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WO2024181449A1 - Transformateur - Google Patents

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Publication number
WO2024181449A1
WO2024181449A1 PCT/JP2024/007122 JP2024007122W WO2024181449A1 WO 2024181449 A1 WO2024181449 A1 WO 2024181449A1 JP 2024007122 W JP2024007122 W JP 2024007122W WO 2024181449 A1 WO2024181449 A1 WO 2024181449A1
Authority
WO
WIPO (PCT)
Prior art keywords
coil
planar coil
transformer
coil element
magnetic
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.)
Ceased
Application number
PCT/JP2024/007122
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English (en)
Japanese (ja)
Inventor
将人 岡部
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Dai Nippon Printing Co Ltd
Original Assignee
Dai Nippon Printing Co Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Dai Nippon Printing Co Ltd filed Critical Dai Nippon Printing Co Ltd
Priority to JP2025503937A priority Critical patent/JPWO2024181449A1/ja
Publication of WO2024181449A1 publication Critical patent/WO2024181449A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F30/00—Fixed transformers not covered by group H01F19/00
    • H01F30/06—Fixed transformers not covered by group H01F19/00 characterised by the structure
    • H01F30/10—Single-phase transformers

Definitions

  • This disclosure relates to a transformer.
  • a transformer that transform voltage is used in the power circuits of various electronic devices.
  • a transformer is generally constructed by winding a primary coil and a secondary coil around a core made of electromagnetic steel sheet or ferrite material. By passing an excitation current through the primary coil, a magnetic field is generated inside the core, and a voltage is induced in the secondary coil by electromagnetic induction.
  • the transformer core is thick and has a three-dimensional shape.
  • an EE core or EER core is formed in an E shape and has three legs. It is preferable for the core to have a large volume in order to suppress magnetic saturation. For this reason, transformers tend to be bulky.
  • the embodiment of the present disclosure aims to make the transformer smaller and thinner.
  • a transformer includes a first magnetic shielding member that is generally flat, a first coil arranged opposite the first magnetic shielding member, the first coil having a first surface facing the first magnetic shielding member and a second surface opposite the first surface, a first magnetic layer having magnetism and at least a portion of which covers the first surface of the first coil, a second coil arranged opposite the second surface of the first coil, the second coil having a third surface facing the first coil and a fourth surface opposite the third surface, a second magnetic shielding member that is generally flat and arranged opposite the fourth surface of the second coil, and a second magnetic layer having magnetism and at least a portion of which covers the fourth surface of the second coil.
  • a transformer according to one embodiment of the present disclosure includes a generally flat magnetic shielding member, a first coil arranged opposite the magnetic shielding member, the first coil having a first surface facing the magnetic shielding member and a second surface opposite the first surface, a second coil arranged opposite the second surface of the first coil, and a magnetic layer having magnetism, at least a portion of which covers the first surface of the first coil.
  • the transformer can be made smaller and thinner.
  • FIG. 1 is a perspective view of a transformer according to a first embodiment.
  • FIG. 2 is an exploded perspective view of a first coil component of the transformer shown in FIG. 3 is an exploded perspective view of a second coil component of the transformer shown in FIG. 1.
  • FIG. 4 is a cross-sectional view of the transformer taken along line IV-IV in FIG.
  • FIG. 5 is a perspective view of a transformer according to the second embodiment.
  • FIG. 6 is an exploded perspective view of the transformer shown in FIG.
  • FIG. 7 is a cross-sectional view of the transformer taken along line VII-VII in FIG.
  • FIG. 8 is a perspective view showing a coil having a total of nine turns.
  • FIG. 9 is a perspective view showing a coil having a total of seven turns.
  • FIG. 10 is a table showing the Q value of the transformer according to the first embodiment obtained by the first simulation.
  • FIG. 11 is a graph showing the Q value of the transformer according to the first embodiment obtained by the first simulation.
  • FIG. 12 is a table showing the Q value of the transformer according to the first embodiment obtained by the second simulation.
  • FIG. 13 is a graph showing the Q value of the transformer according to the first embodiment obtained by the second simulation.
  • FIG. 14 is a perspective view showing the coils of the transformer under conditions 1 and 2 of the third simulation.
  • FIG. 15 is a perspective view showing the coils of the transformers under conditions 3 to 6 of the third simulation.
  • FIG. 16 is a perspective view showing the coils of the transformer under conditions 7 to 9 of the third simulation.
  • FIG. 17 is a table showing the Q value, loss, impedance, inductance, and coupling coefficient of the transformer according to the second embodiment obtained by the third simulation.
  • FIG. 18 is a perspective view showing a coil of a transformer in the fourth simulation.
  • FIG. 19 is a table showing the Q value, loss, impedance, inductance, and coupling coefficient of the transformer according to the second embodiment obtained by the fourth simulation.
  • An embodiment of the present disclosure relates to the following [1] to [36].
  • a first magnetic shield member that is generally flat; a first coil disposed opposite to the first magnetic shield member, the first coil having a first surface facing the first magnetic shield member and a second surface opposite to the first surface; a first magnetic layer having magnetism and at least a portion of which covers the first surface of the first coil; a second coil disposed opposite the second surface of the first coil, the second coil having a third surface facing the first coil and a fourth surface opposite the third surface; a second magnetic shield member that is generally flat and disposed opposite a fourth surface of the second coil; a second magnetic layer having magnetism and at least a portion of which covers the fourth surface of the second coil;
  • a transformer comprising:
  • the first coil having a plurality of planar coil elements; the first coil includes a first shield-side planar coil element that forms the first surface, The transformer according to [2], wherein a thickness of a planar coil element of the first coil other than the first shield-side planar coil element is 0.15 mm or more.
  • the second coil having a plurality of planar coil elements; the second coil includes a second shield-side planar coil element that forms the fourth surface,
  • the first coil has a plurality of planar coil elements; the first coil includes a first shield-side planar coil element that forms the first surface, a thickness of the planar coil elements of the first coil other than the first shield-side planar coil element is 0.15 mm or more;
  • the second coil has a plurality of planar coil elements; the second coil has a second shield-side planar coil element that forms the fourth surface, a thickness of the second shield-side planar coil element is greater than thicknesses of other planar coil elements of the second coil; a thickness of the planar coil elements of the second coil other than the second shield-side planar coil element is 0.15 mm or more;
  • the first coil has a plurality of planar coil elements; the first coil includes a first shield-side planar coil element that forms the first surface, a thickness of a planar coil element of the first coil other than the first shield-side planar coil element is 0.15 mm or more and 0.25 mm or less;
  • the second coil has a plurality of planar coil elements; the second coil includes a second shield-side planar coil element that forms the fourth surface, a thickness of a planar coil element of the second coil other than the second shield-side planar coil element is 0.15 mm or more and 0.25 mm or less;
  • the first magnetic shield member has an inner surface facing the first coil and an outer surface opposite to the inner surface,
  • the transformer according to any one of [1] to [21], wherein a distance between the inner surface of the first magnetic shield member and the first surface of the first coil is 0.5 mm or more and 2 mm or less.
  • the second magnetic shield member has an inner surface facing the second coil and an outer surface opposite to the inner surface,
  • the transformer according to any one of [1] to [22], wherein a distance between the inner surface of the second magnetic shield member and the fourth surface of the second coil is 0.5 mm or more and 2 mm or less.
  • a magnetic shield member which is generally flat; a first coil disposed opposite the magnetic shield member, the first coil having a first surface facing the magnetic shield member and a second surface opposite to the first surface; a second coil disposed opposite the second surface of the first coil; a magnetic layer having magnetism and at least a portion of which covers the first surface of the first coil;
  • a transformer comprising:
  • the first coil and the second coil each have at least one planar coil element; the first coil has a shield-side planar coil element that forms the first surface;
  • the second coil has a third surface facing the first coil and a fourth surface opposite to the third surface,
  • the magnetic shield member has an inner surface facing the first coil and an outer surface opposite to the inner surface,
  • the transformer according to any one of [24] to [34], wherein a distance between the inner surface of the magnetic shield member and the first surface of the first coil is 0.5 mm or more and 2 mm or less.
  • the first coil and the second coil each have at least one planar coil element;
  • the transformer according to any one of [1] to [35], wherein the thickness of the planar coil element is 0.1 mm or more and 2.0 mm or less.
  • sheet is a concept that includes members that may also be called films or plates.
  • Fig. 1 is a perspective view of a transformer 1 according to a first embodiment.
  • Fig. 2 is an exploded perspective view of a first coil component 2 of the transformer 1 shown in Fig. 1.
  • Fig. 3 is an exploded perspective view of a second coil component 3 of the transformer 1 shown in Fig. 1.
  • Fig. 4 is a partial cross-sectional view of the transformer 1 shown in Fig. 1.
  • the transformer 1 includes a first coil component 2 and a second coil component 3.
  • the first coil component 2 and the second coil component 3 are not electrically connected to each other.
  • the first coil component 2 and the second coil component 3 face each other.
  • the direction from the first coil component 2 toward the second coil component 3 is referred to as the first direction D1.
  • the first coil component 2 has a first coil 10, a first magnetic shield member 20, and a first magnetic layer 30.
  • the first magnetic shield member 20 and the first coil 10 are overlapped in this order in the first direction D1.
  • the first coil component 2 further includes a first wall portion 35 and a first core member 38.
  • the first coil 10 is connected to an AC power source. When an AC current is supplied to the first coil 10, a magnetic flux is generated in the first coil 10.
  • the second coil component 3 has a second coil 40, a second magnetic shield member 50, and a second magnetic layer 60.
  • the second coil 40 and the second magnetic shield member 50 are overlapped in this order in the first direction D1.
  • the second coil component 3 further includes a second wall portion 65 and a second core member 68.
  • the second coil 40 is not electrically connected to the first coil 10.
  • the second coil 40 is connected to an electronic device. When a magnetic flux is generated in the first coil 10, a voltage is induced in the second coil 40.
  • the frequency of the AC current supplied to the first coil 10 of the transformer 1 according to the first embodiment described below is not particularly limited.
  • the first coil 10 may be supplied with an AC current of 10 kHz or more.
  • the first coil 10 may be supplied with an AC current of 75 kHz to 100 kHz or less, or an AC current of 79 kHz to 90 kHz or less, or an AC current of 85 kHz.
  • the first coil 10 may also be supplied with an AC current of 80 kHz to 500 kHz or less.
  • the first coil 10 may also be supplied with an AC current of 1 MHz or less, or an AC current of more than 1 MHz.
  • each coil component 2, 3 The elements that make up each coil component 2, 3 are described in detail below.
  • the first coil 10 is made of a conductive material.
  • the first coil 10 may be made of copper, a copper alloy, aluminum, or an aluminum alloy.
  • the first coil 10 is disposed opposite the first magnetic shield member 20. As shown in Fig. 4, the first coil 10 has a first surface 10a facing the first magnetic shield member 20 and a second surface 10b opposite to the first surface 10a.
  • the first coil 10 includes at least one planar coil element.
  • the number of planar coil elements included in the first coil 10 is not particularly limited.
  • the first coil 10 may include a single planar coil element, or may include two or more planar coil elements.
  • the first coil 10 includes a first planar coil element 11 and a second planar coil element 12.
  • the first planar coil element 11 and the second planar coil element 12 are formed from the same material, but this is not limited thereto.
  • the first planar coil element 11 and the second planar coil element 12 may be formed from different materials.
  • the first planar coil element 11 and the second planar coil element 12 overlap in this order in the first direction D1.
  • the first planar coil element 11 and the second planar coil element 12 are spaced apart from each other along the first direction D1.
  • each of the planar coil elements 11 and 12 has a spiral shape.
  • the first planar coil element 11 and the second planar coil element 12 are each formed in a spiral shape around a first central axis C1 extending along a first direction D1, as shown in FIG. 2.
  • the direction means a direction extending on the first central axis C1 or a direction parallel to the first central axis C1.
  • a direction perpendicular to the first central axis C1 is referred to as a radial direction of the planar coil elements 11 and 12.
  • first planar coil element 11 and the second planar coil element 12 do not have to be formed in a spiral shape around a common central axis.
  • the central axis of the first planar coil element 11 and the central axis of the second planar coil element 12 may or may not coincide with each other. It is sufficient that the central axis of the first planar coil element 11 and the central axis of the second planar coil element 12 are parallel to each other.
  • Each of the planar coil elements 11 and 12 is plate-shaped. As shown in FIG. 4, the cross-sectional shape of each of the planar coil elements 11 and 12 in a direction perpendicular to the direction in which the planar coil elements 11 and 12 rotate in a spiral shape is rectangular.
  • the first planar coil element 11 is disposed facing the first magnetic shield member 20.
  • the first planar coil element 11 forms the first surface 10a of the first coil 10.
  • the second planar coil element 12 forms the second surface 10b of the first coil 10.
  • the second planar coil element 12 is disposed between the first planar coil element 11 and the second coil component 3.
  • the first planar coil element 11 is also referred to as the "first shield side planar coil element 11.”
  • the first planar coil element 11 has a conductor 11E having a spiral shape formed by a plurality of turn portions 11n.
  • the plurality of turn portions 11n of the first planar coil element 11 are arranged in a direction perpendicular to the first central axis C1.
  • the plurality of turn portions 11n are connected so as to gradually move away from the first central axis C1 toward the radially outward direction of a circle centered on the first central axis C1. This gives the first planar coil element 11 a spiral shape.
  • the second planar coil element 12 has a conductor 12E having a spiral shape formed by a plurality of turn portions 12n.
  • the plurality of turn portions 12n of the second planar coil element 12 are arranged in a direction perpendicular to the first central axis C1. More specifically, the plurality of turn portions 12n are connected so as to gradually move away from the first central axis C1 toward the radially outward direction of a circle centered on the first central axis C1. This gives the second planar coil element 12 a spiral shape.
  • the turn portions 11n, 12n are basically linear conductor portions that do not form a ring but go around the first central axis C1 360 degrees. In the case of a planar coil element, both ends of the turn portions 11n, 12n are offset in the radial direction. In multiple turn portions 11n, 12n, the radially outer end of one turn portion 11n, 12n is connected to the radially inner end of the other turn portion 11n, 12n, and the other turn portions 11n, 12n extend away from the first central axis C1.
  • turn portion 11n of the first planar coil element 11 that is closest to the first central axis C1 will also be referred to as turn portion 111.
  • the turn portion connected to turn portion 111 will also be referred to as turn portion 112.
  • the turn portions 11n of the first planar coil element 11 are composed of five turn portions 111 to 115. In the following, when describing matters common to each of the turn portions 11n, they will basically be referred to as turn portion 11n.
  • the turn portion 12n of the second planar coil element 12 that is closest to the first central axis C1 is also referred to as turn portion 121.
  • the turn portion connected to turn portion 121 is also referred to as turn portion 122.
  • the turn portions 12n of the second planar coil element 12 are composed of five turn portions 121 to 125. In the following, when describing matters common to each of the turn portions 12n, they are basically referred to as turn portion 12n.
  • the number of turns of first planar coil element 11 and the number of turns of second planar coil element 12 are the same. However, the number of turns of first planar coil element 11 and the number of turns of second planar coil element 12 may be different from each other.
  • the total number of turns of first coil 10 is the sum of the number of turns of planar coil elements 11 and 12 included in first coil 10. Therefore, in the illustrated example, the total number of turns of first coil 10 is 10.
  • the turn sections 11n, 12n rotate to form a rectangle.
  • the turn sections 11n, 12n may also rotate to form a circle.
  • the "spiral shape” referred to in this disclosure means a planar curved shape wound in a spiral shape.
  • the planar curved shape referred to here also includes a planar pattern that rotates repeatedly while bending in a broken line shape as shown in the figure.
  • the "spiral shape” refers to a planar curved shape that moves away from the center as it rotates (or moves closer to the center as it rotates).
  • connection wiring portion 14 shown in FIG. 2 is a conductor and electrically connects the first planar coil element 11 and the second planar coil element 12 in series.
  • the connection wiring portion 14 shown in the figure is formed integrally with the turn portion 121 of the second planar coil element 12, as an example.
  • the connection wiring portion 14 may be connected to the turn portion 121 by ultrasonic connection or the like.
  • the radially outer end (the end farther from the first central axis C1) of the turn portion 115 of the first planar coil element 11 that is the furthest from the first central axis C1 of the multiple turn portions 11n is connected to the first connection terminal 71.
  • the radially outer end of the turn portion 125 of the second planar coil element 12 that is the furthest from the first central axis C1 of the multiple turn portions 12n is connected to the second connection terminal 72.
  • the first connection terminal 71 and the second connection terminal 72 can be used, for example, for connection to an AC power source.
  • the connection between the first connection terminal 71 and the turn portion 115 and the connection between the second connection terminal 72 and the turn portion 125 may be performed by ultrasonic bonding.
  • the connection method is not limited, and for example, a connection using a conductive adhesive may be adopted.
  • the radial inward direction of the first planar coil element 11 means the direction approaching the first central axis C1 in the radial direction.
  • the radial outward direction of the first planar coil element 11 means the direction moving away from the first central axis C1 in the radial direction.
  • the radial inward direction of the second planar coil element 12 means the direction moving toward the first central axis C1 in the radial direction.
  • the radial outward direction of the second planar coil element 12 (turn portion 12n) means the direction moving away from the first central axis C1 in the radial direction.
  • the first central axis C1 of the first planar coil element 11 or the second planar coil element 12 is determined as follows. First, linear virtual turn portions similar in shape to the innermost turn portion 111 or 121 are drawn in sequence from the radially inner end of the innermost turn portion 111 or 121 to form a spiral shape radially inward. Drawing is continued until a virtual turn portion that fits within a diameter of 1 cm is drawn. Then, a line that passes through the radially inner region of the virtual turn portion that fits within a diameter of 1 cm in a direction perpendicular to the circumferential and radial directions of the spiral shape is determined as the first central axis C1 of the planar coil element 11 or 12.
  • any one of the multiple turn portions 11n of the first planar coil element 11 and any one of the multiple turn portions 12n of the second planar coil element 12 partially overlap in the direction along the first central axis C1.
  • the part of the turn portion 11n of the first planar coil element 11 and the part of the turn portion 12n of the second planar coil element 12 that overlap in the direction along the first central axis C1 extend parallel to each other with their respective winding directions aligned.
  • the state in which the winding directions are aligned means that, when viewed in the axial direction of the planar coil elements 11 and 12, the first planar coil element 11 and the second planar coil element 12 do not intersect but overlap a certain distance on the same line.
  • the length of a portion of the turn portion 11n of the first planar coil element 11 and the length of a portion of the turn portion 12n of the second planar coil element 12, which overlap and extend parallel to each other as described above, may be 1/2 or more, or 3/4 or more, of their respective total lengths.
  • the inventors have found that the greater the proportion of overlap between the first planar coil element 11 and the second planar coil element 12 while extending parallel to each other, the more eddy current loss can be suppressed.
  • the radially inner end of the turn portion 111 closest to the first central axis C1 is electrically connected to the second planar coil element 12. More specifically, the radially inner end of the turn portion 111 is connected to the inner end of the turn portion 121 in the second planar coil element 12 via the connection wiring portion 14.
  • the direction in which the first planar coil element 11 goes around from the end not connected to the second planar coil element 12 (the radially outer end of the turn portion 115) to the end connected to the second planar coil element 12 is the same as the direction in which the second planar coil element 12 goes around from the end connected to the first planar coil element 11 to the end not connected to the first planar coil element 11 (the radially outer end of the turn portion 125). This suppresses an increase in electrical resistance.
  • the thicknesses T11, T12 of the planar coil elements 11, 12 of the first coil component 2 may be, for example, 0.1 mm or more and 2.0 mm or less. Therefore, the thicknesses T11, T12 may be 0.15 mm or more, 0.2 mm or more, 0.25 mm or more, 0.3 mm or more, 0.35 mm or more, 0.4 mm or more, 0.45 mm or more, 0.5 mm or more, 0.55 mm or more, or 0.6 mm or more. In addition, the thicknesses T11, T12 may be 1.75 mm or less, 1.5 mm or less, 1.25 mm or less, 1.0 mm or less, 0.75 mm or less, or 0.5 mm or less.
  • the thickness T11 of the first shield side planar coil element (first planar coil element) 11 is greater than the thickness T12 of the other planar coil elements (second planar coil elements) 12 of the first coil 10, but is not limited to this.
  • the thickness T11 of the first shield side planar coil element 11 may be the same as the thickness T12 of the other planar coil elements 12 of the first coil 10, or may be smaller than the thickness T12 of the other planar coil elements 12 of the first coil 10.
  • the thickness T11 of the first shield side planar coil element 11 may be greater or smaller than the thicknesses T41, T42 of the planar coil elements 41, 42 of the second coil 40 described later, or may be the same as the thicknesses T41, T42 of the planar coil elements 41, 42 of the second coil 40. Therefore, the thickness T11 of the first shield side planar coil element 11 may be greater than or less than the thicknesses T12, T41, T42 of the other planar coil elements 12, 41, 42 of the first coil 10 and the second coil 40, or may be the same as the thicknesses T12, T41, T42 of the other planar coil elements 12, 41, 42.
  • the line width of the planar coil elements 11, 12 (line width of the conductors 11E, 12E), i.e., the radial width (width in the radial direction) of each turn portion 11n, 12n, is not particularly limited.
  • the radial width of the turn portions 11n, 12n may be, for example, 2 mm or more and 20 mm or less, 2 mm or more and 16 mm or less, 2 mm or more and 12 mm or less, or 2 mm or more and 8 mm or less.
  • the number of turns of the first coil 10 is not particularly limited. The number of turns of the first coil 10 may be, for example, 2 to 15 or less, or 5 to 10 or less.
  • the radius of the planar coil elements 11, 12 (the distance from the first central axis C1 to the part farthest in the radial direction) may be 80 mm or more, or may be 80 mm or more and 450 mm or less.
  • the aspect ratio of the planar coil elements 11, 12 (conductors 11E, 12E) having a rectangular cross-sectional shape is determined by dividing the line width (radial width of the turn portions 11n, 12n) of the planar coil elements 11, 12 (conductors 11E, 12E) by the thickness of the planar coil elements 11, 12 (conductors 11E, 12E).
  • the aspect ratio of the planar coil elements 11, 12 (conductors 11E, 12E) may be 2 or more and 12 or less, or may be 3 or more and 10 or less.
  • planar coil elements 11 and 12 are formed, for example, by punching a metal plate into a spiral shape. However, the planar coil elements 11 and 12 can also be formed by etching a metal foil into a spiral shape.
  • the gap between first planar coil element 11 and second planar coil element 12 may be 0.5 mm or more and 2 mm or less.
  • the gap is not particularly limited, but if the gap is too small, insulation breakdown is likely to occur between planar coil elements 11 and 12. If the gap is too large, the thinning of transformer 1 is hindered.
  • the first magnetic shield member 20 is a flat sheet-like member.
  • the first magnetic shield member 20 is disposed facing the first surface 10a of the first coil 10.
  • the first magnetic shield member 20 is provided to suppress magnetic transmission and/or leakage magnetic field.
  • the first magnetic shield member 20 has an inner surface 20b facing the first coil 10 and an outer surface 20a opposite to the inner surface 20b.
  • the first magnetic shield member 20 is separate from the first coil 10 and the first magnetic layer 30.
  • the first magnetic shield member 20 being separate from the first coil 10 and the first magnetic layer 30 means that the first magnetic shield member 20 is not integrated with the first coil 10 and the first magnetic layer 30.
  • the first magnetic shield member 20 may be joined to the first magnetic layer 30 via an adhesive layer or the like.
  • the first magnetic shield member 20 is formed to a size that encompasses the first coil 10 when viewed in the first direction D1.
  • the first magnetic shield member 20 overlaps the first coil 10 and the first magnetic layer 30, and is in direct contact with the first magnetic layer 30.
  • the first magnetic shield member 20 in this embodiment is magnetic and contains a magnetic material or is made of a magnetic material.
  • a magnetic field is generated when a current is supplied to the first coil 10.
  • the magnetic field generated in the first coil component 2 spreads in all directions relative to the first central axis C1.
  • the first magnetic shield member 20 is magnetic, so that the spreading magnetic flux lines can be oriented toward the first central axis C1.
  • the transformer 1 can be incorporated into an electronic device, and if the magnetic field generated by the transformer 1 flows to other components of the electronic device, this may have an adverse effect on the components. In such cases, the first magnetic shield member 20 can suppress leakage magnetic fields that do not contribute to the generation of current.
  • the first magnetic shield member 20 preferably includes a soft magnetic material or a nanocrystalline magnetic material. More specifically, the first magnetic shield member 20 includes ferrite, preferably soft ferrite. The first magnetic shield member 20 may include flat ferrite. More specifically, the first magnetic shield member 20 may be configured by arranging a plurality of flat ferrite plates in a sheet shape.
  • the relative permeability of the first magnetic shield member 20 may be 500 or more, or 1000 or more.
  • the relative permeability of the first magnetic shield member 20 may be 500 or more and 3000 or less, or 1000 or more and 3000 or less. Note that the relative permeability in this specification is a value measured at a frequency of 85 kHz and an environmental temperature of 23 degrees.
  • the thickness of the first magnetic shield member 20 may be, for example, 0.5 mm or more and 5 mm or less.
  • the distance between the outer edge of the first magnetic shield member 20 and the outer edge of the first coil 10 may be 0.5 mm or more and 10 mm or less.
  • the distance between the first magnetic shield member 20 and the first coil 10 i.e., the distance between the inner surface 20b of the first magnetic shield member 20 and the first surface 10a of the first coil 10) may be, for example, 0.5 mm or more and 2 mm or less.
  • the first core member 38 is disposed on the inner surface 20b of the first magnetic shield member 20.
  • the first core member 38 extends along the first direction D1 within a region surrounded by the innermost turn portions 111, 121 of the first coil 10.
  • the first core member 38 penetrates the first magnetic layer 30.
  • the first core member 38 preferably includes a soft magnetic material or a nanocrystalline magnetic material. More specifically, the first core member 38 includes a ferrite, preferably a soft ferrite.
  • the relative permeability of the first core member 38 may be 500 or more, or 1000 or more.
  • the relative permeability of the first core member 38 may be 500 or more and 3000 or less, or 1000 or more and 3000 or less.
  • the presence of the first core member 38 improves the flow of magnetic flux within the transformer 1.
  • the first magnetic layer 30 has magnetic properties. As shown in Fig. 4, at least a portion of the first magnetic layer 30 is disposed between the first coil 10 and the first magnetic shield member 20 and covers the first surface 10a of the first coil 10.
  • the first magnetic layer 30 has a fifth surface 30a facing the first magnetic shield member 20 and a sixth surface 30b opposite to the fifth surface 30a.
  • the first coil 10 is embedded in the first magnetic layer 30.
  • the first magnetic layer 30 holds the first planar coil element 11 and the second planar coil element 12 together. More specifically, the first magnetic layer 30 covers the first surface 10a of the first coil 10 and fills the gap between the first planar coil element 11 and the second planar coil element 12. The first magnetic layer 30 fills the gap between the first planar coil element 11 and the second planar coil element 12, thereby covering the surface of the second planar coil element 12 facing the first planar coil element 11. The first magnetic layer 30 does not cover the second surface 10b of the first coil 10.
  • the first magnetic layer 30 has a first portion 31 and a second portion 32.
  • the first portion 31 and the second portion 32 are formed integrally without any seams.
  • the first portion 31 and the second portion 32 are formed to a size sufficient to encompass the entire first coil 10 when viewed in the first direction D1.
  • the first portion 31 covers the first surface 10a of the first coil 10.
  • the first portion 31 forms the fifth surface 30a of the first magnetic layer 30.
  • the first portion 31 contacts the first magnetic shield member 20.
  • the first portion 31 also covers the side surface of the first planar coil element 11.
  • the second portion 32 is interposed between the first planar coil element 11 and the second planar coil element 12. That is, the second portion 32 fills the gap between the first planar coil element 11 and the second planar coil element 12. The second portion 32 also covers the side surface of the second planar coil element 12. The second portion 32 forms the sixth surface 30b of the first magnetic layer 30. In the illustrated example, the sixth surface 30b and the second surface 10b of the first coil 10 are flush with each other.
  • the first magnetic layer 30 is magnetic as a whole. That is, the first portion 31 and the second portion 32 are each magnetic.
  • the first magnetic layer 30 suppresses eddy current loss and leakage flux through magnetism, and increases the coupling coefficient, thereby improving coil performance.
  • the relative permeability of the first magnetic layer 30 is preferably 2.0 or more, and may be 2.0 or more and 10.0 or less.
  • the relative permeability of the first magnetic layer 30 is more preferably 5.0 or more, and may be 5.0 or more and 10.0 or less.
  • the relative permeability of the first magnetic layer 30 is not particularly limited, but if it is too large, the flexibility and strength of the first magnetic layer 30 may be undesirably impaired. Therefore, the relative permeability of the first magnetic layer 30 may be 200 or less.
  • the first wall portion 35 protrudes in the first direction D1 from the sixth surface 30b of the first magnetic layer 30.
  • the first wall portion 35 has a spiral shape when viewed in the first direction D1, and extends along the second planar coil element 12.
  • the first wall portion 35 is seamlessly and integrally formed with the first magnetic layer 30.
  • the first wall portion 35 has magnetic properties. By providing the first coil component 2 with the first wall portion 35, the coil performance can be effectively improved.
  • the relative permeability of the first wall portion 35 is preferably 2.0 or more, and may be 2.0 or more and 10.0 or less.
  • the relative permeability of the first wall portion 35 is more preferably 5.0 or more, and may be 5.0 or more and 10.0 or less.
  • the relative permeability of the first wall portion 35 is not particularly limited, but if it is too large, the flexibility and strength of the first wall portion 35 may be undesirably impaired. Therefore, the relative permeability of the first wall portion 35 may be 200 or less.
  • the height of the first wall portion 35 is not particularly limited, but may be, for example, 0.5 mm or more, or 1.0 mm or more.
  • the greater the height of the first wall portion 35 the more effectively the proximity effect between the adjacent turn portions 11n or 12n of the first coil 10 can be suppressed, and the more effectively the increase in the resistance of the first coil 10 can be suppressed.
  • the greater the height of the first wall portion 35 the more likely the first wall portion 35 is to be damaged starting from its base. Therefore, the height of the first wall portion 35 may be, for example, 10 mm or less. Note that the first coil component 2 does not have to have the first wall portion 35.
  • the first magnetic layer 30 and the first wall portion 35 include, as an example, a resin and a plurality or an infinite number of magnetic particles made of a magnetic material.
  • the magnetic particles are held by the resin as a holding material.
  • the magnetic particles may be made of any one or more of ferrite, particularly soft magnetic ferrite, nanocrystalline magnetic material, silicon steel, soft magnetic iron, and amorphous metal.
  • the resin as the retaining material may be glass fiber reinforced polyamide. That is, the resin may be made of a material containing polyamide as a thermoplastic resin (thermoplastic material) and glass fiber.
  • thermoplastic material thermoplastic material
  • the materials from which the first magnetic layer 30 and the first wall portion 35 are made are not particularly limited.
  • the second coil 40 is made of a conductive material.
  • the second coil 40 may be made of copper, a copper alloy, aluminum, or an aluminum alloy.
  • the second coil 40 is disposed opposite the second magnetic shield member 50.
  • the second coil 40 has a third surface 40a facing the first coil 10 and a fourth surface 40b opposite the third surface 40a.
  • the second coil 40 overlaps the first coil 10 with a gap therebetween.
  • the second coil 40 is spaced from the first coil 10 in the first direction D1.
  • the distance between the second coil 40 and the first coil 10 i.e., the distance between the third surface 40a of the second coil 40 and the second surface 10b of the first coil 10) is not particularly limited, but may be, for example, 0.5 mm or more and 30 mm or less. If the gap is too small, insulation breakdown is more likely to occur between the coils 10 and 40. Furthermore, if the gap is too large, the thinning of the transformer 1 is impaired.
  • the second coil 40 includes at least one planar coil element.
  • the number of planar coil elements included in the second coil 40 is not particularly limited.
  • the second coil 40 may include a single planar coil element, or may include two or more planar coil elements.
  • the second coil 40 includes a third planar coil element 41 and a fourth planar coil element 42.
  • the third planar coil element 41 and the fourth planar coil element 42 are formed from the same material, but this is not limited thereto.
  • the third planar coil element 41 and the fourth planar coil element 42 may be formed from different materials.
  • the third planar coil element 41 and the fourth planar coil element 42 overlap in this order in the first direction D1.
  • the third planar coil element 41 and the fourth planar coil element 42 are spaced apart from each other along the first direction D1.
  • each of the planar coil elements 41 and 42 has a spiral shape.
  • the third planar coil element 41 and the fourth planar coil element 42 are each formed in a spiral shape around the second central axis C2 extending along the first direction D1, as shown in FIG. 3.
  • the direction means a direction extending on the second central axis C2 or a direction parallel to the second central axis C2.
  • the direction perpendicular to the second central axis C2 is referred to as the radial direction of the planar coil elements 41 and 42.
  • the third planar coil element 41 and the fourth planar coil element 42 do not have to be formed in a spiral shape around a common central axis.
  • the central axis of the third planar coil element 41 and the central axis of the fourth planar coil element 42 may or may not coincide with each other. It is sufficient that the central axis of the third planar coil element 41 and the central axis of the fourth planar coil element 42 are parallel to each other.
  • the second central axis C2 may or may not coincide with the first central axis C1.
  • the second central axis C2 may be parallel to the first central axis C2.
  • Each of the planar coil elements 41, 42 is plate-shaped. As shown in FIG. 4, the cross-sectional shape of each of the planar coil elements 41, 42 in a direction perpendicular to the direction in which the planar coil elements 41, 42 rotate in a spiral shape is rectangular.
  • the third planar coil element 41 is disposed opposite the first coil 10.
  • the third planar coil element 41 forms the third surface 40a of the second coil 40.
  • the fourth planar coil element 42 forms the fourth surface 40b of the second coil 40.
  • the fourth planar coil element 42 is disposed opposite the second magnetic shield member 50.
  • the fourth planar coil element 42 is also referred to as the "second shield side planar coil element 42.”
  • the third planar coil element 41 has a conductor 41E having a spiral shape formed by a plurality of turn portions 41n.
  • the plurality of turn portions 41n of the third planar coil element 41 are arranged in a direction perpendicular to the second central axis C2. More specifically, the plurality of turn portions 41n are connected so as to gradually move away from the second central axis C2 toward the radially outward direction of a circle centered on the second central axis C2. This gives the third planar coil element 41 a spiral shape.
  • the fourth planar coil element 42 has a conductor 42E having a spiral shape formed by a plurality of turn portions 42n.
  • the plurality of turn portions 42n of the fourth planar coil element 42 are arranged in a direction perpendicular to the second central axis C2. More specifically, the plurality of turn portions 42n are connected so as to gradually move away from the second central axis C2 toward the radially outward direction of a circle centered on the second central axis C2. This gives the fourth planar coil element 42 a spiral shape.
  • the turn portions 41n, 42n are basically linear conductor portions that do not form a ring but go around the second central axis C2 360 degrees. In the case of a planar coil element, both ends of the turn portions 41n, 42n are offset in the radial direction. In multiple turn portions 41n, 42n, the radially outer end of one turn portion 41n, 42n is connected to the radially inner end of another turn portion 41n, 42n, and the other turn portions 41n, 42n extend away from the second central axis C2.
  • the turn portion 41n of the third planar coil element 41 that is closest to the second central axis C2 may be referred to as the turn portion 411.
  • the turn portion connected to the turn portion 411 may be referred to as the turn portion 412.
  • the turn portions 41n of the third planar coil element 41 are composed of four turn portions 411 to 414. In the following, when describing matters common to each of the turn portions 41n, they are basically referred to as the turn portion 41n.
  • the turn portion 421 the one of the multiple turn portions 42n of the fourth planar coil element 42 that is closest to the second central axis C2 may be referred to as the turn portion 421.
  • the turn portion connected to the turn portion 421 may be referred to as the turn portion 422.
  • the multiple turn portions 42n of the fourth planar coil element 42 are composed of four turn portions 421 to 424. Below, when describing matters common to each of the multiple turn portions 42n, they will basically be referred to as the turn portion 42n.
  • the number of turns of the third planar coil element 41 and the number of turns of the fourth planar coil element 42 are the same. However, the number of turns of the third planar coil element 41 and the number of turns of the fourth planar coil element 42 may be different from each other.
  • the total number of turns of the second coil 40 is the sum of the number of turns of the planar coil elements 41 and 42 included in the second coil 40. Therefore, in the illustrated example, the total number of turns of the second coil 40 is 8.
  • the turn portions 41n, 42n go around in a rectangular shape.
  • the turn portions 41n, 42n may also go around in a circular shape.
  • connection wiring portion 44 shown in FIG. 2 is a conductor and electrically connects the third planar coil element 41 and the fourth planar coil element 42 in series.
  • the connection wiring portion 44 shown in the figure is formed integrally with the turn portion 421 of the fourth planar coil element 42, as an example.
  • the connection wiring portion 44 may be connected to the turn portion 421 by ultrasonic connection or the like.
  • the radially outer end (the end farther from the second central axis C2) of the turn portion 414 of the plurality of turn portions 41n of the third planar coil element 41 that is the furthest from the second central axis C2 is connected to the third connection terminal 73.
  • the radially outer end of the turn portion 424 of the plurality of turn portions 42n of the fourth planar coil element 42 that is the furthest from the second central axis C2 is connected to the fourth connection terminal 74.
  • the third connection terminal 73 and the fourth connection terminal 74 can be used, for example, for connection to an electronic device.
  • the connection between the third connection terminal 73 and the turn portion 414 and the connection between the fourth connection terminal 74 and the turn portion 424 may be performed by ultrasonic bonding.
  • the connection method is not limited, and for example, a connection using a conductive adhesive may be adopted.
  • the radial inward direction of the third planar coil element 41 means the direction approaching the second central axis C2 in the radial direction.
  • the radial outward direction of the third planar coil element 41 means the direction moving away from the second central axis C2 in the radial direction.
  • the radial inward direction of the fourth planar coil element 42 means the direction moving toward the second central axis C2 in the radial direction.
  • the radial outward direction of the fourth planar coil element 42 (turn portion 42n) means the direction moving away from the second central axis C2 in the radial direction.
  • the second central axis C2 of the third planar coil element 41 or the fourth planar coil element 42 is determined as follows. First, linear virtual turn portions similar in shape to the innermost turn portion 411 or 421 are drawn in sequence from the radially inner end of the innermost turn portion 411 or 421 to form a spiral shape radially inward. Drawing is continued until a virtual turn portion that fits within a diameter of 1 cm is drawn. Then, a line that passes through the radially inner region of the virtual turn portion that fits within a diameter of 1 cm in a direction perpendicular to the circumferential and radial directions of the spiral shape is determined as the second central axis C2 of the planar coil element 41 or 42.
  • any one of the multiple turn portions 41n of the third planar coil element 41 and any one of the multiple turn portions 42n of the fourth planar coil element 42 partially overlap in the direction along the second central axis C2.
  • the part of the turn portion 41n of the third planar coil element 41 and the part of the turn portion 42n of the fourth planar coil element 42 that overlap in the direction along the second central axis C2 extend parallel to each other with their respective winding directions aligned.
  • the state in which the winding directions are aligned means that, when viewed in the axial direction of the planar coil elements 41 and 42, the third planar coil element 41 and the fourth planar coil element 42 do not intersect but overlap a certain distance on the same line.
  • the length of a portion of the turn portion 41n of the third planar coil element 41 and the length of a portion of the turn portion 42n of the fourth planar coil element 42, which overlap and extend parallel to each other as described above, may be 1/2 or more, or 3/4 or more, of their respective total lengths.
  • the inventors have found that the greater the proportion of overlap between the third planar coil element 41 and the fourth planar coil element 42 while extending parallel to each other, the more eddy current loss can be suppressed.
  • the radially inner end of the turn portion 411 closest to the second central axis C2 is electrically connected to the fourth planar coil element 42. More specifically, the radially inner end of the turn portion 411 is connected to the inner end of the turn portion 421 in the fourth planar coil element 42 via the connection wiring portion 44.
  • the direction in which the third planar coil element 41 goes around from the end not connected to the fourth planar coil element 42 (the radially outer end of the turn portion 414) to the end connected to the fourth planar coil element 42 is the same as the direction in which the fourth planar coil element 42 goes around from the end connected to the third planar coil element 41 to the end not connected to the third planar coil element 41 (the radially outer end of the turn portion 424). This suppresses an increase in electrical resistance.
  • the thicknesses T41, T42 of the planar coil elements 41, 42 of the second coil 40 may be, for example, 0.1 mm or more and 2.0 mm or less. Therefore, the thicknesses T41, T42 may be 0.15 mm or more, 0.2 mm or more, 0.25 mm or more, 0.3 mm or more, 0.35 mm or more, 0.4 mm or more, 0.45 mm or more, 0.5 mm or more, 0.55 mm or more, or 0.6 mm or more. In addition, the thicknesses T41, T42 may be 1.75 mm or less, 1.5 mm or less, 1.25 mm or less, 1.0 mm or less, 0.75 mm or less, or 0.5 mm or less.
  • the thickness T42 of the second shield side planar coil element (fourth planar coil element) 42 is greater than the thickness T41 of the other planar coil elements (third planar coil element) 41 of the second coil 40, but is not limited to this.
  • the thickness T42 of the second shield side planar coil element 42 may be the same as the thickness T41 of the other planar coil elements 41 of the second coil 40, or may be smaller than the thickness T41 of the other planar coil elements 41 of the second coil 40.
  • the thickness T42 of the second shield side planar coil element 42 may be greater or smaller than the thicknesses T11, T12 of the planar coil elements 11, 12 of the first coil 10, or may be the same as the thicknesses T11, T12 of the planar coil elements 11, 12 of the first coil 10. Therefore, the thickness T42 of the second shield side planar coil element 42 may be greater than or less than the thicknesses T11, T12, T41 of the other planar coil elements 11, 12, 41 of the first coil 10 and the second coil 40, or may be the same as the thicknesses T11, T12, T41 of the other planar coil elements 11, 12, 41.
  • the line width of the planar coil elements 41, 42 (line width of the conductors 41E, 42E), i.e., the radial width (width in the radial direction) of each turn portion 41n, 42n, is not particularly limited.
  • the radial width of the turn portions 41n, 42n may be, for example, 2 mm or more and 20 mm or less, 2 mm or more and 16 mm or less, 2 mm or more and 12 mm or less, or 2 mm or more and 8 mm or less.
  • the number of turns of the second coil 40 is not particularly limited. The number of turns of the second coil 40 may be, for example, 2 to 15 or less, or 5 to 10 or less.
  • the radius of the planar coil elements 41, 42 (the distance from the second central axis C2 to the part farthest in the radial direction) may be 80 mm or more, or may be 80 mm or more and 450 mm or less.
  • the aspect ratio of the planar coil elements 41, 42 (conductors 41E, 42E) having a rectangular cross-sectional shape is determined by dividing the line width (radial width of the turn portions 41n, 42n) of the planar coil elements 41, 42 (conductors 41E, 42E) by the thickness of the planar coil elements 41, 42 (conductors 41E, 42E).
  • the aspect ratio of the planar coil elements 41, 42 (conductors 41E, 42E) may be 2 or more and 12 or less, or may be 3 or more and 10 or less.
  • planar coil elements 41 and 42 are formed by punching a metal plate into a spiral shape.
  • the planar coil elements 41 and 42 can also be formed by etching a metal foil into a spiral shape.
  • the gap between the third planar coil element 41 and the fourth planar coil element 42 may be 0.5 mm or more and 2 mm or less.
  • the gap is not particularly limited, but if the gap is too small, insulation breakdown is likely to occur between the planar coil elements 41 and 42. If the gap is too large, the thinning of the transformer 1 is hindered.
  • the second magnetic shield member 50 is a flat sheet-like member.
  • the second magnetic shield member 50 is disposed facing the fourth surface 40b of the second coil 40.
  • the second magnetic shield member 50 is provided to suppress magnetic transmission and/or leakage magnetic field.
  • the second magnetic shield member 50 has an inner surface 50a facing the second coil 40 and an outer surface 50b opposite to the inner surface 50a.
  • the second magnetic shield member 50 is separate from the second coil 40 and the second magnetic layer 60.
  • the second magnetic shield member 50 being separate from the second coil 40 and the second magnetic layer 60 means that the second magnetic shield member 50 is not integrated with the second coil 40 and the second magnetic layer 60.
  • the second magnetic shield member 50 may be joined to the second magnetic layer 60 via an adhesive layer or the like.
  • the second magnetic shield member 50 is formed to a size that encompasses the second coil 40 when viewed in the first direction D1.
  • the second magnetic shield member 50 overlaps the second coil 40 and the second magnetic layer 60, and is in direct contact with the second magnetic layer 60.
  • the second magnetic shield member 50 in this embodiment is magnetic and contains a magnetic material or is made of a magnetic material. As described above, in the first coil component 2, a magnetic field is generated when a current is supplied to the first coil 10. The magnetic field generated in the first coil component 2 is generated so as to spread in all directions relative to the first central axis C1. At this time, the second magnetic shield member 50 is magnetic, and can orient the spreading magnetic flux lines toward the first central axis C1.
  • the transformer 1 can be incorporated into an electronic device, and if the magnetic field generated by the transformer 1 flows to other components of the electronic device, it may have an adverse effect on those components. In such a case, the second magnetic shield member 50 can suppress leakage magnetic fields that do not contribute to the generation of current.
  • the second magnetic shield member 50 preferably includes a soft magnetic material or a nanocrystalline magnetic material. More specifically, the second magnetic shield member 50 includes ferrite, preferably soft ferrite. The second magnetic shield member 50 may include flat ferrite. More specifically, the second magnetic shield member 50 may be configured by arranging a plurality of flat ferrite plates in a sheet shape.
  • the relative permeability of the second magnetic shield member 50 may be 500 or more, or 1000 or more.
  • the relative permeability of the second magnetic shield member 50 may be 500 or more and 3000 or less, or 1000 or more and 3000 or less.
  • the thickness of the second magnetic shield member 50 may be, for example, 0.5 mm or more and 5 mm or less.
  • the distance between the outer periphery of the second magnetic shield member 50 and the outer periphery of the second coil 40 may be 0.5 mm or more and 10 mm or less.
  • the distance between the second magnetic shield member 50 and the second coil 40 i.e., the distance between the inner surface 50a of the second magnetic shield member 50 and the fourth surface 40b of the second coil 40
  • the second core member 68 is disposed on the inner surface 50a of the second magnetic shield member 50.
  • the second core member 68 extends along the first direction D1 within a region surrounded by the innermost turn portions 411, 421 of the second coil 40.
  • the second core member 68 penetrates the second magnetic layer 60.
  • the second core member 68 preferably includes a soft magnetic material or a nanocrystalline magnetic material. More specifically, the second core member 68 includes a ferrite, preferably a soft ferrite.
  • the relative permeability of the second core member 68 may be 500 or more, or 1000 or more.
  • the relative permeability of the second core member 68 may be 500 or more and 3000 or less, or 1000 or more and 3000 or less.
  • the presence of the second core member 68 improves the flow of magnetic flux within the transformer 1.
  • the second magnetic layer 60 has magnetic properties. As shown in Fig. 4, at least a portion of the second magnetic layer 60 is disposed between the second coil 40 and the second magnetic shield member 50, and covers the fourth surface 40b of the second coil 40.
  • the second magnetic layer 60 has a seventh surface 60a facing the first coil component 2, and an eighth surface 60b opposite to the seventh surface 60a.
  • the second coil 40 is embedded in the second magnetic layer 60.
  • the second magnetic layer 60 holds the third planar coil element 41 and the fourth planar coil element 42 together. More specifically, the second magnetic layer 60 covers the fourth surface 40b of the second coil 40 and fills the gap between the third planar coil element 41 and the fourth planar coil element 42. The second magnetic layer 60 fills the gap between the third planar coil element 41 and the fourth planar coil element 42, thereby covering the surface of the third planar coil element 41 facing the fourth planar coil element 42. The second magnetic layer 60 does not cover the third surface 40a of the second coil 40.
  • the second magnetic layer 60 has a third portion 61 and a fourth portion 62.
  • the third portion 61 and the fourth portion 62 are formed integrally without any seams.
  • the third portion 61 and the fourth portion 62 are formed to a size sufficient to encompass the entire second coil 40 when viewed in the first direction D1.
  • the fourth portion 62 covers the fourth surface 40b of the second coil 40.
  • the fourth portion 62 forms the eighth surface 60b of the second magnetic layer 60.
  • the fourth portion 62 contacts the second magnetic shield member 50.
  • the fourth portion 62 also covers the side surface of the fourth planar coil element 42.
  • the third portion 61 is interposed between the third planar coil element 41 and the fourth planar coil element 42. That is, the third portion 61 fills the gap between the third planar coil element 41 and the fourth planar coil element 42.
  • the third portion 61 also covers the side surface of the third planar coil element 41.
  • the third portion 61 forms the seventh surface 60a of the second magnetic layer 60. In the illustrated example, the seventh surface 60a and the third surface 40a of the second coil 40 are flush with each other.
  • a gap is formed between the second magnetic layer 60 and the first magnetic layer 30.
  • a layer of air is interposed between the second magnetic layer 60 and the first magnetic layer 30.
  • other layers may be disposed between the second magnetic layer 60 and the first magnetic layer 30.
  • an additional magnetic layer may be disposed between the second magnetic layer 60 and the first magnetic layer 30.
  • the additional magnetic layer may be formed integrally with the first magnetic layer 30 and the second magnetic layer 60.
  • the second magnetic layer 60 is magnetic as a whole. That is, the third portion 61 and the fourth portion 62 are each magnetic.
  • the second magnetic layer 60 suppresses eddy current loss and leakage flux through magnetism, and increases the coupling coefficient, thereby improving coil performance.
  • the relative permeability of the second magnetic layer 60 is preferably 2.0 or more, and may be 2.0 or more and 10.0 or less.
  • the relative permeability of the second magnetic layer 60 is more preferably 5.0 or more, and may be 5.0 or more and 10.0 or less.
  • the relative permeability of the second magnetic layer 60 is not particularly limited, but if it is too large, the flexibility and strength of the second magnetic layer 60 may be undesirably impaired. Therefore, the relative permeability of the second magnetic layer 60 may be 200 or less.
  • the second wall portion 65 protrudes from the seventh surface 60a of the second magnetic layer 60 in the direction opposite to the first direction D1.
  • the second wall portion 65 has a spiral shape when viewed in the first direction D1, and extends along the third planar coil element 41.
  • the second wall portion 65 is seamlessly and integrally formed with the second magnetic layer 60.
  • the second wall portion 65 is also magnetic.
  • the second coil component 3 has the second wall portion 65, which can effectively improve the coil performance.
  • the relative permeability of the second wall portion 65 is preferably 2.0 or more, and may be 2.0 or more and 10.0 or less.
  • the relative permeability of the second wall portion 65 is more preferably 5.0 or more, and may be 5.0 or more and 10.0 or less.
  • the relative permeability of the second wall portion 65 is not particularly limited, but if it is too large, the flexibility and strength of the second wall portion 65 may be undesirably impaired. Therefore, the relative permeability of the second wall portion 65 may be 200 or less.
  • the height of the second wall portion 65 is not particularly limited, but may be, for example, 0.5 mm or more, or 1.0 mm or more.
  • the height of the second wall portion 65 the more effectively the proximity effect between the adjacent turn portions 41n or 42n of the second coil 40 can be suppressed, and the more effectively the increase in the resistance of the second coil 40 can be suppressed.
  • the greater the height of the second wall portion 65 the more likely the second wall portion 65 is to be damaged starting from its base. Therefore, the height of the second wall portion 65 may be, for example, 10 mm or less. Note that the second coil component 3 does not have to have the second wall portion 65.
  • the second magnetic layer 60 and the second wall portion 65 may be formed of the same or similar material as the first magnetic layer 30 and the first wall portion 35.
  • the thickness T11 of the first shield-side planar coil element 11 may be the same as the thicknesses T12, T41, T42 of the other planar coil elements 12, 41, 42 of the first coil 10 and the second coil 40. Also, the thickness T11 of the first shield-side planar coil element 11 may be larger or smaller than the thicknesses T12, T41, T42 of the other planar coil elements 12, 41, 42 of the first coil 10 and the second coil 40. Also, the thickness T42 of the second shield-side planar coil element 42 may be the same as the thicknesses T11, T12, T41 of the other planar coil elements 11, 12, 41 of the first coil 10 and the second coil 40. Also, the thickness T42 of the second shield-side planar coil element 42 may be larger or smaller than the thicknesses T11, T12, T41 of the other planar coil elements 11, 12, 41 of the first coil 10 and the second coil 40.
  • the present inventor has found the following. That is, in this case, regardless of the frequency of the AC current supplied to the first coil 10, the Q value of the transformer 1 tends to improve as the thickness T12 of the planar coil elements 12 of the first coil 10 other than the first shield side planar coil element 11 increases.
  • the Q value of the transformer 1 in which the thickness T12 of the planar coil elements 12 of the first coil 10 other than the first shield side planar coil element 11 is 0.15 mm or more tends to be higher than the Q value of the transformer 1 in which the thickness T12 of the planar coil elements 12 of the first coil 10 other than the first shield side planar coil element 11 is less than 0.15 mm.
  • the present inventor has found the following. That is, in this case, regardless of the frequency of the AC current supplied to the first coil 10, the Q value of the transformer 1 tends to improve as the thickness T41 of the planar coil elements 41 of the second coil 40 other than the second shield side planar coil elements 42 increases.
  • the Q value of the transformer 1 in which the thickness T41 of the planar coil elements 41 of the second coil 40 other than the second shield side planar coil elements 42 is 0.15 mm or more tends to be higher than the Q value of the transformer 1 in which the thickness T41 of the planar coil elements 41 of the second coil 40 other than the second shield side planar coil elements 42 is less than 0.15 mm.
  • the inventors have found the following when the distance between the second surface 10b of the first coil 10 and the third surface 40a of the second coil 40 is greater than 10 mm and the frequency of the AC current supplied to the first coil 10 is greater than 1 MHz. That is, in this case, the Q value of the transformer 1 tends to improve as the thickness T12 of the planar coil elements 12 of the first coil 10 other than the first shield side planar coil element 11 increases.
  • the Q value of the transformer 1 in which the thickness T12 of the planar coil elements 12 of the first coil 10 other than the first shield side planar coil element 11 is 0.15 mm or more tends to be higher than the Q value of the transformer 1 in which the thickness T12 of the planar coil elements 12 of the first coil 10 other than the first shield side planar coil element 11 is less than 0.15 mm.
  • the inventors have found the following when the distance between the second surface 10b of the first coil 10 and the third surface 40a of the second coil 40 is greater than 10 mm and the frequency of the AC current supplied to the first coil 10 is greater than 1 MHz. That is, in this case, the Q value of the transformer 1 tends to improve as the thickness T41 of the planar coil elements 41 of the second coil 40 other than the second shield side planar coil elements 42 increases.
  • the Q value of the transformer 1 in which the thickness T41 of the planar coil elements 41 of the second coil 40 other than the second shield side planar coil elements 42 is 0.15 mm or greater tends to be higher than the Q value of the transformer 1 in which the thickness T41 of the planar coil elements 41 of the second coil 40 other than the second shield side planar coil elements 42 is less than 0.15 mm.
  • the inventors have found the following.
  • the Q value of the transformer 1 in which the thickness T12 of the planar coil elements 12 of the first coil 10 other than the first shield-side planar coil element 11 is greater than or equal to 0.15 mm and less than or equal to 0.25 mm tends to be higher than the Q value of the transformer 1 in which the thickness T12 of the planar coil elements 12 of the first coil 10 other than the first shield-side planar coil element 11 is less than 0.15 mm or greater than 0.25 mm.
  • the inventors have found the following.
  • the Q value of the transformer 1 in which the thickness T41 of the planar coil elements 41 of the second coil 40 other than the second shield-side planar coil element 42 is greater than or equal to 0.15 mm and less than or equal to 0.25 mm tends to be higher than the Q value of the transformer 1 in which the thickness T41 of the planar coil elements 41 of the second coil 40 other than the second shield-side planar coil element 42 is less than 0.15 mm or greater than 0.25 mm.
  • the inventors have confirmed through experiments and simulations that these tendencies occur under conditions that assume at least the radial widths (2 mm to 20 mm) of the turn portions 11n, 12n, 41n, and 42n exemplified above and the number of turns (2 to 12) of the first coil 10 and the second coil 40.
  • the present disclosure is not limited to the conditions exemplified in the embodiments. In other words, these tendencies can occur without being limited by dimensions other than the thickness of the planar coil element or the number of turns of each coil 10, 40.
  • Fig. 5 is a perspective view of the transformer 100 according to the second embodiment.
  • Fig. 6 is an exploded perspective view of the transformer 100 shown in Fig. 5.
  • Fig. 7 is a cross-sectional view of the transformer 100 shown in Fig. 5.
  • Components in the second embodiment that are the same as those in the first embodiment are given the same reference numerals, and duplicated descriptions will be omitted.
  • the transformer 100 has a first coil 10, a second coil 140, a magnetic shielding member 20, and a magnetic layer 130.
  • the first coil 10 and the second coil 140 are not electrically connected to each other.
  • the magnetic shielding member 20, the first coil 10, and the second coil 140 are stacked in this order in the first direction D1.
  • the transformer 100 further includes a wall portion 135 and a core member 138.
  • the frequency of the AC current supplied to the first coil 10 of the transformer 100 according to the second embodiment described below is not particularly limited.
  • the first coil 10 may be supplied with an AC current of 10 kHz or more.
  • the first coil 10 may be supplied with an AC current of 75 kHz to 100 kHz or less, or an AC current of 79 kHz to 90 kHz or less, or an AC current of 85 kHz.
  • the first coil 10 may also be supplied with an AC current of 80 kHz to 500 kHz or less.
  • the first coil 10 may also be supplied with an AC current of 1 MHz or less, or an AC current of more than 1 MHz.
  • the second coil 140 is made of a conductive material.
  • the second coil 140 may be made of copper, a copper alloy, aluminum, or an aluminum alloy.
  • the second coil 140 is disposed opposite the second surface 10b of the first coil 10.
  • the second coil 140 has a third surface 140a facing the first coil 10 and a fourth surface 140b opposite the third surface 140a.
  • the second coil 140 overlaps the first coil 10 with a gap therebetween.
  • the second coil 140 is spaced apart from the first coil 10 in the first direction D1.
  • the distance between the second coil 140 and the first coil 10 i.e., the distance between the third surface 140a of the second coil 140 and the second surface 10b of the first coil 10) is not particularly limited, but may be 0.5 mm or more and 10 mm or less. If the gap is too small, insulation breakdown is more likely to occur between the coils 10 and 140. Also, if the gap is too large, the thinning of the transformer is impaired.
  • the second coil 140 includes at least one planar coil element.
  • the second coil 140 includes a third planar coil element 141.
  • the second coil 140 may include multiple planar coil elements, similar to the second coil 40 of the first embodiment.
  • the third planar coil element 141 has a spiral shape.
  • the third planar coil element 141 is formed in a spiral shape around a second central axis C2 extending along the first direction D1, as shown in Figures 5 and 6.
  • the third planar coil element 141 is plate-shaped. As shown in FIG. 7, the cross-sectional shape of the third planar coil element 141 in a direction perpendicular to the direction in which the third planar coil element 141 winds around in a spiral shape is rectangular.
  • One surface of the third planar coil element 141 forms the third surface 140a of the second coil 140.
  • the other surface of the third planar coil element 141 forms the fourth surface 140b of the second coil 140.
  • the third planar coil element 141 has a conductor 141E having a spiral shape formed by a plurality of turn portions 141n.
  • the plurality of turn portions 141n of the third planar coil element 141 are arranged in a direction perpendicular to the second central axis C2. More specifically, the plurality of turn portions 141n are connected so as to gradually move away from the second central axis C2 toward the radially outward direction of a circle centered on the second central axis C2. This gives the third planar coil element 141 a spiral shape.
  • the turn portion 141n is basically a linear conductor portion that does not form a ring but goes around the second central axis C2 360 degrees. In the case of a planar coil element, both ends of the turn portion 141n are offset in the radial direction. In a case of multiple turn portions 141n, the radially outer end of one turn portion 141n is connected to the radially inner end of another turn portion 141n, and the other turn portions 141n extend away from the second central axis C2.
  • the turn portion 141n of the third planar coil element 141 that is closest to the second central axis C2 is also referred to as the turn portion 1411.
  • the turn portion connected to the turn portion 1411 is also referred to as the turn portion 1412.
  • the turn portions 141n of the third planar coil element 141 are composed of five turn portions 1411 to 1415. In the following, when describing matters common to each of the turn portions 141n, they are basically referred to as the turn portion 141n.
  • the number of turns of the third planar coil element 141 is 5.
  • the total number of turns of the second coil 140 is the sum of the number of turns of the planar coil elements 141 included in the second coil 140. Therefore, in the illustrated example, the total number of turns of the second coil 140 is 5.
  • the turn portion 141n goes around in a rectangular shape.
  • the turn portion 141n may also go around in a circular shape.
  • the radially inner end (the end closest to the second central axis C2) of the turn portion 1411 closest to the second central axis C2 of the third planar coil element 141 is connected to the third connection terminal 73.
  • the radially outer end (the end away from the second central axis C2) of the turn portion 1415, which is the furthest from the second central axis C2 among the multiple turn portions 141n of the third planar coil element 141, is connected to the third connection terminal 73.
  • the second central axis C2 of the third planar coil element 141 may be determined in a manner similar to that for the first central axis C1 of the third planar coil element 41 of the first embodiment.
  • any one of the multiple turn portions 141n of the third planar coil element 141 partially overlaps any one of the multiple turn portions 11n, 12n of the first planar coil element 11 and the second planar coil element 12 in the direction along the central axes C1, C2.
  • the part of the turn portion 141n of the third planar coil element 141 and the part of the multiple turn portions 11n, 12n of the first planar coil element 11 and the second planar coil element 12 that overlap in the direction along the central axes C1, C2 extend parallel to each other with their respective winding directions aligned.
  • the state where the winding directions are aligned means that, when viewed in the axial direction of the planar coil elements 11, 12, and 141, the third planar coil element 141 does not intersect with the first planar coil element 11 and the second planar coil element 12, but overlaps by a certain distance on the same line.
  • the length of a portion of the turn portion 141n of the third planar coil element 141 and the length of a portion of the multiple turn portions 11n, 12n of the first planar coil element 11 and the second planar coil element 12, which overlap and extend parallel to each other as described above, may be 1/2 or more, or 3/4 or more, of the respective total lengths.
  • the present inventors have found that the greater the proportion of overlap between the third planar coil element 141 and the first and second planar coil elements 11 and 12 extending parallel to each other, the more eddy current loss can be suppressed.
  • the thickness T141 of the planar coil element 141 of the second coil 140 may be, for example, 0.1 mm or more and 2.0 mm or less. Therefore, the thickness T141 may be 0.15 mm or more, 0.2 mm or more, 0.25 mm or more, 0.3 mm or more, 0.35 mm or more, 0.4 mm or more, 0.45 mm or more, 0.5 mm or more, 0.55 mm or more, or 0.6 mm or more. In addition, the thickness T141 may be 1.75 mm or less, 1.5 mm or less, 1.25 mm or less, 1.0 mm or less, 0.75 mm or less, or 0.5 mm or less.
  • the thickness T141 of the planar coil element 141 of the second coil 140 is smaller than the thickness T11 of the first shield side planar coil element (first planar coil element) 11, but is not limited to this.
  • the thickness T141 of the planar coil element 141 of the second coil 140 may be the same as the thickness T11 of the first shield side planar coil element 11, or may be larger than the thickness T11 of the first shield side planar coil element 11.
  • the line width of the third planar coil element 141 (line width of the conductor 141E), i.e., the radial width (width in the radial direction) of each turn portion 141n, is not particularly limited.
  • the radial width of the turn portion 141n may be, for example, 2 mm or more and 20 mm or less, 2 mm or more and 16 mm or less, 2 mm or more and 12 mm or less, or 2 mm or more and 8 mm or less.
  • the number of turns of the second coil 140 is not particularly limited. The number of turns of the second coil 140 may be, for example, 2 to 15 or less, or 5 to 10 or less.
  • the radius of the planar coil element 141 (the distance from the second central axis C2 to the part farthest in the radial direction) may be 80 mm or more, or may be 80 mm or more and 450 mm or less.
  • the aspect ratio of the planar coil element 141 (conductor 141E) having a rectangular cross-sectional shape is determined by dividing the line width (radial width of the turn portion 141n) of the planar coil element 141 (conductor 141E) by the thickness of the planar coil element 141 (conductor 141E).
  • the aspect ratio of the planar coil element 141 (conductor 141E) may be 2 or more and 12 or less, or may be 3 or more and 10 or less.
  • planar coil element 141 is formed by punching a metal plate into a spiral shape.
  • the planar coil element 141 can also be formed by etching a metal foil into a spiral shape.
  • the fourth surface 140b of the second coil 140 does not face the magnetic shielding member.
  • the transformer 100 does not have a magnetic shielding member that faces the fourth surface 140b of the second coil 140.
  • the core member 138 is disposed on the inner surface 20b of the first magnetic shield member 20.
  • the core member 138 extends along the first direction D1 within a region surrounded by the innermost turn portions 111, 121, and 1411 of the coils 10 and 140.
  • the core member 138 penetrates the magnetic layer 130. The presence of the core member 138 improves the passage of magnetic flux within the transformer 100.
  • the core member 138 preferably comprises a soft magnetic material or a nanocrystalline magnetic material. More specifically, the core member 138 comprises a ferrite, preferably a soft ferrite.
  • the relative magnetic permeability of the core member 138 may be 500 or more, or 1000 or more.
  • the relative magnetic permeability of the core member 138 may be 500 or more and 3000 or less, or 1000 or more and 3000 or less.
  • the magnetic layer 130 is disposed between the first coil 10 and the magnetic shield member 20 and covers the first surface 10a of the first coil 10.
  • the magnetic layer 130 has a fifth surface 130a facing the magnetic shield member 20 and a sixth surface 130b opposite to the fifth surface 130a.
  • the first coil 10 is embedded in the magnetic layer 130.
  • the magnetic layer 130 holds the first planar coil element 11 and the second planar coil element 12 together. More specifically, the magnetic layer 130 covers the first surface 10a of the first coil 10.
  • the magnetic layer 130 fills the gap between the first planar coil element 11 and the second planar coil element 12. In other words, at least a portion of the magnetic layer 130 is disposed between the first coil 10 and the second coil 140.
  • the magnetic layer 130 fills the gap between the first planar coil element 11 and the second planar coil element 12, thereby covering the surface of the second planar coil element 12 facing the first planar coil element 11.
  • the second coil 140 is embedded in the magnetic layer 130.
  • the magnetic layer 130 holds the first coil 10 and the second coil 140 together. More specifically, the magnetic layer 130 fills the gap between the second planar coil element 12 and the third planar coil element 141. By filling the gap between the second planar coil element 12 and the third planar coil element 141, the magnetic layer 130 covers the surface of the third planar coil element 141 that faces the first coil 10. The magnetic layer 130 does not cover the fourth surface 140b of the second coil 140.
  • the magnetic layer 130 has a first portion 31, a second portion 32, and a third portion 133.
  • the first portion 31, the second portion 32, and the third portion 133 are formed integrally without any seams.
  • the first portion 31, the second portion 32, and the third portion 133 are formed to a size sufficient to encompass the entire first coil 10 when viewed in the first direction D1.
  • the third portion 133 is interposed between the first coil 10 and the second coil 140. That is, the third portion 133 fills the gap between the first coil 10 and the second coil 140.
  • the third portion 133 also covers the side surface of the third planar coil element 141.
  • the third portion 133 forms the sixth surface 130b of the magnetic layer 30. In the illustrated example, the sixth surface 130b and the fourth surface 140b of the second coil 140 are flush with each other.
  • the magnetic layer 130 as a whole is magnetic.
  • the relative permeability of the magnetic layer 130 is preferably 2.0 or more, similar to the first magnetic layer 30 of the first embodiment, and may be 2.0 or more and 10.0 or less.
  • the relative permeability of the magnetic layer 130 is more preferably 5.0 or more, and may be 5.0 or more and 10.0 or less.
  • the relative permeability of the magnetic layer 130 may be 200 or less.
  • the wall portion 135 protrudes in the first direction D1 from the sixth surface 130b of the magnetic layer 130.
  • the wall portion 135 has a spiral shape when viewed in the first direction D1, and extends along the third planar coil element 141.
  • the wall portion 135 is seamlessly and integrally formed with the magnetic layer 130.
  • the wall portion 135 is magnetic.
  • the relative permeability of the wall portion 135 is preferably 2.0 or more, and may be 2.0 or more and 10.0 or less, similar to the first wall portion 35 of the first embodiment.
  • the relative permeability of the wall portion 135 is more preferably 5.0 or more, and may be 5.0 or more and 10.0 or less.
  • the relative permeability of the wall portion 135 may be 200 or less.
  • the height of the wall portion 135 is not particularly limited, similar to the first wall portion 35 of the first embodiment, and may be, for example, 0.5 mm or more, or 1.0 mm or more.
  • the magnetic layer 130 and wall portion 135 in this embodiment may be formed of the same or similar material as the first magnetic layer 30 and first wall portion 35 in the first embodiment.
  • the thickness T11 of the first shield-side planar coil element 11 may be the same as the thicknesses T12, T141 of the other planar coil elements 12, 141 of the first coil 10 and the second coil 140.
  • the thickness of the first shield-side planar coil element 11 may be greater or smaller than the thicknesses T12, T141 of the other planar coil elements 12, 141 of the first coil 10 and the second coil 140.
  • the inventors when an AC current of 75 kHz or more and 100 kHz or less is supplied to the first coil 10, the inventors have found the following. That is, in this case, the Q value of the transformer 100 in which the thickness T11 of the first shield side planar coil element 11 is greater than the thicknesses T12, T141 of the other planar coil elements 12, 141 of the first coil 10 and the second coil 140 tends to be higher than the Q value of the transformer 100 in which the thickness T11 of the first shield side planar coil element 11 is the same as or smaller than the thicknesses T12, T141 of the other planar coil elements 12, 141 of the first coil 10 and the second coil 140.
  • Performance evaluation simulation of transformer 1 >> The results of performance evaluation of the transformer 1 according to the first embodiment will be described below.
  • the thickness of each planar coil element included in the transformer 1 and the frequency of the AC current supplied to the first coil 10 were changed to various values, and the Q value was calculated. Specifically, the Q value was calculated from a simulation. The simulation was performed using Femtet (registered trademark) manufactured by Murata Software Co., Ltd.
  • the common conditions in the first simulation are as follows.
  • the distance between the first coil 10 and the second coil 40 is small, being 8.5 mm.
  • the first coil 10 has a first shield-side planar coil element (first planar coil element) 11 and a second planar coil element 12 .
  • the second coil 40 has a third planar coil element 41 and a second shield-side planar coil element (fourth planar coil element) 42 .
  • Each planar coil element is made of copper.
  • the number of turns of each of the first shield-side planar coil element (first planar coil element) 11 and the second planar coil element 12 is 4.5. Therefore, the total number of turns of the first coil 10 is 9 (see FIG. 8 ).
  • the number of turns of each of the second shield-side planar coil element (fourth planar coil element) 42 and the third planar coil element 41 is 3.5. Therefore, the total number of turns of the second coil 40 is 7 (see FIG. 9 ).
  • the relative magnetic permeability of the first magnetic shield member 20, the second magnetic shield member 50, the first core member 38 and the second core member 68 is all 3000.
  • the first magnetic layer 30, the second magnetic layer 60, the first wall portion 35, and the second wall portion 65 all have a relative magnetic permeability of 5.0.
  • the input current value of the high frequency current supplied to the first coil 10 is 50A.
  • the frequencies of the high-frequency current supplied to the first coil 10 are 20 kHz, 40 kHz, 60 kHz, 80 kHz, 85 kHz, 100 kHz, 125 kHz, 150 kHz, 200 kHz, 400 kHz, 600 kHz, 800 kHz, 1 MHz, 6.78 MHz, and 13.56 MHz.
  • the individual conditions for the thicknesses T11, T12, T41, and T42 of the planar coil elements 11, 12, 41, and 42 included in the coils 10 and 40 of the transformer 1 that is the subject of the first simulation are as follows.
  • Condition 1 The thicknesses T11 and T42 of the first shield-side planar coil element (first planar coil element) 11 and the second shield-side planar coil element (fourth planar coil element) 42 are each 0.5 mm.
  • the thicknesses T12 and T41 of the second planar coil element 12 and the third planar coil element 41 are each 0.1 mm (Cu0.5_0.1).
  • Condition 2 The thicknesses T11 and T42 of the first shield-side planar coil element (first planar coil element) 11 and the second shield-side planar coil element (fourth planar coil element) 42 are each 0.5 mm.
  • the thicknesses T12 and T41 of the second planar coil element 12 and the third planar coil element 41 are each 0.15 mm (Cu0.5_0.15).
  • Condition 3 The thicknesses T11 and T42 of the first shield-side planar coil element (first planar coil element) 11 and the second shield-side planar coil element (fourth planar coil element) 42 are each 0.5 mm.
  • the thicknesses T12 and T41 of the second planar coil element 12 and the third planar coil element 41 are each 0.25 mm (Cu0.5_0.25).
  • the thicknesses T11 and T42 of the first shield-side planar coil element (first planar coil element) 11 and the second shield-side planar coil element (fourth planar coil element) 42 are each 0.5 mm.
  • the thicknesses T12 and T41 of the second planar coil element 12 and the third planar coil element 41 are each 0.5 mm (Cu0.5_0.5).
  • Figures 10 and 11 show the Q value of transformer 1 obtained by the first simulation.
  • the line indicated by the symbol S1 shows the results for condition 1 (Cu0.5_0.1)
  • the line indicated by the symbol S2 shows the results for condition 2 (Cu0.5_0.15)
  • the line indicated by the symbol S3 shows the results for condition 3 (Cu0.5_0.25)
  • the line indicated by the symbol S4 shows the results for condition 4 (Cu0.5_0.5).
  • the Q value of the transformer 1 tends to improve as the thickness T12 of the planar coil elements 12 of the first coil 10 other than the first shield side planar coil element 11 increases, regardless of the frequency of the AC current supplied to the first coil 10. More specifically, it can be seen that the Q value of the transformer 1 in which the thickness T12 of the planar coil elements 12 of the first coil 10 other than the first shield side planar coil element 11 is 0.15 mm or more tends to be higher than the Q value of the transformer 1 in which the thickness T12 of the planar coil elements 12 of the first coil 10 other than the first shield side planar coil element 11 is less than 0.15 mm. Also, it can be seen from FIGS.
  • the Q value of the transformer 1 tends to improve as the thickness T41 of the planar coil elements 41 of the second coil 40 other than the second shield side planar coil element 42 increases, regardless of the frequency of the AC current supplied to the first coil 10. More specifically, it is understood that the Q value of a transformer 1 in which the thickness T41 of the planar coil elements 41 of the second coil 40 other than the second shield side planar coil element 42 is 0.15 mm or more tends to be higher than the Q value of a transformer 1 in which the thickness T41 of the planar coil elements 41 of the second coil 40 other than the second shield side planar coil element 42 is less than 0.15 mm.
  • the distance between the first coil 10 and the second coil 40 is large, being 16 mm.
  • the other conditions of the second simulation are the same as those of the first simulation. Therefore, the conditions 1 to 4 of the second simulation are as follows: Condition 1: the first shield-side planar coil element (first planar coil element) 11 and the second shield-side planar coil element (fourth planar coil element) 42 each have a thickness of 0.5 mm.
  • the second planar coil element 12 and the third planar coil element 41 each have a thickness of 0.1 mm (Cu0.5_0.1).
  • Condition 2 the first shield-side planar coil element (first planar coil element) 11 and the second shield-side planar coil element (fourth planar coil element) 42 each have a thickness of 0.5 mm.
  • the second planar coil element 12 and the third planar coil element 41 each have a thickness of 0.15 mm (Cu0.5_0.15).
  • Condition 3 the first shield-side planar coil element (first planar coil element) 11 and the second shield-side planar coil element (fourth planar coil element) 42 each have a thickness of 0.5 mm.
  • the second planar coil element 12 and the third planar coil element 41 each have a thickness of 0.25 mm (Cu0.5_0.25).
  • the first shield-side planar coil element (first planar coil element) 11 and the second shield-side planar coil element (fourth planar coil element) 42 each have a thickness of 0.5 mm.
  • the second planar coil element 12 and the third planar coil element 41 each have a thickness of 0.5 mm (Cu0.5_0.5).
  • Figures 12 and 13 show the Q value of transformer 1 obtained by the second simulation.
  • the line indicated by the symbol S1 shows the results for condition 1 (Cu0.5_0.1)
  • the line indicated by the symbol S2 shows the results for condition 2 (Cu0.5_0.15)
  • the line indicated by the symbol S3 shows the results for condition 3 (Cu0.5_0.25)
  • the line indicated by the symbol S4 shows the results for condition 4 (Cu0.5_0.5).
  • the Q value of the transformer 1 tends to improve as the thickness T12 of the planar coil elements 12 of the first coil 10 other than the first shield side planar coil element 11 increases. More specifically, it is understood that the Q value of the transformer 1 in which the thickness T12 of the planar coil elements 12 of the first coil 10 other than the first shield side planar coil element 11 is 0.15 mm or more tends to be higher than the Q value of the transformer 1 in which the thickness T12 of the planar coil elements 12 of the first coil 10 other than the first shield side planar coil element 11 is less than 0.15 mm.
  • the Q value of the transformer 1 tends to improve as the thickness T41 of the planar coil elements 41 of the second coil 40 other than the second shield side planar coil element 42 increases. More specifically, it is understood that the Q value of a transformer 1 in which the thickness T41 of the planar coil elements 41 of the second coil 40 other than the second shield side planar coil element 42 is 0.15 mm or more tends to be higher than the Q value of a transformer 1 in which the thickness T41 of the planar coil elements 41 of the second coil 40 other than the second shield side planar coil element 42 is less than 0.15 mm.
  • the Q value of the transformer 1 in which the thickness T41 of the planar coil elements 41 of the second coil 40 other than the second shield side planar coil element 42 is 0.15 mm or more and 0.25 mm or less tends to be higher than the Q value of the transformer 1 in which the thickness T41 of the planar coil elements 41 of the second coil 40 other than the second shield side planar coil element 42 is less than 0.15 mm or more than 0.25 mm.
  • Performance evaluation simulation of transformer 100 The results of performance evaluation of the transformer 100 according to the second embodiment will be described below.
  • the Q value, loss, impedance, inductance, and coupling coefficient were calculated by simulation.
  • the simulation was performed using Femtet (registered trademark) manufactured by Murata Software Co., Ltd.
  • each planar coil element is made of copper.
  • the first magnetic shield member 20, the second magnetic shield member 50, and the core member 138 all have a relative magnetic permeability of 3,000.
  • the magnetic layer 130 and the wall portion 135 each have a relative magnetic permeability of 5.0.
  • FIG. 14 shows a perspective view of the first coil 10 and second coil 140 of the transformer 100 under conditions 1 and 2.
  • FIG. 15 shows a perspective view of the first coil 10 and second coil 140 of the transformer 100 under conditions 3 to 6.
  • FIG. 16 shows a perspective view of the first coil 10 and second coil 140 of the transformer 100 under conditions 7 to 9.
  • the input current value of the high frequency current supplied to the first coil 10 is 50 A, and the frequency is 85 kHz.
  • a high-frequency current of 25 A is input as a current value flowing through the second coil 140 by electromagnetic induction.
  • the first coil 10 has a shield-side planar coil element (first planar coil element) 11 and a second planar coil element 12.
  • the number of turns of each of the shield-side planar coil element 11 and the second planar coil element 12 is 4.5. Therefore, the total number of turns of the first coil 10 is 9.
  • Second coil 140 has third planar coil element 141.
  • the number of turns in third planar coil element 141 is 5. Therefore, the total number of turns in second coil 140 is 5.
  • the thickness T11 of the shield-side planar coil element (first planar coil element) 11 is 0.5 mm. (Other conditions of condition 1) The thicknesses T12, T141 of the planar coil elements 12, 141 other than the shield-side planar coil element (first planar coil element) 11 are 0.25 mm. (Other conditions of condition 2) The thicknesses T12, T141 of the planar coil elements 12, 141 other than the shield-side planar coil element (first planar coil element) 11 are 0.5 mm.
  • the first coil 10 has a shield-side planar coil element (first planar coil element) 11.
  • the number of turns of the shield-side planar coil element 11 is 5. Therefore, the total number of turns of the first coil 10 is 5.
  • Second coil 140 has third planar coil element 141 and fourth planar coil element 142.
  • the number of turns of third planar coil element 141 and fourth planar coil element 142 is both 4.5. Therefore, the total number of turns of second coil 140 is 9.
  • the input current value of the high frequency current supplied to the first coil 10 is 50 A, and the frequency is 85 kHz.
  • a high-frequency current of 25 A is input as a current value flowing through the second coil 140 by electromagnetic induction.
  • the thickness T11 of the shield-side planar coil element (first planar coil element) 11 is 0.5 mm.
  • the thicknesses T141, T142 of the planar coil elements 141, 142 other than the shield-side planar coil element (first planar coil element) 11 are 0.25 mm. (Other conditions of condition 4)
  • the input current value of the high frequency current supplied to the first coil 10 is 25 A, and the frequency is 85 kHz.
  • a high-frequency current of 50 A is input as a current value flowing through the second coil 140 by electromagnetic induction.
  • the thickness T11 of the shield-side planar coil element (first planar coil element) 11 is 0.5 mm.
  • the thicknesses T141, T142 of the planar coil elements 141, 142 other than the shield-side planar coil element (first planar coil element) 11 are also 0.5 mm. (Other conditions of condition 5)
  • the input current value of the high frequency current supplied to the first coil 10 is 50 A, and the frequency is 85 kHz.
  • a high-frequency current of 25 A is input as a current value flowing through the second coil 140 by electromagnetic induction.
  • the thickness T11 of the shield-side planar coil element (first planar coil element) 11 is 0.25 mm.
  • the thicknesses T141, T142 of the planar coil elements 141, 142 other than the shield-side planar coil element (first planar coil element) 11 are also 0.25 mm.
  • the input current value of the high frequency current supplied to the first coil 10 is 50 A, and the frequency is 85 kHz.
  • a high-frequency current of 25 A is input as a current value flowing through the second coil 140 by electromagnetic induction.
  • the thickness T11 of the shield-side planar coil element (first planar coil element) 11 is 0.25 mm.
  • the thickness T141 of the third planar coil element 141 is 0.25 mm.
  • the thickness T142 of the fourth planar coil element 142 is 0.5 mm.
  • the first coil 10 has a shield-side planar coil element (first planar coil element) 11 and a second planar coil element 12.
  • the number of turns of each of the shield-side planar coil element 11 and the second planar coil element 12 is 4.5. Therefore, the total number of turns of the first coil 10 is 9.
  • Second coil 140 has third planar coil element 141 and fourth planar coil element 142.
  • the number of turns of third planar coil element 141 and fourth planar coil element 142 is both 4.5. Therefore, the total number of turns of second coil 140 is 9.
  • the input current value of the high frequency current supplied to the first coil 10 is 25 A, and the frequency is 85 kHz.
  • a high-frequency current of 50 A is input as a current value flowing through the second coil 140 by electromagnetic induction.
  • the thickness T11 of the shield-side planar coil element (first planar coil element) 11 is 0.5 mm.
  • the thicknesses T12, T141, and T142 of the other planar coil elements 12, 141, and 142 are all 0.25 mm. (Other conditions of Condition 8)
  • the input current value of the high frequency current supplied to the first coil 10 is 25 A, and the frequency is 85 kHz.
  • a high-frequency current of 50 A is input as a current value flowing through the second coil 140 by electromagnetic induction.
  • the thickness T11 of the shield-side planar coil element (first planar coil element) 11 is 0.5 mm.
  • the thicknesses T12, T141 of the second planar coil element 12 and the third planar coil element 141 are both 0.25 mm.
  • the thickness T142 of the fourth planar coil element 142 is 0.5 mm. (Other conditions of Condition 9)
  • the input current value of the high frequency current supplied to the first coil 10 is 50 A, and the frequency is 85 kHz.
  • a high-frequency current of 25 A is input as a current value flowing through the second coil 140 by electromagnetic induction.
  • the thicknesses T11, T12, T141, and T142 of the planar coil elements 11, 12, 141, and 142 are all 0.5 mm.
  • Figure 17 shows the Q value, loss, impedance, inductance, and coupling coefficient of the transformer 100 obtained by the third simulation.
  • the Q value of the transformer 100 in which the thickness T11 of the shield side planar coil element 11 is greater than any of the thicknesses T12, T141, and T142 of the other planar coil elements 12, 141, and 142 tends to be higher than the Q value of the transformer 100 in which the thickness T11 of the shield side planar coil element 11 is the same as any of the thicknesses T12, T141, and T142 of the other planar coil elements 12, 141, and 142 or is smaller than any of the thicknesses T12, T141, and T142 of the other planar coil elements 12, 141, and 142.
  • Fig. 18 shows a perspective view of the first coil 10 and the second coil 140 of the transformer 100 that is the subject of the fourth simulation.
  • the common conditions in the fourth simulation are as follows.
  • the first coil 10 has a shield-side planar coil element (first planar coil element) 11.
  • the number of turns of the shield-side planar coil element 11 is 5. Therefore, the total number of turns of the first coil 10 is 5.
  • the thickness T11 of the shield-side planar coil element (first planar coil element) 11 is 0.5 mm.
  • Second coil 140 has third planar coil element 141.
  • the number of turns in third planar coil element 141 is 5. Therefore, the total number of turns in second coil 140 is 5.
  • the input current value of the high frequency current supplied to the first coil 10 is 50 A, and the frequency is 85 kHz.
  • a high-frequency current of 25 A is input as a current value flowing through the second coil 140 by electromagnetic induction.
  • Each planar coil element is made of copper.
  • the first magnetic shield member 20, the second magnetic shield member 50, and the core member 138 all have a relative magnetic permeability of 3,000.
  • the magnetic layer 130 and the wall portion 135 each have a relative magnetic permeability of 5.0.
  • the individual conditions regarding the thickness of the planar coil elements included in each of the coils 10 and 140 of the transformer 100 that is the subject of the fourth simulation are as follows.
  • Condition 1 The thickness T141 of the third planar coil element 141 is 0.1 mm.
  • Condition 2 The thickness T141 of the third planar coil element 141 is 0.15 mm.
  • Condition 3 The thickness T141 of the third planar coil element 141 is 0.2 mm.
  • Condition 4 The thickness T141 of the third planar coil element 141 is 0.25 mm.
  • Condition 5 The thickness T141 of the third planar coil element 141 is 0.35 mm.
  • Condition 6 The thickness T141 of the third planar coil element 141 is 0.5 mm, that is, the same as the thickness T11 of the shield-side planar coil element 11.
  • Figure 19 shows the Q value, loss, impedance, inductance, and coupling coefficient of the transformer 100 obtained by the fourth simulation.
  • the Q value of the transformer 100 in which the thickness T11 of the shield side planar coil element 11 is greater than the thickness T141 of the other planar coil elements 141 tends to be higher compared to the Q value of the transformer 100 in which the thickness T11 of the shield side planar coil element 11 is the same as the thickness T141 of the other planar coil elements 141.
  • the transformer 1 includes a first magnetic shield member 20, a first coil 10, a first magnetic layer 30, a second coil 40, a second magnetic shield member 50, and a second magnetic layer 60.
  • the first magnetic shield member 20 is a flat plate as a whole.
  • the first coil 10 is arranged opposite the first magnetic shield member 20.
  • the first coil 10 has a first surface 10a facing the first magnetic shield member 20 and a second surface 10b opposite the first surface 10a. At least a portion of the first magnetic layer 30 covers the first surface 10a of the first coil 10.
  • the first magnetic layer 30 is magnetic.
  • the second coil 40 is arranged opposite the second surface 10b of the first coil 10.
  • the second coil 40 has a third surface 40a facing the first coil 10 and a fourth surface 40b opposite the third surface 40a.
  • the second magnetic shield member 50 is disposed facing the fourth surface 40b of the second coil 40.
  • the second magnetic shield member 50 is generally a flat plate. At least a portion of the second magnetic layer 60 covers the fourth surface 40b of the second coil 40.
  • the second magnetic layer 60 has magnetic properties. In this case, the transformer 1 can be effectively made smaller and thinner.
  • the distance between the second surface 10b and the third surface 40a is 10 mm or less.
  • the first coil 10 has a plurality of planar coil elements 11, 12.
  • the first coil 10 includes a first shield side planar coil element 11 that forms the first surface 10a.
  • the thickness T12 of the planar coil elements 12 of the first coil 10 other than the first shield side planar coil element 11 is 0.15 mm or more. In this case, the performance of the transformer 1 can be improved.
  • the second coil 40 has a plurality of planar coil elements 41, 42.
  • the second coil 40 includes a second shield side planar coil element 42 that forms the fourth surface 40b.
  • the thickness T41 of the planar coil elements 41 of the second coil 40 other than the second shield side planar coil element 42 is 0.15 mm or more. In this case, the performance of the transformer 1 can be improved.
  • the distance between the second surface 10b and the third surface 40a is greater than 10 mm.
  • the first coil 10 has a plurality of planar coil elements 11, 12.
  • the first coil 10 includes a first shield side planar coil element 11 that forms the first surface 10a.
  • the thickness T12 of the planar coil elements 12 of the first coil 10 other than the first shield side planar coil element 11 is 0.15 mm or more.
  • An AC current of greater than 1 MHz is supplied to the first coil 10. In this case, the performance of the transformer 1 can be improved.
  • the second coil 40 has a plurality of planar coil elements 41, 42.
  • the second coil 40 has a second shield side planar coil element 42 that forms the fourth surface 40b.
  • the thickness T42 of the second shield side planar coil element 42 is greater than the thickness T41 of the other planar coil elements 41 of the second coil 40.
  • the thickness T41 of the planar coil elements 41 of the second coil 40 other than the second shield side planar coil element 42 is 0.15 mm or greater.
  • An AC current of greater than 1 MHz is supplied to the first coil 10. In this case, the performance of the transformer 1 can be improved.
  • the first coil 10 has a plurality of planar coil elements 11, 12.
  • the first coil 10 includes a first shield side planar coil element 11 that forms the first surface 10a.
  • the thickness T12 of the planar coil elements 12 of the first coil 10 other than the first shield side planar coil element 11 is 0.15 mm or more and 0.25 mm or less.
  • An AC current of 80 kHz or more and less than 500 kHz is supplied to the first coil 10. In this case, the performance of the transformer 1 can be improved.
  • the second coil 40 has a plurality of planar coil elements 41, 42.
  • the second coil 40 includes a second shield side planar coil element 42 that forms the fourth surface 40b.
  • the thickness T41 of the planar coil elements 41 of the second coil 40 other than the second shield side planar coil element 42 is 0.15 mm or more and 0.25 mm or less.
  • An AC current of 80 kHz or more and less than 500 kHz is supplied to the first coil 10. In this case, the performance of the transformer 1 can be improved.
  • the first coil 10 is embedded in the first magnetic layer 30.
  • the second coil 40 is embedded in the second magnetic layer 60.
  • the first magnetic layer 30 includes a resin and magnetic particles held in the resin.
  • the second magnetic layer 60 includes a resin and magnetic particles held in the resin.
  • the relative permeability of the first magnetic layer 30 is 5 or more.
  • the relative permeability of the second magnetic layer 60 is 5 or more.
  • the thickness of the first magnetic shield member 20 is 0.5 mm or more and 5 mm or less. In this case, the transformer 1 can be effectively made smaller and thinner.
  • the thickness of the second magnetic shield member 50 is 0.5 mm or more and 5 mm or less. In this case, the transformer 1 can be effectively made smaller and thinner.
  • the first magnetic shield member 20 contains ferrite.
  • the second magnetic shield member 50 contains ferrite.
  • the relative permeability of the first magnetic shield member 20 is 500 or more.
  • the relative permeability of the second magnetic shield member 50 is 500 or more.
  • the first magnetic shield member 20 has an inner surface 20b facing the first coil 10 and an outer surface 20a opposite the inner surface 20b.
  • the distance between the inner surface 20b of the first magnetic shield member 20 and the first surface 10a of the first coil 10 is 0.5 mm or more and 2 mm or less. In this case, the transformer 1 can be effectively made smaller and thinner.
  • the second magnetic shield member 50 has an inner surface 50a facing the second coil 40 and an outer surface 50b opposite the inner surface 50a.
  • the distance between the inner surface 50a of the second magnetic shield member 50 and the fourth surface 50b of the second coil 40 is 0.5 mm or more and 2 mm or less. In this case, the transformer 1 can be effectively made smaller and thinner.
  • the transformer 100 includes a magnetic shield member 20, a first coil 10, a second coil 140, and a magnetic layer 130.
  • the magnetic shield member 20 is generally flat.
  • the first coil 10 is disposed opposite the magnetic shield member 20.
  • the first coil 10 has a first surface 10a facing the magnetic shield member 20 and a second surface 10b opposite the first surface 10a.
  • the second coil 140 is disposed opposite the second surface 10b of the first coil 10.
  • At least a portion of the magnetic layer 130 covers the first surface 10a of the first coil 10. In this case, the transformer 1 can be effectively made smaller and thinner.
  • the first coil 10 and the second coil 140 each have at least one planar coil element 11, 12, 141.
  • the first coil 10 has a shield side planar coil element 11 that forms the first surface 10a.
  • the thickness of the shield side planar coil element 11 is greater than the thickness of the planar coil elements 12, 141 other than the shield side planar coil element 11 among the planar coil elements 11, 12, 141 of the first coil 10 and the second coil 140. In this case, the performance of the transformer 1 can be improved.
  • the second coil 140 has a third surface 140a facing the first coil 10, and a fourth surface 140b opposite the third surface 140a.
  • the distance between the second surface of the first coil and the third surface of the second coil is 0.5 mm or more and 10 mm or less. In this case, the transformer 1 can be effectively made smaller and thinner.
  • the first coil 10 is embedded in the magnetic layer 130.
  • At least a portion of the magnetic layer 130 is disposed between the first coil 10 and the second coil 140.
  • the first coil 10 and the second coil 140 are embedded in the magnetic layer 130.
  • the magnetic layer 130 includes a resin and magnetic particles held in the resin.
  • the relative permeability of the magnetic layer 130 is 5 or more.
  • the thickness of the magnetic shield member 20 is 0.5 mm or more and 5 mm or less. In this case, the transformer 100 can be effectively made smaller and thinner.
  • the magnetic shield member 20 contains ferrite.
  • the relative permeability of the magnetic shielding member 20 is 500 or more.
  • the magnetic shield member 20 has an inner surface 20b facing the first coil 10 and an outer surface 20a opposite the inner surface 20b.
  • the distance between the inner surface 20b of the magnetic shield member 20 and the first surface 10a of the first coil 10 is 0.5 mm or more and 2 mm or less. In this case, the transformer 100 can be effectively made smaller and thinner.
  • the first coil 10 and the second coil 40, 140 each have at least one planar coil element 11, 12, 41, 42, 141.
  • the thickness of the planar coil elements 11, 12, 41, 42, 141 is 0.1 mm or more and 2.0 mm or less. In this case, the transformer 100 can be effectively made smaller and thinner.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Coils Or Transformers For Communication (AREA)

Abstract

L'invention concerne un transformateur (1) comprenant un premier élément de blindage magnétique (20), une première bobine (10), une première couche magnétique (30), une seconde bobine (40), un second élément de blindage magnétique (50) et une seconde couche magnétique (60). Le premier élément de blindage magnétique (20) est entièrement une plaque plate. La première bobine (10) a une première surface (10a) qui fait face au premier élément de blindage magnétique (20) et une deuxième surface (10b) qui est sur le côté inverse de la première surface (10a). Au moins une partie de la première couche magnétique (30) recouvre la première surface (10a) de la première bobine (10). La seconde bobine (40) est disposée de manière à faire face à la deuxième surface (10b) de la première bobine (10). La seconde bobine (40) a une troisième surface (40a) qui fait face à la première bobine (10) et une quatrième surface (40b) qui est sur le côté inverse de la troisième surface (40a). Le second élément de blindage magnétique (50) est disposé de façon à faire face à la quatrième surface (40b) de la seconde bobine (40). Le second élément de blindage magnétique (50) est entièrement une plaque plate. Au moins une partie de la seconde couche magnétique (60) recouvre la quatrième surface (40b) de la seconde bobine (40).
PCT/JP2024/007122 2023-02-27 2024-02-27 Transformateur Ceased WO2024181449A1 (fr)

Priority Applications (1)

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JP2025503937A JPWO2024181449A1 (fr) 2023-02-27 2024-02-27

Applications Claiming Priority (2)

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JP2023028961 2023-02-27

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WO2024181449A1 true WO2024181449A1 (fr) 2024-09-06

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Country Link
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WO (1) WO2024181449A1 (fr)

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2020047614A (ja) * 2018-09-14 2020-03-26 国立大学法人信州大学 ワイヤレス電力伝送コイルユニット
JP2021027112A (ja) * 2019-08-02 2021-02-22 国立大学法人信州大学 非接触給電用コイル

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2020047614A (ja) * 2018-09-14 2020-03-26 国立大学法人信州大学 ワイヤレス電力伝送コイルユニット
JP2021027112A (ja) * 2019-08-02 2021-02-22 国立大学法人信州大学 非接触給電用コイル

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