2010080594A - Laminated common mode choke coil, and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a laminated common mode choke coil capable of securing a large area for forming a conductor pattern, improving inductance to a large value and reducing stray capacitance, and a manufacturing method thereof. Means First, an intermediate layer is formed by a printing lamination step (a), and then an upper layer and a lower layer are formed by a sheet forming step (b) to produce a predetermined sectional structure (c). The conductor pattern 4 is formed in a predetermined spiral shape in the corresponding layer, and via holes 6 are provided at predetermined positions in the film layer of the nonmagnetic material 5 to connect the conductor pattern 4 to form coils A and B. It is placed in an embedded state in the film layer of the non-magnetic material 5 so as to have an electrically complementary operation. In the lamination, the central portion of each layer is formed from the magnetic body 7 to form the core 1, and the upper and lower layers are formed from the magnetic body 7 to form the outer core 2. The core 3 is configured as an open magnetic path in which both ends of the columnar core 1 are sandwiched between plate-like outer cores 2.
[Selection] Figure 2

Description

  The present invention relates to a laminated common mode choke coil and a method for manufacturing the same, and more specifically, a laminated structure in which a core made of a magnetic material and a coil having a conductor pattern are incorporated, and a conductor embedded in a nonmagnetic film layer. The present invention relates to an improvement in the arrangement of a magnetic part relative to a pattern.

  As is well known, a differential transmission system is widely used for data transmission in digital electronic devices such as personal computers. This differential transmission method is a method of transmitting two types of signals having opposite phases to a pair of transmission lines at a time, and has an advantage of being resistant to external noise and generating less noise and suitable for high-speed data transmission. It is used for many high-speed digital communications such as IEEEl394, LVDS. However, in the differential transmission method, there is a problem that a common mode component (common mode) is generated due to a slight difference in transmission characteristics between a pair of transmission lines, resulting in a noise current. A mode choke coil is used.

  The common mode choke coil consists of two coils with the same number of turns. For the normal differential signal (differential mode), the magnetic flux generated in the two coils cancels each other and passes the signal as it is. On the other hand, the magnetic fluxes generated in the two coils are strengthened to generate a large impedance, and therefore, the operation of removing common mode noise is performed.

As the common mode choke coil, there is a winding type in which a wire is wound around a core. However, as seen in Patent Document 1, for example, there is a laminated type in which a coil is built in a laminated body. It is preferred because it can be downsized. As shown in FIG. 1, in the laminated type, the conductor pattern 4 to be the coils A and B is formed in the region of the nonmagnetic material 5, and the central portion, the outer portion, the upper layer, and the lower layer of the two coils A and B are formed of the magnetic material. 7, which are a core core 1 and an outer core 2.
JP 2007-200903 A

  However, the conventional laminated common mode choke coil has the following problems. That is, in the conventional type, the core made of a magnetic material has a closed magnetic circuit configuration as shown in FIG. 1, so that the region of the inner non-magnetic material 5 is narrow and the conductor pattern 4 is patterned into a spiral shape. There is a problem that the area to do is narrow. This makes it impossible to obtain a large number of turns of the coil, and a large inductance cannot be obtained, so that transmission characteristics related to noise removal deteriorate. In addition, since the conductor pattern 4 is routed around the narrow non-magnetic material 5 region, there are many overlapping portions in the upper and lower layers, which increases the stray capacitance component, which also causes a problem of deteriorating transmission characteristics.

  SUMMARY OF THE INVENTION The present invention solves the above-described problems, and its object is to provide a laminated common that can secure a large area for patterning a conductor pattern, can increase inductance, and can reduce stray capacitance. It is to provide a mode choke coil and a manufacturing method thereof.

  In order to achieve the above-described object, a laminated common mode choke coil according to the present invention (1) circulates between a core and a core made of a magnetic material and sandwiching both ends of a columnar core by a plate-shaped outer core. A coil having a conductor pattern, and the coils are arranged so as to be electrically complementary to each other and embedded in a non-magnetic film layer, and the conductor pattern has a spiral shape in a predetermined layer. The coil is formed by providing a via hole at a predetermined position of the non-magnetic film layer and connecting the conductor pattern, and the central portion of each layer is formed from a magnetic material in the lamination to form a core core, and further, The outer film layer is made of a magnetic material to form an outer core.

  (2) The core core may be configured to provide a gap having a predetermined length for the magnetic circuit by replacing a part of the columnar shape with a non-magnetic material. (3) The gap portion may be a nonmagnetic sheet film layer, or (4) a nonmagnetic paste film layer printed on the magnetic sheet.

  (5) Further, it has a coil having a conductor pattern and a core having a pair of plate-shaped outer cores arranged at a predetermined distance on both sides in the axial direction of the coil, and the two coils are electrically connected. A laminated common mode choke coil which is arranged in a complementary manner so as to be embedded in a non-magnetic film layer, and the conductor pattern forms a spiral shape in the corresponding layer, and the non-magnetic film The coil is formed by providing a via hole at a predetermined position of the layer and connecting the conductor pattern, and no magnetic material is disposed on the outer peripheral side of the coil, and the core constitutes an open magnetic circuit. Also good. In the present invention, there is no magnetic body in the core core portion in each of the above-described inventions, and the configuration is like an air core coil.

  (6) In each of the above inventions, the non-magnetic material can be made of Zn ferrite or a low dielectric constant material such as alumina or silica. (7) Furthermore, the number of turns in each layer of the pattern constituting the coil may be varied. Of course, the number of turns in each layer may be set to be substantially equal.

  (8) In the method for manufacturing a laminated common mode choke coil according to the present invention, the conductor pattern is formed in a predetermined spiral shape in the corresponding layer, and a via hole is provided at a predetermined position of the nonmagnetic film layer to connect the conductor pattern. The coil is formed by the above method, and the central portion of each layer in the lamination is a predetermined opening portion. The conductor pattern, the via hole, and the non-magnetic portion are formed by a printing lamination method, and the magnetic material is formed in the opening portion after the lamination. A core core is formed by filling, and then a step of pressing the magnetic sheet on the upper and lower outer sides of the laminate by a sheet forming method to form the outer core to a predetermined thickness can be performed.

  (9) The conductor pattern is formed in a predetermined shape in the corresponding layer, and a coil is formed by connecting the conductor pattern by providing a via hole at a predetermined position of the non-magnetic film layer. Concerning the configuration of a predetermined non-magnetic region, the conductor pattern, the via hole, and the non-magnetic region are formed by a printing lamination method, and after the lamination, a predetermined opening portion is formed by punching in the non-magnetic region. The core portion is formed by filling the opening with a magnetic material, and the outer core is formed into a predetermined thickness by pressing the magnetic material sheet on the upper and lower sides of the laminate by a sheet forming method. Good.

  On the premise of the invention described in the above (8) or (9), (10) a magnetic substance filling the opening part is a magnetic paste, and the magnetic substance paste is embedded and filled in the opening part by screen printing. (11) The magnetic material filled in the opening portion may be a magnetic paste, and a step of filling and filling the magnetic paste in the opening portion with a metal mask may be performed.

  Further, in the sheet forming method according to each of the inventions described in (8) to (11) above, (12) either the upper or lower first sheet and / or a plurality of subsequent sheets are provided with a non-magnetic material sheet. A step of providing a gap having a predetermined length with respect to the core, or (13) forming a non-magnetic film layer in a predetermined thickness on the inner surface of at least one of the upper and lower first magnetic sheets. A step of providing a gap having a predetermined length with respect to the core may be performed.

  (14) Further, in the method for manufacturing a laminated common mode choke coil according to the present invention, the conductor pattern is formed in a predetermined spiral shape in the corresponding layer, and a via hole is provided at a predetermined position of the nonmagnetic film layer to connect the conductor pattern. In the stack, the central portion of each layer is formed from a magnetic body to form a core core, and the upper and lower film layers of the stack are formed from a magnetic body to form an outer core. The via hole, the non-magnetic part, and the magnetic part to be the core core are formed by a printing lamination method, and then a magnetic sheet is pressed on the upper and lower sides of the lamination by a sheet molding method so that the outer core has a predetermined thickness. Forming a gap of a predetermined length with respect to the core by disposing a non-magnetic sheet on the first sheet and / or a plurality of subsequent sheets. It may be so.

  (15) Further, the conductor pattern is formed in a predetermined shape in the corresponding layer, a coil is formed by connecting the conductor pattern by providing a via hole at a predetermined position of the non-magnetic film layer, and the center of each layer in the lamination For the structure in which the core part is formed from a magnetic material, and the upper and lower outer film layers are formed from a magnetic material to form the outer core, the conductor pattern, via hole, nonmagnetic material part, and the magnetic core The body part is formed by the printing lamination method, and then the outer core is formed to a predetermined thickness by pressing the magnetic material sheet on the upper and lower outer sides of the lamination by the sheet molding method. For the magnetic sheet of the eye, a step of forming a non-magnetic film layer with a predetermined thickness on the inner layer side surface in advance and providing a gap with a predetermined length with respect to the core core may be performed.

  In the invention described in (1), the core has a form in which both ends of the columnar core are sandwiched between plate-shaped outer cores, and is configured as an open magnetic path unlike the conventional closed magnetic path configuration. The area becomes wider. Therefore, a large area for patterning the conductor pattern can be secured, and the number of turns of the conductor pattern can be increased in each layer. And since the area | region of the outer periphery of a core core becomes large, the overlap of the conductor pattern in an upper and lower layer can be shifted to a shift position suitably. As described above, the structure in which the overlapping of the conductor patterns is shifted, the number of turns of each layer is made different as in the invention described in (7), so that the portions where the conductor patterns arranged in the layers adjacent to each other do not face each other can be simplified. It is possible to increase the distance between the conductive patterns that are vertically opposed to each other, and to reduce the stray capacitance. The characteristics of these open magnetic paths are the same in any of the inventions according to (2) and the invention according to any of the independent claims of the invention according to (5) in which the magnetic core is not present in the core portion. It is.

  In the invention of (2), since the core core replaces a part of the magnetic material with a non-magnetic material to provide a gap, the frequency characteristics of the core can be improved. Therefore, impedance characteristics can be improved by appropriately adjusting the core gap. As a result, the common mode impedance can be increased.

  The core gap can be formed when an intermediate layer is first formed by a printing lamination process, and an upper layer and a lower layer are formed by a sheet molding method on the intermediate layer. That is, the magnetic sheet may be replaced with a nonmagnetic sheet as in the invention described in (14), or a nonmagnetic film layer is formed on the magnetic sheet as in the invention described in (15). You may form in predetermined thickness. Therefore, the gap can be easily formed, and the film layer thickness (gap) of the nonmagnetic material can be easily adjusted. In this case, the gap can be formed in the sheet forming process, and the manufacturing can be performed without newly adding the manufacturing process, and the productivity is excellent.

  Further, in the formation of the core, as in the invention described in (8), in the printing lamination process, a predetermined opening part can be formed in the central part, and then a filling process for filling the opening part with a magnetic material can be performed. . Alternatively, as in the invention described in (9), in the printing lamination process, a predetermined nonmagnetic material region is formed in the central portion, and then an opening portion is formed in the nonmagnetic material region by a punching process, and the opening portion is magnetically formed. A filling step of filling the body can be performed. In this case, the printing lamination process does not require the patterning of the magnetic material in each layer, can be performed efficiently, and the core core can be easily formed.

  In the laminated common mode choke coil according to the present invention, the core is configured as an open magnetic circuit in which both ends of the columnar core are sandwiched between plate-shaped outer cores, so that a large area for patterning the conductor pattern is secured. In addition, since the outer peripheral area of the core is widened, the overlapping of the conductor patterns in the upper and lower layers can be appropriately shifted to the shift position. As a result, the inductance can be increased to a large value and the stray capacitance can be reduced.

  FIG. 2 shows a first embodiment of the present invention. As shown in FIG. 2 (c), in this embodiment, the laminated common mode choke coil circulates around the core 3 in a form in which both ends of the columnar core 1 are sandwiched by the plate-shaped outer core 2 and the outer periphery of the core 1. And coils A and B by the conductor pattern 4 to be provided. The coils A and B are arranged so as to be electrically complementary to each other, and are embedded in the film layer of the nonmagnetic material 5 in a buried state.

  The conductor pattern 4 has a spiral shape formed in a predetermined layer in the corresponding layer, and a via hole 6 is provided at a predetermined position of the film layer of the nonmagnetic material 5 so that the conductor patterns 4 formed on the upper and lower sides are appropriately connected to each other. B is formed. In the lamination, the central portion of each layer is formed from the magnetic body 7 to form the core 1, and the upper and lower film layers of the lamination are formed from the magnetic body 8 to form the outer core 2.

  Thereby, the laminated common mode choke coil according to the present embodiment employs a configuration in which the magnetic material is not disposed around the outer periphery of the film layer made of the nonmagnetic material 5 and the side surface of the nonmagnetic material 5 is exposed to the outside. .

  Next, an embodiment of a method for manufacturing the laminated common mode choke coil having the above configuration will be described. In the laminate, first, an intermediate layer is formed by a printing lamination method as shown in FIG. 2A, and then an upper layer and a lower layer are formed by a sheet molding method as shown in FIG. Thus, the cross-sectional structure shown in FIG. The specific manufacturing process of each process is as follows.

  In the printing lamination step shown in FIG. 2A, the second to eighth layers of the intermediate layer are laminated. Each layer is a film layer based on the nonmagnetic material 5 and appropriately includes a patterning portion of the conductor pattern 4, a formation portion of the via hole 6, and a formation portion of the magnetic material 7. The spiral conductive patterns 4 are formed on every second, fourth, sixth and eighth layers, and the second and fourth conductive patterns 4 are connected by providing via holes 6 on the third layer. A, and the conductor patterns 4 of the sixth and eighth layers constitute the coil B by providing via holes 6 in the seventh layer and connecting them. And the magnetic body 7 is formed in the center part of each layer, and these magnetic bodies 7 comprise the core core 1 continuous up and down by taking the arrangement | positioning which overlaps up and down. In the present embodiment, the magnetic body 7 at the center of each layer is formed on all the layers from the second layer to the eighth layer, so that the upper and lower sides of the core 1 made of the magnetic body 7 are exposed.

  The conductor pattern 4 is formed using, for example, silver paste. For example, Zn ferrite is used for the nonmagnetic material 5. As the nonmagnetic material 5, it is also preferable to use a low dielectric constant material such as alumina or silica.

  In the sheet forming step shown in FIG. 2B, the first and ninth layers as upper and lower surfaces are formed on the intermediate layer laminate 28 manufactured through the step of FIG. For this purpose, a large number of magnetic sheets 8 are stacked on the upper and lower surfaces of the intermediate layer laminate 28 and bonded by applying pressure to form a film layer having a predetermined thickness. The first and ninth layers configured by laminating the predetermined number of magnetic sheets 8 constitute the outer core 2. The magnetic material sheet 8 may be formed by forming a first layer and a ninth layer by pressing one sheet having a predetermined thickness by a sheet forming method. As described above, since both the upper and lower (axial) ends of the core core 1 are exposed, the core core 1 and the first and ninth layers of the magnetic sheet 8 (outer core 2) are obtained by executing this step. And the core 3 is connected.

  As described above, the core 3 has a form in which both ends of the columnar core 1 are sandwiched between the plate-like outer cores 2 and is configured as an open magnetic path, unlike the conventional closed magnetic path, and thus has the same external dimensions as the conventional one. In this case, the area of the nonmagnetic material 5 existing on the outer periphery of the core core 1 is widened. Therefore, a large area for patterning the conductor pattern 4 can be secured, and the number of turns of the conductor pattern 4 can be increased in each layer. As a result, the number of turns of the coils A and B can be increased, and the inductance can be improved to a large value. And since the area | region of the outer periphery of the core core 1 becomes large, the overlap of the conductor pattern 4 in an upper and lower layer can be shifted to a shift position suitably, As a result, stray capacitance can be reduced.

(Verification by numerical analysis)
The configuration of the present invention shown in FIG. 2 was modeled and numerical analysis was performed to evaluate transmission characteristics. For comparison, the conventional example shown in FIG. 1 is also modeled, and both models have the same outer size of the laminate. Here, in the conventional model, the number of turns of the conductor pattern 4 is 2 turns in the second layer (sixth layer) and 1.5 turns in the fourth layer (eighth layer). On the other hand, the model of the present invention can set the number of turns of the conductor pattern 4 to 3 turns in the second layer (sixth layer) when the outer dimensions of the multilayer body are set to be the same. The eighth layer) is configured to be 0.5 turns. That is, the number of turns of the coils A and B is set to 3.5 turns in both models, and the stray capacitance can be compared.

  As a result of the numerical analysis, the transmission characteristics are as shown in the graph of FIG. In the figure, the dotted line t0 is the characteristic of the conventional example of FIG. 1, and the solid line t1 is the characteristic of the present invention of FIG. As is clear from the figure, the transmission characteristic of the present invention (solid line t1) is improved, which can be said to be a result of the reduction of stray capacitance.

  FIG. 4 shows a second embodiment of the present invention. In this embodiment, the laminated common mode choke coil is basically the same as that of the first embodiment, and includes a core 3 having both ends of a columnar core core 1 sandwiched between plate-like outer cores 2 and a core core 1. The coils A and B are formed of a conductive pattern 4 that circulates, and the coils A and B are arranged so as to be electrically complementary to each other and are embedded in the film layer of the nonmagnetic material 5 in a buried state. . The same components as those in the first embodiment are denoted by the same reference numerals, and the description thereof is omitted.

  In this embodiment, the core core 1 is provided with a predetermined gap g to change the characteristics of the magnetic circuit. Also in this case, in the laminate, the intermediate layer is first formed by the printing lamination method as shown in FIG. 4A, and the upper layer and the lower layer are then formed by the sheet molding method as shown in FIG. 4B. The cross-sectional structure shown in FIG.

  The gap g of the core core 1 that is the main part of the present embodiment can be formed in the printing lamination process shown in FIG. That is, in the step of laminating the second layer to the eighth layer of the intermediate layer, the magnetic body 7 is basically formed at the center of each layer, so that the magnetic bodies 7 are arranged so as to overlap each other vertically. Although it constitutes the core 1, the predetermined layers (fourth, fifth and sixth layers in the figure) constituting the intermediate layer do not form the magnetic body 7, and the non-magnetic body 5 may be disposed in this portion. The gap g can be adjusted by changing the intermediate film layer in which the magnetic body 7 is not provided at the center. Further, the gap g is adjusted not by changing the number of intermediate layers not forming the magnetic body 7 but also by appropriately setting the film thickness of the intermediate layer (for example, the fifth layer) not forming the magnetic body 7. be able to.

  In the illustrated example, the gap g is provided at the central position in the vertical direction of the core 1, but the present invention is not limited to this, and the position where the gap g is formed may be appropriately shifted in the vertical direction. . Further, the number of installations is not limited to one as illustrated, and may be provided at a plurality of locations.

  Further, since the core 3 has a configuration in which both ends of the columnar core 1 are sandwiched between the plate-shaped outer cores 2, the core gap is non-magnetic as shown in FIG. It can also be formed by filling with the body 5. In this case, the facing interval between the upper and lower outer cores 2 becomes the interval in the magnetic circuit as it is and becomes the core gap. In this case, since there is no magnetic body in the core core 1, it is also a kind of air core. In the laminated common mode choke coil having such a configuration, the nonmagnetic material 5 is placed in the center of all the intermediate layers (second to eighth layers) in the printing lamination process shown in FIG. Thus, an intermediate layer laminate 28 in which the core part is entirely non-magnetic is produced. Next, in the sheet forming step shown in FIG. 2 (b), the laminated common mode choke coil shown in FIG. 5 (c) is obtained by attaching and compressing the first and ninth layers above and below the laminated body 28. To manufacture. Also in this embodiment, the interval of the core gap can be adjusted by appropriately setting the thickness of each layer.

  In this case, since the core core 1 replaces a part of the magnetic body 7 with the non-magnetic body 5 and provides the gap g, the frequency characteristics of the core 3 can be improved. Therefore, impedance characteristics can be improved by appropriately adjusting the core gap. As a result, the common mode impedance can be increased.

(Verification by numerical analysis)
The configurations shown in FIGS. 4 and 5 were modeled and numerical analysis was performed, and transmission characteristics and impedance characteristics were evaluated. As a result, the transmission characteristics are as shown in the graph of FIG. In the figure, a dotted line g0 is a characteristic without gaps in the configuration model of FIG. 4, and a solid line g400 is a characteristic with a maximum gap in the configuration model of FIG. As is apparent from the figure, the gap no g0 and the core core part are generally overlapped with the gap g400, and the characteristic that the dotted line and the solid line cannot be distinguished was obtained. In other words, it was confirmed that even when the core gap was set to the maximum interval, the transmission characteristics were not affected at all and the transmission characteristics could be obtained satisfactorily.

  As a result of the numerical analysis, the impedance characteristic is as shown in the graph of FIG. The figure shows the characteristics of a plurality of examples using the gap as a parameter. In the figure, g0 is the characteristic of the configuration model shown in FIG. 4 but no gap, g21 is the characteristic model of FIG. 4 and the gap is 21 μm, g43 4 is a characteristic with a gap of 43 μm in the structural model of FIG. 4, g85 is a characteristic of the structural model of FIG. 4 with a gap of 85 μm, and g400 is a characteristic of the structural model of FIG. As is clear from the figure, the impedance can be increased as the gap is increased, and the impedance peak shifts to the high frequency side. Therefore, it was confirmed that by providing the core gap, the impedance in the common mode can be increased and higher frequency can be achieved.

  In this case, the impedance characteristic depends on the dielectric constant of the nonmagnetic material 5 in terms of electrical / magnetic properties. Therefore, the impedance can be increased by changing the dielectric constant of the nonmagnetic material 5. Therefore, in addition to the method of setting and adjusting the core gap, it can be said that it is also effective to use a method of adjusting the impedance as desired by applying a non-magnetic material 5 having an appropriate dielectric constant.

  FIG. 8 shows a third embodiment of the present invention. In this embodiment, the laminated common mode choke coil is basically the same as that of the first embodiment, and in particular, an improved manufacturing process. Therefore, as shown in FIG. 8D, the structure of the finally manufactured laminated common mode choke coil includes a core 3 having both ends of a columnar core 1 sandwiched between plate-shaped outer cores 2 and a core. The coils A and B have conductor patterns 4 that circulate around the core 1, and the coils A and B are arranged so as to be electrically complementary to each other and are embedded in the film layer of the non-magnetic material 5 in a buried state. The core core 1 is also continuous vertically without a gap, and both ends thereof are connected to the upper and lower outer cores 2. The same components as those in the first embodiment are denoted by the same reference numerals, and the description thereof is omitted.

  That is, in this embodiment, the core core 1 forming process is devised, and the core core 1 is formed in the next process following the printing lamination process. That is, in the laminate 28, an intermediate layer is first formed by a printing lamination method as shown in FIG. 8A, and then the core core 1 is formed by a magnetic material filling process as shown in FIG. 8B. Next, as in the above-described embodiments, the upper layer and the lower layer made of a magnetic material disposed on the upper and lower surfaces of the laminate 28 are formed by a sheet molding method as shown in FIG. ). The specific process is as follows.

  In the printing lamination step shown in FIG. 8A, the central portion of each layer is a predetermined opening portion 9, and the opening portions 9 are arranged so as to overlap each other. Accordingly, in the intermediate layer laminate 28 manufactured by completing this printing lamination step, the opening 9 is opened up and down at the center as shown in FIG. 8 (b-1).

  Subsequently, in the magnetic substance filling step shown in FIG. 8B, a magnetic paste is screen-printed and applied on the upper surface of the laminate 28 shown in FIG. 8B-1. As a result, the magnetic film 15 is formed on the entire upper surface of the laminate 2, and the magnetic paste flows into the opening 9 to fill the opening 9 with the magnetic material as shown in FIG. 8B-2. As a result, the core 1 is formed. Also, a metal mask may be used for filling, and a method of filling and filling the magnetic paste in the opening portion 9 with a metal mask can be performed.

  After that, a predetermined number of magnetic films are formed on the upper and lower surfaces of the laminate 28 (the upper surface is covered with a magnetic film) manufactured through the above-described magnetic material filling step by the sheet forming method shown in FIG. A laminated common choke coil shown in FIG. 8D is manufactured by attaching the sheet 8 and sandwiching the sheet 8 from above and below at a predetermined pressure. As is apparent from FIGS. 8B-2 and 8C, in this embodiment, the magnetic film 15 printed on the upper surface of the intermediate layer stack 28 and the magnetic sheet 8 attached to the upper surface of the magnetic film 15 are printed. Thus, the upper outer core 2 is formed.

  In the present embodiment, the printing lamination step shown in FIG. 8A eliminates the need for patterning the magnetic body 7 when forming each layer, and the work can be performed efficiently. That is, it is only necessary to pattern the conductor pattern 4 and the via hole 6, and the same conductive material can be used for both. The subsequent filling process of the magnetic material is a simple filling operation, so that it is not necessary to consider positional misalignment and the like, and can be easily performed. As a result, the core core 1 can be easily formed.

  FIG. 9 shows a fourth embodiment of the present invention. In this embodiment, the laminated common mode choke coil is basically the same as in the first and third embodiments, and the core 3 having a shape in which both ends of the columnar core 1 are sandwiched by the plate-shaped outer core 2 and the core The coils A and B have conductor patterns 4 that circulate around the core 1, and the coils A and B are arranged so as to be electrically complementary to each other, and are embedded in the film layer of the non-magnetic material 5. It has become. The same components as those in the first and third embodiments are denoted by the same reference numerals, and the description thereof is omitted.

  In this embodiment, the process for forming the core core 1 is devised in the same manner as in the third embodiment, but the manufacturing process of the core core 1 following the printing lamination process adopts a process different from that in the third embodiment. That is, in the laminate, first, an intermediate layer is formed by a printing lamination method as shown in FIG. 9A, and then the core 1 is formed by a punching process and a magnetic material filling process as shown in FIG. 9B. Form. Next, with respect to the laminate 28 manufactured through these steps, the upper layer and the lower layer are formed by a sheet forming method as shown in FIG. 9C, and the laminate having the cross-sectional structure shown in FIG. Manufactures common mode choke coils. The specific process is as follows.

  In the printing lamination process shown in FIG. 9A, the central portion of each layer is a predetermined non-magnetic region. That is, the nonmagnetic body 5 of the base without patterning is formed without forming the magnetic body 7 as in the first embodiment or forming the opening 9 as in the third embodiment. To the area where exists. As a result, as shown in FIG. 9B, a laminated body 28 in which the predetermined conductor pattern 4 is built in the block made of the nonmagnetic material 5 is manufactured.

  Subsequently, a punching process is performed on the laminated body 28. That is, as shown in FIG. 9 (b-2), the nonmagnetic material region at the central portion of the laminated body 28 of FIG. An opening portion 9 penetrating vertically is formed at the center. Then, in the magnetic material filling step, the core portion 1 is formed by filling the opening portion 9 with the magnetic material 7. That is, as shown in FIG. 9B-3, the magnetic layer 15 is formed on the upper surface of the multilayer body 28 by applying a magnetic paste, which is a magnetic material, to the upper surface of the multilayer body 28 by screen printing or the like. The core core 1 is formed by embedding and filling a magnetic paste in the opening 9. Also, a metal mask may be used for filling, and a method of filling and filling the magnetic paste in the opening portion 9 with a metal mask can be performed.

  Also in this case, the printing lamination process shown in FIG. 9A does not require the patterning of the magnetic body 7 in each layer, and unlike the third embodiment, the patterning of the opening portion 9 is not performed at this stage. One factor of anxiety that causes misalignment is reduced, and work can be performed more efficiently. In the subsequent punching process, since the opening portion 9 is formed by a single punching operation, it is sufficient to reliably perform such a single operation, and it can be said that the operation is easy. And since the filling process of a magnetic body is a simple filling operation, it is not necessary to consider misalignment or the like and can be easily performed. As a result, the core core 1 can be easily formed.

  In the third and fourth embodiments described above, as shown in the first embodiment, there is an improvement in the manufacturing process of the laminated common mode choke coil having a structure in which no gap is formed in the core core 1. Also in each of these embodiments, a gap can be formed in the core core 1 by the steps shown below.

  That is, the gap with respect to the core core 1 can be formed when the upper layer and the lower layer are formed by a sheet forming method, and the interval can be adjusted. As shown in FIG. 10 to FIG. 12, in the sheet forming method, either the upper or lower first sheet and / or a plurality of subsequent sheets are arranged by adhering a non-magnetic sheet 10 and applying pressure, A step of forming an upper layer and a lower layer is performed. Thereby, the nonmagnetic sheet 10 becomes a gap having a predetermined length with respect to the core core 1. For example, when the non-magnetic sheet 10 is manufactured with a thickness of 50 μm, the gap can be adjusted to 50 μm by inserting one non-magnetic sheet 10 as shown in FIG. Accordingly, the gap can be adjusted by increasing or decreasing the number of the non-magnetic sheets 10. FIG. 11 shows a configuration example in which two nonmagnetic sheets 10 are inserted to set the gap to 100 μm, and FIG. 12 shows a configuration example in which four nonmagnetic sheets 10 are inserted to set the gap to 200 μm.

  Further, as shown in FIG. 13, the gap with respect to the core 1 is preliminarily determined in advance by forming a film layer of the non-magnetic material 5 on the inner layer side surface of at least one of the upper and lower first magnetic sheets 8 in the sheet forming method. It is also possible to perform a step of forming the upper layer and the lower layer by forming a thickness and bonding the sheets by applying pressure. Thereby, the film layer of the nonmagnetic material 5 becomes a gap having a predetermined length with respect to the core 1. The film thickness of the nonmagnetic material 5 can be adjusted as appropriate by screen printing or the like, and can be, for example, about 10 μm or 30 μm. As shown in the drawing, the inner layer side surface is the upper surface side surface in the case of the lower magnetic layer sheet 8.

  Of course, although not shown, the nonmagnetic material sheet 10 is arranged up to the nth sheet, and the film layer of the nonmagnetic material 5 having a predetermined thickness is formed on the inner layer side surface of the (n + 1) th magnetic sheet 8. It may be. As a result, finer gap adjustment and setting can be performed. Although not shown, a nonmagnetic material may be disposed on the upper layer side, or a nonmagnetic material may be disposed on both the upper layer and the lower layer.

  Thus, the formation of the core gap can be carried out when an intermediate layer is first formed by a printing lamination process, and an upper layer and a lower layer are formed on the intermediate layer by a sheet forming method. May be replaced with the non-magnetic material sheet 10, or the film layer of the non-magnetic material 5 may be formed on the magnetic material sheet 8 to a predetermined thickness. Therefore, the gap can be easily formed, and the film layer thickness (gap) of the nonmagnetic material 5 can be easily adjusted. In this case, the gap can be formed in the sheet forming process, and the manufacturing can be performed without newly adding the manufacturing process, and the productivity is excellent.

  In addition, in any of the third and fourth embodiments, the intermediate layer stack 28 can be made common regardless of the length of the gap g, and the sheet molding that does not require patterning is changed. Since a combination of a magnetic sheet and a non-magnetic sheet used in the process is sufficient, manufacturing and management can be performed easily.

(Verification by numerical analysis)
The configurations shown in FIGS. 9 to 13 were modeled and numerical analysis was performed to evaluate impedance characteristics. As a result, the impedance characteristic is as shown in the graph of FIG. The figure shows the characteristics of a plurality of examples using the gap as a parameter. In the figure, g0 is a characteristic without a gap in the configuration model of FIG. 9, g10 is a characteristic with a gap of 10 μm in the configuration model of FIG. 13, and g30 is a figure. 13 with a gap of 30 μm, g50 with the configuration model of FIG. 10 with a gap of 53 μm, g100 with the configuration model of FIG. 11 with a gap of 100 μm, g200 with the configuration model of FIG. 12 with a gap of 200 μm It is a characteristic. As is clear from the figure, the impedance can be increased as the gap is increased, and the impedance peak shifts to the high frequency side. Therefore, it was confirmed that by providing the core gap, the impedance in the common mode can be increased and higher frequency can be achieved. In addition, the same result was obtained even if the characteristic was based on any of the third and fourth embodiments.

  FIG. 15 shows a fifth embodiment of the present invention. In this embodiment, the laminated common mode choke coil has a configuration in which a gap g is provided at a predetermined position of the core core 1 as in the second embodiment, and the manufacturing process uses the manufacturing process of the third embodiment. . The gap g is formed by a predetermined length from the lower side of the core core 1. In addition, the same code | symbol is attached | subjected to the structure similar to said each embodiment, The description is abbreviate | omitted.

  In the present embodiment, in the printing lamination process for manufacturing the intermediate layer laminate 28 shown in FIG. 15A, the opening portion 9 is provided at the central portion of each layer as in the third embodiment. Therefore, the non-magnetic material is left without providing the opening portion 9 for the predetermined layer. That is, no patterning is performed on the central portion. As a result, the intermediate layer laminate 28 manufactured by completing the printing lamination step has the opening portion 9 connected to the central portion on the upper surface side of the laminate 28 as shown in FIG. A bottomed recess 9 'is formed.

  Subsequently, in the magnetic substance filling step shown in FIG. 15B, a magnetic paste is applied to the upper surface of the laminate 28 shown in FIG. 15B-1 by screen printing or the like. Then, the magnetic film 15 is formed on the entire upper surface of the laminate 2, and the magnetic paste flows into the concave portion 9 ', and the magnetic material is filled into the concave portion 9' as shown in FIG. 15 (b-2). As a result, the core 1 is formed. A nonmagnetic material 5 is present on the lower end side of the core core 1.

  Thereafter, a predetermined number of magnetic films are formed on the upper and lower surfaces of the laminated body 28 (the upper surface is covered with a magnetic film) manufactured through the above-described magnetic material filling step by the sheet molding method shown in FIG. A laminated common choke coil shown in FIG. 15D is manufactured by attaching the sheet 8 and sandwiching the sheet 8 from above and below at a predetermined pressure. As is apparent from FIGS. 15B-2 and 15C, in this embodiment, the nonmagnetic material 5 exists between the core core 1 and the lower outer core 2, and a gap g is formed. . The length of the gap g can be adjusted by changing the number of layers to be left as the non-magnetic material 5 without providing the opening portion 9 at the festival to be printed and laminated in FIG. Although not specifically shown, the configuration of the present embodiment can be manufactured by applying the manufacturing process in the fourth embodiment.

It is sectional drawing which shows an example of the conventional laminated common mode choke coil. 1 shows a first embodiment of a laminated common mode choke coil according to the present invention, (a) is a perspective view showing each layer in a printing lamination process separately, and (b) is a perspective view showing each layer in a sheet forming process separately. FIG. 2C is a cross-sectional view after completion. It is a graph which shows the transmission characteristic of a lamination | stacking common mode choke coil, and has shown the characteristic (dotted line t0) of the prior art example of FIG. 1, and the characteristic (solid line t1) of this invention of FIG. 2A and 2B show a second embodiment of a laminated common mode choke coil according to the present invention, in which FIG. 3A is a perspective view showing separated layers in a printing lamination process, and FIG. 4B is a perspective view showing separated layers in a sheet forming process. FIG. 2C is a cross-sectional view after completion. Fig. 4 shows another example of the core gap in the lamination, (a) is a perspective view showing the layers in the printing lamination process separately, (b) is a perspective view showing the layers in the sheet forming process separately, and (c) is completed. FIG. It is a graph which shows the transmission characteristic of a lamination | stacking common mode choke coil, and has shown the characteristic (solid line g400) of the present invention which made the core core part all the gap the characteristic (dotted line g0) of a comparative example without a gap. It is a graph which shows the impedance characteristic of a lamination | stacking common mode choke coil, and has shown the characteristic of the several example which used the gap as a parameter. 3A and 3B show a third embodiment of a laminated common mode choke coil according to the present invention, in which FIG. 3A is a perspective view showing separated layers of a printing lamination process, and FIG. 3B is a cross-sectional view explaining a magnetic material filling process; (C) is the perspective view which isolate | separates and shows each layer of a sheet forming process, (d) is sectional drawing after completion. 4A and 4B show a fourth embodiment of a laminated common mode choke coil according to the present invention, in which FIG. 4A is a perspective view showing separated layers in a printing lamination process, and FIG. 5B explains a punching process and a magnetic material filling process. Sectional drawing, (c) is a perspective view showing each layer in the sheet forming step separately, and (d) is a sectional view after completion. The formation process of gap 50micrometer is shown, (a) is sectional drawing which isolate | separates and shows each part, (b) is sectional drawing after completion. The formation process of gap 100micrometer is shown, (a) is sectional drawing which isolate | separates and shows each part, (b) is sectional drawing after completion. The formation process of gap 200 micrometers is shown, (a) is sectional drawing which isolate | separates and shows each part, (b) is sectional drawing after completion. The formation process of gap 10micrometer and 30 micrometers is shown, (a) is sectional drawing which isolate | separates and shows each part, (b) is sectional drawing after completion. It is a graph which shows the impedance characteristic of a lamination | stacking common mode choke coil, and has shown the characteristic of the several example which used the gap as a parameter. 5 shows a fifth embodiment of the laminated common mode choke coil according to the present invention, (a) is a perspective view showing each layer of the printing lamination process separately, (b) is a cross-sectional view explaining the magnetic material filling process, (C) is the perspective view which isolate | separates and shows each layer of a sheet forming process, (d) is sectional drawing after completion.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Core core 2 Outer core 3 Core 4 Conductor pattern 5 Nonmagnetic material 6 Via hole 7 Magnetic material 8 Magnetic material sheet 9 Opening part 10 Nonmagnetic material sheet 15 Magnetic film 28 Laminate

Claims (15)

A core made of a magnetic material and having both ends of a columnar core core sandwiched between plate-shaped outer cores, and a coil having a conductor pattern that circulates around the core core, the two coils electrically complementing each other. A laminated common mode choke coil that is arranged and embedded in a non-magnetic film layer in an embedded state,
The coil is formed by forming a spiral shape in the corresponding layer in the conductor pattern, providing a via hole at a predetermined position of the nonmagnetic film layer, and connecting the conductor pattern,
In the lamination, the central portion of each layer is formed from the magnetic material to form the core core,
Further, the outer and upper outer film layers are formed from the magnetic body as the outer core,
A laminated common mode choke coil, wherein no magnetic material is disposed on the outer peripheral side of the coil, and the core constitutes an open magnetic path. A core made of a magnetic material and having both ends of a columnar core core sandwiched between plate-shaped outer cores and a coil having a conductor pattern that circulates around the core core, and the coils are arranged to electrically complement each other. A laminated common mode choke coil embedded in a non-magnetic material film layer,
The coil is formed by connecting the conductor pattern by forming a spiral shape in a predetermined layer in the conductor pattern and providing a via hole at a predetermined position of the non-magnetic film layer,
In the lamination, the central portion of each layer is formed from the magnetic material to form the core core,
Further, the outer and upper outer film layers are formed from the magnetic body as the outer core,
The core core replaces a part of the columnar shape with the nonmagnetic material to provide a gap of a predetermined length for the magnetic circuit,
A laminated common mode choke coil, wherein no magnetic material is disposed on the outer peripheral side of the coil, and the core constitutes an open magnetic path.   The laminated common mode choke coil according to claim 2, wherein the gap portion is a film layer of a nonmagnetic sheet.   3. The laminated common mode choke coil according to claim 2, wherein the gap portion is a film layer of a non-magnetic paste printed on a magnetic sheet. A coil having a conductor pattern; and a core having a pair of plate-like outer cores arranged at a predetermined distance on both sides in the axial direction of the coil, and the coils electrically complement each other. A laminated common mode choke coil that is arranged and embedded in a non-magnetic film layer in a buried state,
The coil is formed by forming a spiral shape in the corresponding layer in the conductor pattern, providing a via hole at a predetermined position of the nonmagnetic film layer, and connecting the conductor pattern,
A laminated common mode choke coil, wherein no magnetic material is disposed on the outer peripheral side of the coil, and the core constitutes an open magnetic path.   The multilayer common mode choke coil according to any one of claims 1 to 5, wherein the nonmagnetic material is made of Zn ferrite or a low dielectric constant material such as alumina or silica.   The multilayer common mode choke coil according to any one of claims 1 to 6, wherein the number of turns in each layer of the pattern constituting the coil is varied. A core made of a magnetic material and having both ends of a columnar core core sandwiched between plate-shaped outer cores and a coil having a conductor pattern that circulates around the core core, and the coils are arranged to electrically complement each other. A method for manufacturing a laminated common mode choke coil embedded in a non-magnetic film layer,
The conductor pattern is formed in a predetermined spiral shape in the corresponding layer, and the coil is formed by connecting the conductor pattern by providing a via hole at a predetermined position of the non-magnetic film layer. Is a predetermined opening part,
The conductor pattern, the via hole, and the non-magnetic part are formed by a printing lamination method. After the lamination, the opening is filled with the magnetic substance to form the core core, and then the upper and lower outer sides of the lamination are formed. A method of manufacturing a laminated common mode choke coil, wherein a magnetic sheet is pressed by a sheet forming method to form the outer core to a predetermined thickness. A core made of a magnetic material and having both ends of a columnar core core sandwiched between plate-shaped outer cores and a coil having a conductor pattern that circulates around the core core, and the coils are arranged to electrically complement each other. A method for manufacturing a laminated common mode choke coil embedded in a non-magnetic film layer,
The conductor pattern is formed in a predetermined spiral shape in the corresponding layer, and the coil is formed by connecting the conductor pattern by providing a via hole at a predetermined position of the non-magnetic film layer. Is a predetermined non-magnetic region,
The conductor pattern, the via hole, and the non-magnetic portion are formed by a printing lamination method, and after the lamination, a predetermined opening portion is formed in the non-magnetic region by punching, and then the magnetic portion is formed in the opening portion. A laminated common mode choke coil, wherein the core is formed by filling a body, and the outer core is formed to have a predetermined thickness by pressing a magnetic material sheet on the upper and lower sides of the laminate by a sheet molding method. Manufacturing method.   10. The laminated common mode choke coil according to claim 8, wherein the magnetic material to be filled in the opening portion is a magnetic paste, and the magnetic paste is embedded and filled in the opening portion by screen printing. Method.   10. The laminated common mode choke coil according to claim 8, wherein the magnetic material to be filled in the opening portion is a magnetic paste, and the magnetic paste is embedded and filled in the opening portion with a metal mask. Method.   2. The sheet forming method according to claim 1, wherein a nonmagnetic material sheet is disposed on either the upper or lower first sheet and / or a plurality of subsequent sheets to provide a gap having a predetermined length with respect to the core core. The manufacturing method of the lamination | stacking common mode choke coil of any one of 8-11.   In the sheet molding method, at least one of the upper and lower first magnetic sheets is formed with a non-magnetic film layer having a predetermined thickness on the inner surface, and a gap having a predetermined length with respect to the core core. The method for manufacturing a laminated common mode choke coil according to any one of claims 8 to 11, wherein: A core made of a magnetic material and having both ends of a pillar-shaped core core sandwiched between plate-shaped outer cores and a coil having a conductor pattern that circulates around the core core, and the coils are arranged so as to electrically complement each other. A method for manufacturing a laminated common mode choke coil embedded in a non-magnetic film layer,
The conductor pattern is formed in a predetermined spiral shape in the corresponding layer, and the coil is formed by connecting the conductor pattern by providing a via hole at a predetermined position of the non-magnetic film layer. Formed from the magnetic body as the core core, and further, the upper and lower outer film layers are formed from the magnetic body as the outer core,
The conductor pattern, the via hole, the part of the non-magnetic material and the part of the magnetic material to be the core core are formed by a printing lamination method,
Next, the outer core is formed to have a predetermined thickness by pressing a magnetic sheet on the upper and lower sides of the laminate by a sheet forming method, but either the first sheet on the upper or lower side or the subsequent sheets are non-magnetic. A method for manufacturing a laminated common mode choke coil, wherein a body sheet is disposed to provide a gap having a predetermined length with respect to the core core. A core made of a magnetic material and having both ends of a columnar core core sandwiched between plate-shaped outer cores and a coil having a conductor pattern that circulates around the core core, and the coils are arranged to electrically complement each other. A method for manufacturing a laminated common mode choke coil embedded in a non-magnetic film layer,
The conductor pattern is formed in a predetermined spiral shape in the corresponding layer, and the coil is formed by connecting the conductor pattern by providing a via hole at a predetermined position of the non-magnetic film layer. Formed from the magnetic body as the core core, and further, the upper and lower outer film layers are formed from the magnetic body as the outer core,
The conductor pattern, the via hole, the part of the non-magnetic material and the part of the magnetic material to be the core core are formed by a printing lamination method,
Next, the outer core is formed to have a predetermined thickness by pressing a magnetic sheet on the upper and lower outer sides of the laminate by a sheet forming method, but at least one of the upper and lower first magnetic sheets is not on the inner layer side surface. A method of manufacturing a laminated common mode choke coil, wherein a film layer of a magnetic material is formed in advance to a predetermined thickness, and a gap having a predetermined length is provided with respect to the core core.

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