Coil component and electronic / electrical machine

Abstract

The coil component 100 has a coil with a shape that improves the overall performance L×Isat / DCR of the coil component. It has a spiral conductor portion (first spiral conductor portion 11) with a central axis O along a first direction and having multiple turns, and a lead-out conductor portion (first lead-out portion 14) extending from the outer peripheral end of the spiral conductor portion towards a second direction (X1-X2 direction) intersecting the first direction (Z1-Z2 direction); and a core body portion 30 containing magnetic powder and adhesive material, covering the spiral conductor portion and the lead-out conductor portion, and exposing the end face of the lead-out conductor portion (first lead-out portion end face 14E). The two sides of the lead-out conductor portion along the second direction (inner side 14i and outer side 14p) have non-parallel portions when viewed along the first direction.

Description

Technical Field

[0001] This invention relates to a coil component and an electronic / electrical machine in which the coil component is mounted. Background Technology

[0002] Patent Document 1 discloses an electronic component comprising a coil holder having at least one coil pattern layer having at least a portion of a coil pattern formed on the same plane by means of a conductor, and at least one insulating resin layer formed of an insulating resin and stacked with the coil pattern layer, wherein a coil is formed by the at least one coil pattern layer and the coil pattern layer is fixed by the insulating resin; and a magnetic body portion formed of a composite magnetic material that is mixed with magnetic particles and resin and cured thereunder to cover the coil holder except for the terminal portion.

[0003] Existing technical documents Patent documents Patent Document 1: Japanese Invention Patent Publication No. 2015-126198 Summary of the Invention

[0004] The problem that the invention aims to solve Regarding the coil component 900 of the aforementioned Patent Document 1, the coil includes the following: Figure 14A The structure is shown. At one end of the spiral-shaped first coil pattern 913a, a terminal pattern 913b is formed to connect the coil pattern to the external terminal 914. (See diagram below.) Figure 14B ( Figure 14A As shown in the enlarged view of the part, near the connection between the terminal pattern 913b and the first coil pattern 913a, the DC resistance value DCR (unit: mΩ) of this part tends to increase locally because the direction of current flow is greatly bent.

[0005] In addition, such as Figure 14B As shown, the induced magnetic field Mia generated by the current flowing through the first coil pattern 913a along the virtual conductive center line Lfa, and the induced magnetic field Mib generated by the current flowing through the terminal pattern 913b along the virtual conductive center line Lfb, mutually reinforce or weaken each other, thus forming regions with different local magnetic field strengths. Specifically, the magnetic field strength is relatively high in region R1 (shown by the dashed line) and relatively low in region R2 (shown by the dashed line). This fluctuation in magnetic field strength causes a change in the self-inductance L (unit: μH) of the coil component 900, which in turn affects the DC superimposed rated current Isat (unit: A), thus negatively impacting the L×Isat / DCR (unit: mHAΩ-1), which is a comprehensive characteristic of the coil component 900. Furthermore, in this specification, the DC superimposed rated current Isat refers to the current value at which the self-inductance L decreases by 30% when DC superposition is performed.

[0006] The purpose of this invention is to provide a coil component and an electronic / electrical machine in which the coil component is mounted, which can minimize the negative impact of the coil pattern and the shape of the pattern of the terminals of the coil on the coil component, and improve the overall characteristics L×Isat / DCR of the coil component.

[0007] Technical means to solve the problem The present invention, provided to solve the above-mentioned problems, provides a coil component in one aspect, comprising: a coil portion; a helical conductor portion having a central axis along a first direction and having a plurality of turns; and a lead-out conductor portion extending from the outer peripheral end of the helical conductor portion toward a second direction intersecting the first direction; and a core body portion comprising magnetic powder and an adhesive material, covering the helical conductor portion and the lead-out conductor portion, and exposing the end face of the lead-out conductor portion; characterized in that two side surfaces of the lead-out conductor portion along the second direction have non-parallel portions when viewed along the first direction.

[0008] This reduces interference between the magnetic field generated by the helical conductor (coil pattern) and the magnetic field generated by the lead conductor (terminal pattern), thereby improving the characteristics of the coil components. Furthermore, the reduced bend in current flow from the helical conductor to the lead conductor (and vice versa) helps lower the DC resistance (DCR).

[0009] In the aforementioned coil component, the lead-out conductor portion may have a wider section that increases in width closer to the boundary with the helical conductor portion. This allows for a stable reduction in interference between the magnetic field generated by the helical conductor portion and the magnetic field generated by the lead-out conductor portion, and also makes the current flow from the helical conductor portion to the lead-out conductor portion smoother.

[0010] In the aforementioned coil component, when viewed along the first direction, the tangent drawn from the midpoint of the line formed by the end faces of the lead conductors to the inner circumference of the outermost turn among the multiple turns can overlap with the outermost turn and the lead conductor between its tangent point and its midpoint. This allows for a more stable reduction of interference between the magnetic field generated by the helical conductor and the magnetic field generated by the lead conductor, and also makes the current flow from the helical conductor to the lead conductor smoother.

[0011] In the aforementioned coil component, when viewed along the first direction, when a tangent is drawn from the midpoint of the line formed by the end faces of the lead conductors to the inner periphery of the outermost turn among the multiple turns, the distance from the tangent to the tangent is such that the distance between the closest point to the tangent in the line formed by the outer circumferential side of the outermost turn and the side face of the lead conductor continuous with that outer circumferential side is greater than 1 / 4 and less than 3 / 4 of the width of the outermost turn at the tangent point. This significantly reduces interference between the magnetic field generated by the helical conductor and the magnetic field generated by the lead conductor, and the current flow from the helical conductor to the lead conductor becomes smoother. Furthermore, it suppresses the decrease in self-inductance L caused by the widening of the width of the outermost turn and the lead conductor, easily improving the overall characteristic L×Isat / DCR of the coil component.

[0012] In the aforementioned coil assembly, when viewed along the first direction, a tangent is drawn from the midpoint of the line formed by the end faces of the lead conductor portion to the inner circumference of the outermost turn among the multiple turns. When the portion of the inner circumference of the outermost turn from the point of tangency of the tangent to the end of the lead conductor portion is approximated by an arc, the line segment connecting the center of the arc and the midpoint can be parallel to the side surface of the lead conductor portion connecting the inner circumference of the outermost turn. This results in a particularly stable reduction of magnetic field interference near the connection between the lead conductor portion and the helical conductor portion. Furthermore, it suppresses the decrease in self-inductance L caused by the widening of the lead conductor portion, easily improving the overall characteristic L×Isat / DCR of the coil assembly.

[0013] In the aforementioned coil component, when viewed along the first direction, when a tangent is drawn from the midpoint of the line formed by the end faces of the lead conductor portion to the inner periphery of the outermost turn among the multiple turns, the first line obtained by connecting the outer periphery endpoint of the width at the tangent point with the outer periphery endpoint of the line formed by the end faces of the lead conductor portion can have a portion located further inward than the outer periphery of the outermost turn. This results in a particularly stable reduction of magnetic field interference near the connection portion between the lead conductor portion and the helical conductor portion. Furthermore, it suppresses the decrease in self-inductance L caused by the widening of the lead conductor portion, easily improving the overall characteristic L×Isat / DCR of the coil component. When viewed along the first direction, if the portion of the line formed by the outer peripheral side of the outermost turn and the side of the lead conductor portion that is continuous with the outer peripheral side is defined as the outer peripheral side portion, and if the distance from the farthest point of the outer peripheral side portion to the first line is more than 1 / 10 of the width of the outermost turn at the aforementioned tangent point, the overall characteristic L×Isat / DCR of the coil component can be particularly improved.

[0014] When viewed along the first direction, the coil component described above may have at least one of the following features: (A) A tangent is drawn from the midpoint of the line formed by the end face of the lead conductor portion to the inner periphery of the outermost outermost turn among a plurality of turns, and in the line formed by the outer periphery side surface of the outermost outermost turn, the portion closer to the end face of the lead conductor portion than the width at the tangent point has an approximately circular arc shape with the center located on the inner periphery side.

[0015] (B) Assuming that the outer end is along the width of the most bend in the virtual conductive center line, which is obtained by connecting the outermost outermost turn of a plurality of turns and the midpoint of the width of the lead conductor, the outer peripheral end of the line formed by the outer end overlaps with the outer peripheral end of the line formed by the exposed end face of the lead conductor.

[0016] (C) A tangent is drawn from the midpoint of the line formed by the end face of the lead conductor to the inner periphery of the outermost turn among the multiple turns. When the side face of the lead conductor that is continuous on the outer periphery side of the outermost turn is taken as the outer side face of the lead, the point closest to the tangent in the line formed by the outer periphery side face of the outermost turn and the outer side face of the lead overlaps with the outer periphery end point of the outermost turn in the line formed by the exposed end face of the lead conductor.

[0017] The coil component described above may also include an external electrode disposed on the core body and electrically connected to the end face of the lead conductor portion exposed from the core body.

[0018] In another aspect, the present invention provides an electronic / electrical device incorporating the aforementioned coil component, wherein the coil component is connected to a substrate at the external electrode. Examples of such electronic / electrical devices include power supply units comprising power switching circuits, voltage boosting circuits, smoothing circuits, etc., or small portable communication devices. Because the electronic / electrical device according to the present invention includes the aforementioned coil component, it exhibits excellent quality and size.

[0019] The effects of the invention According to the present invention, a coil component and an electronic / electrical machine having the coil component mounted thereon can be provided, the coil component having a shape that minimizes the negative impact of the coil pattern and the shape of the pattern of the terminals continuously disposed on the coil component on the coil component, and improves the overall characteristic L×Isat / DCR of the coil component. Attached Figure Description

[0020] Figure 1 This is a perspective view conceptually illustrating the shape of a coil component according to an embodiment of the present invention.

[0021] Figure 2This is a diagram illustrating the structure of the coil conductor portion included in a coil component according to an embodiment of the present invention.

[0022] Figure 3 An XY plan view illustrating the structure of the coil conductor portion included in a coil component according to an embodiment of the present invention.

[0023] Figure 4 yes Figure 2 XZ cross-section at line A-A'.

[0024] Figure 5 yes Figure 3 A partially enlarged view illustrating the structure near the outer periphery of the coil conductor and the lead-out end.

[0025] Figure 6A This is a diagram illustrating the structure of the coil conductor portion of the coil component in the comparative example.

[0026] Figure 6B yes Figure 6A A magnified view of a portion of the image.

[0027] Figure 7A This is an explanatory diagram of the coil conductor portion structure of a coil component according to an embodiment (Example 1) of the present invention.

[0028] Figure 7B yes Figure 7A A magnified view of a portion of the image.

[0029] Figure 8A This is an explanatory diagram of the coil conductor portion structure of a coil component according to an example of an embodiment (Example 2) of the present invention.

[0030] Figure 8B yes Figure 8A A magnified view of a portion of the image.

[0031] Figure 9A This is an explanatory diagram of the coil conductor portion structure of a coil component according to an example of an embodiment (Example 3) of the present invention.

[0032] Figure 9B yes Figure 9A A magnified view of a portion of the image.

[0033] Figure 10A This is an explanatory diagram of the coil conductor portion structure of a coil component according to an example of an embodiment (Example 4) of the present invention.

[0034] Figure 10B yes Figure 10A A magnified view of a portion of the image.

[0035] Figure 11A This is an explanatory diagram of the coil conductor portion structure of a coil component according to an example of an embodiment (Example 5) of the present invention.

[0036] Figure 11B yes Figure 11A A magnified view of a portion of the image.

[0037] Figure 12A This is an explanatory diagram of the coil conductor portion structure of a coil component according to an example of an embodiment (Example 6) of the present invention.

[0038] Figure 12B yes Figure 12A A magnified view of a portion of the image.

[0039] Figure 13A This is an explanatory diagram of the coil conductor portion structure of a coil component according to an example of an embodiment (Example 7) of the present invention.

[0040] Figure 13B yes Figure 13A A magnified view of a portion of the image.

[0041] Figure 14A This is a diagram illustrating the structure of a coil component in the prior art.

[0042] Figure 14B yes Figure 14A A magnified view of a portion of the image. Detailed Implementation

[0043] The following is a reference to the appendix. Figure 1 The embodiments of the present invention will be described in detail below.

[0044] Figure 1 This is a perspective view conceptually illustrating the shape of a coil component according to an embodiment of the present invention. Figure 2 This is a diagram illustrating the structure of the coil conductor portion included in a coil component according to an embodiment of the present invention. Figure 2 For ease of explanation, the coil conductor is depicted with solid lines, the core body with dashed lines, and the representation of other constituent elements is omitted. Furthermore, Figure 2 The A-A' line is a line that passes through the center of the coil component in the Y1-Y2 direction and is parallel to the X1-X2 direction. Figure 3 This is an XY plan view illustrating the structure of the coil conductor portion included in a coil component according to an embodiment of the present invention.

[0045] (Overall composition) According to one embodiment of the present invention, the coil component 100 includes a coil portion 10 having a coil conductor portion 20, a core body portion 30, a first external electrode 41, a second external electrode 42, and outer casings 50 and 60.

[0046] (coil) like Figure 2 and Figure 3As shown, the coil portion 10 has a coil conductor portion 20, including a first helical conductor portion 11. An inner circumferential end portion 12, which is the inner circumferential end portion of the first helical conductor portion 11, extends towards an outer circumferential end portion 13, which is the outer circumferential end portion of the first helical conductor portion 11, forming a helical shape away from the central axis O extending along a first direction (Z1-Z2 direction) around the central axis O. Figure 2 In this embodiment, the first helical conductor portion 11 is provided with a helical conductor that, when viewed from the Z1 side in the Z1 direction (Z1-Z2), extends clockwise from the inner peripheral end 12 to the outer peripheral end 13 away from the central axis O. In this specification, the "helical direction" in the first helical conductor portion 11 refers to the direction extending from the inner peripheral end 12 to the outer peripheral end 13. The same applies to the second helical conductor portion 21, which will be described later.

[0047] The conductor (conductive material) constituting the coil conductor portion 20 is not limited as long as it has suitable conductivity. Copper, copper alloys, aluminum, aluminum alloys, and other metals are specific examples of conductors constituting the coil conductor portion 20. For example, the coil conductor portion 20 can be manufactured using film-forming techniques such as plating. The coil portion 10 has an insulating coil insulation portion (…) on the surface of the coil conductor portion 20. Figures 1 to 3 (Not shown in the image). This coil insulation ensures insulation between adjacent conductors (between opposing conductor surfaces) in the coil conductor section 20. The coil insulation is made of, for example, resin material. No coil insulation is provided at the two ends of the coil conductor section 20 (first lead-out end face 14E, second lead-out end face 24E), where the coil section 10 can be electrically connected to other components.

[0048] like Figure 2 As shown, the coil conductor portion 20 has a second helical conductor portion 21 arranged side-by-side with the first helical conductor portion 11 along a first direction. The second helical conductor portion 21 has a helical shape around a central axis O along the first direction (Z1-Z2 direction), extending from its inner circumferential end 22 toward its outer circumferential end 23 away from the central axis O. In the second helical conductor portion 21, when viewed from the Z1 side in the Z1-Z2 direction, it is arranged in the opposite direction to the first helical conductor portion 11. Figure 2The coil 100 is a spiral conductor (rotating counterclockwise) away from the central axis O. The average value of the spacing in the first direction (Z1-Z2 direction) between the first spiral conductor portion 11 and the second spiral conductor portion 21 is not particularly limited. A smaller spacing makes it easier to reduce the height (Z1-Z2 direction dimension) of the coil component 100, but if it is too small, the insulation between the first spiral conductor portion 11 and the second spiral conductor portion 21 is easily reduced. From the viewpoint of balancing the height of the coil component 100 with the high insulation between the first spiral conductor portion 11 and the second spiral conductor portion 21, the spacing is preferably 0.4 μm or more and 20 μm or less. In terms of manufacturing, to reduce spacing deviations and more reliably support the coil in the same plane, this spacing is more preferably 1.0 μm or more, and even more preferably 5.0 μm or more.

[0049] The inner circumferential end 12 of the first helical conductor portion 11 and the inner circumferential end 22 of the second helical conductor portion 21 are electrically connected through a through-hole portion VP. The through-hole portion VP can be made of the same conductor as the coil conductor portion 20. In a specific example, the through-hole portion VP is made of the same material as the first helical conductor portion 11 and the second helical conductor portion 21, and is manufactured simultaneously with the first helical conductor portion 11 and the second helical conductor portion 21. In this case, the through-hole portion VP is integrated with the inner circumferential end 12 of the first helical conductor portion 11 and the inner circumferential end 22 of the second helical conductor portion 21.

[0050] A first lead-out portion 14 is continuously provided on the outer peripheral end portion 13 of the first helical conductor portion 11, and a second lead-out portion 24 is continuously provided on the outer peripheral end portion 23 of the second helical conductor portion 21. Therefore, the outer peripheral end portion 13 of the first helical conductor portion 11 is essentially the boundary with the first lead-out portion 14, and the outer peripheral end portion 23 of the second helical conductor portion 21 is essentially the boundary with the second lead-out portion 24. In a specific example, the first lead-out portion 14 and the second lead-out portion 24 are made of the same material as the first helical conductor portion 11 and the second helical conductor portion 21, and are manufactured simultaneously with them. In this case, the first lead-out portion 14 is integrated with the outer peripheral end portion 13 of the first helical conductor portion 11, and the second lead-out portion 24 is integrated with the outer peripheral end portion 23 of the second helical conductor portion 21.

[0051] That is, in this embodiment, the coil conductor portion 20 has a first helical conductor portion 11 and a second helical conductor portion 21, a through hole portion VP, and a first lead-out portion 14 and a second lead-out portion 24, and these are formed of a common conductive material. Thus, the coil conductor portion 20 has a conductive path from the outer peripheral end 13 of the first helical conductor portion 11 through the first helical conductor portion 11 to the inner peripheral end 12, through the through hole portion VP that contacts the inner peripheral end 12 to the inner peripheral end 22 of the second helical conductor portion 21, and from the inner peripheral end 22 through the second helical conductor portion 21 to the outer peripheral end 23 of the second helical conductor portion 21.

[0052] Figure 4 This describes the XZ plane (composed of) the coil section structure included in the coil component of an embodiment of the present invention. Figure 2 A cross-sectional view (XZ section) of the surface shown by line A-A'. Furthermore, in Figure 4 Elements other than the coil section 10 are hidden inside.

[0053] like Figure 3 and Figure 4 As shown in the cross-section, the turns of the first helical conductor portion 11 and the turns of the second helical conductor portion 21 are arranged along a first direction. The first helical conductor portion 11 has a turn located at the innermost periphery, namely a first inner peripheral side turn 111, a turn located at the outermost periphery, namely a first outermost peripheral turn 113, and a turn located between them, namely a first central turn 112. The second helical conductor portion 21 has a turn located at the innermost periphery, namely a second inner peripheral side turn 211, a turn located at the outermost periphery, namely a second outermost peripheral turn 213, and a turn located between them, namely a second central turn 212.

[0054] The Z1-Z2 direction Z2 side of the first inner peripheral side ring 111 is located on the second inner peripheral side ring 211, the Z1-Z2 direction Z2 side of the first outermost peripheral ring 113 is located on the second outermost peripheral ring 213, and the Z1-Z2 direction Z2 side of the first central ring 112 is located on the second central ring 212. Figure 4 In the coil section 10 shown, there is no second lead-out section 24 on the Z2 side of the outer peripheral end 13 of the first helical conductor section 11 in the Z1-Z2 direction, and there is no first lead-out section 14 on the Z1 side of the outer peripheral end 23 of the second helical conductor section 21 in the Z1 side of the Z1-Z2 direction.

[0055] (First conductor section, second conductor section) like Figure 4 As shown, the first spiral conductor portion 11 has a first conductor portion 11A extending along a conductive path from the outer peripheral end portion 13 of the first spiral conductor portion 11 through the through hole portion VP to the outer peripheral end portion 23 of the second spiral conductor portion 21 and is made of a first conductive material, and a second conductor portion 11B made of a second conductive material and covering at least a portion of the first conductor portion 11A.

[0056] As described below, in one example, the first conductor portion 11A and the second conductor portion 11B are manufactured using different manufacturing processes. In this case, even if the materials are homogeneous (e.g., materials containing Cu, such as Cu, Cu alloys, etc.), they can be identified by cross-sectional observation due to differences in their tectonic characteristics such as crystal structure, crystal orientation, and crystal growth direction. In a specific example, the first conductor portion 11A is composed of an electrolytically plated precipitate, and the second conductor portion 11B is composed of a plating precipitate. In this case, the plating precipitate can be either an electrolytically plated precipitate or an electroless plating precipitate. From the viewpoint of improving the controllability of the thickness of the second conductor portion 11B, the plating precipitate is preferably an electrolytically plated precipitate.

[0057] In this embodiment, at the end of the first conductor portion 11A opposite to the second spiral conductor portion 21 along the first direction (Z1-Z2 direction) (Z2 side of the Z1-Z2 direction), a [missing information] is provided. Figure 4 The third conductor portion 11C is shown. The third conductive material constituting the third conductor portion 11C is not limited. It can be the same as the material constituting the first conductor portion 11A (e.g., Cu, Cu alloys, or other Cu-containing materials), or it can be different. From a manufacturing point of view (as the bottom film of the electrolytic plating layer), the third conductor portion 11C is preferably made of a material containing at least one of Ni and Cr. The etching characteristics of the material constituting the first conductor portion 11A and the material constituting the third conductor portion 11C are preferably different. For example, when the first conductor portion 11A is made of Cu and the third conductor portion 11C is made of Ni, Ni can be etched with high selectivity depending on the etching conditions. The third conductor portion 11C can be a film or a laminate of different materials.

[0058] The second helical conductor portion 21, like the first helical conductor portion 11, has a first conductor portion 21A extending along the conductive path and made of a first conductive material, and a second conductor portion 21B made of a second conductive material and covering at least a portion of the first conductor portion 21A; in this embodiment, it further has a third conductor portion 21C (refer to the end of the first conductor portion 21A on the side opposite to the first helical conductor portion 11 in the first direction (Z1-Z2 direction, Z1 side)) made of a third conductive material. Figure 4 ).

[0059] In addition, such as Figure 4As shown, the first lead-out portion 14 and the second lead-out portion 24 also have the same first conductor portions 14A and 24A, second conductor portions 14B and 24B, and third conductor portions 14C and 24C as the first spiral conductor portion 11 and the second spiral conductor portion 21. That is, the first conductor portions 14A, 11A, 21A, and 24A extend from the end face 14E of the first lead-out portion, sequentially through the first lead-out portion 14, the first spiral conductor portion 11, the through hole portion VP, the second spiral conductor portion 21, and the second lead-out portion 24, to the end face 24E of the second lead-out portion.

[0060] (The structure near the outer peripheral end of the coil conductor and the lead-out end) Figure 5 yes Figure 3 A partial enlarged view of the X2 side in the X1-X2 direction, illustrating the structure near the outer peripheral end of the coil conductor and the lead-out end. Figure 6A This is a diagram illustrating the structure of the coil conductor portion of the coil component in the comparative example; Figure 6B yes Figure 6A A magnified view of the area on the X2 side in the X1-X2 direction and on the Y2 side in the Y1-Y2 direction. Figure 7A This is a diagram illustrating the structure of the coil conductor portion of a coil component according to an example of an embodiment (Example 1) of the present invention; Figure 7B yes Figure 7A A magnified view of the area on the X2 side in the X1-X2 direction and on the Y2 side in the Y1-Y2 direction. Figure 8A This is a diagram illustrating the structure of the coil conductor portion of a coil component according to an example (Example 2) of an embodiment of the present invention; Figure 8B yes Figure 8A A magnified view of the area on the X2 side in the X1-X2 direction and on the Y2 side in the Y1-Y2 direction. Figure 9A This is a diagram illustrating the structure of the coil conductor portion of a coil component according to an example (Example 3) of an embodiment of the present invention; Figure 9B yes Figure 9A A magnified view of the area on the X2 side in the X1-X2 direction and on the Y2 side in the Y1-Y2 direction. Figure 10A This is a diagram illustrating the structure of the coil conductor portion of a coil component according to an example of an embodiment (Example 4) of the present invention; Figure 10B yes Figure 10A A magnified view of the area on the X2 side in the X1-X2 direction and on the Y2 side in the Y1-Y2 direction. Figure 11A This is a diagram illustrating the structure of the coil conductor portion of a coil component according to an example (Example 5) of an embodiment of the present invention; Figure 11B yes Figure 11A A magnified view of the area on the X2 side in the X1-X2 direction and on the Y2 side in the Y1-Y2 direction. Figure 12A This is a diagram illustrating the structure of the coil conductor portion of a coil component according to an example of an embodiment (Example 6) of the present invention; Figure 12B yes Figure 12A A magnified view of the area on the X2 side in the X1-X2 direction and on the Y2 side in the Y1-Y2 direction. Figure 13A This is a diagram illustrating the structure of the coil conductor portion of a coil component according to an example of an embodiment (Example 7) of the present invention; Figure 13B yes Figure 13A A magnified view of the area on the X2 side in the X1-X2 direction and on the Y2 side in the Y1-Y2 direction.

[0061] Figure 6A and Figure 6B The comparative example shown has a coil conductor portion 20, and Figures 7A to 13B The coil conductor portions 20 shown in Embodiments 1 to 7 all share the same shape for their first helical conductor portion 11 and second helical conductor portion 21, while the shapes for their first lead-out portion 14 and second lead-out portion 24 differ. In all examples, the shape of the first lead-out portion 14 is the same as the shape of the second lead-out portion 24. Furthermore, the shape characteristics of each example will be explained in the simulation results description below.

[0062] (Definition of width and outer perimeter end) First, using Figure 5 The width W of the coil conductor portion 20 is defined. Figure 5 In the coil conductor portion 20 shown, the first lead-out portion 14 has an inner lead-out portion 14i that is continuous with the inner peripheral side surface 113i of the first outermost peripheral turn 113 and located on the Y1 side in the Y1-Y2 direction, and an outer lead-out portion 14p that is continuous with the outer peripheral side surface 113p of the first outermost peripheral turn 113 and located on the Y2 side in the Y1-Y2 direction. When viewed along the first direction, the inner lead-out portion 14i is longer than the outer lead-out portion 14p, therefore the width W is defined from the inner lead-out portion 14i side.

[0063] Specifically, when viewed along the first direction, starting from a point on the line formed by the inner surface 14i of the lead-out portion, determine the nearest point on the line formed by the outer surface 14p of the lead-out portion, and define the line segment connecting these points as the width W at that point. The width W in... Figure 5 The width W, as defined herein, is defined from the endpoint of the line formed by the inner side surface 14i of the lead-out portion on the end face 14E side of the first lead-out portion, along the X1 side in the X1-X2 direction, along the line formed by the inner side surface 14i of the lead-out portion, and further along the line formed by the inner side surface 113i of the first outermost circumferential ring 113 (inner circumference).

[0064] After setting the width W for the first lead-out portion 14 and the first outermost circumferential turn 113, the midpoints of each width W are connected when viewed along the first direction to obtain the virtual conductive center line Lf. The virtual conductive center line Lf is the line along which the current most easily flows in the coil conductor portion 20 when the coil component 100 is energized. Figure 5 The lines are represented by thick dashed lines. When viewed along the first direction, the virtual conductive center line Lf passes through the midpoint Pm of the line formed by the first lead-out end face 14E. In this specification, the width Wb at the maximum bending point Pb of the virtual conductive center line Lf, where the bending degree is greatest when viewed along the first direction, is defined as the boundary between the first lead-out 14 and the first outermost circumferential turn 113, i.e., the outer peripheral end 13 of the first spiral conductor portion 11. Therefore, when viewed along the first direction, the two endpoints of the width Wb passing through the maximum bending point Pb become the boundaries between the inner peripheral side surface 113i of the first outermost circumferential turn 113 and the inner side surface 14i of the lead-out, and the boundaries between the outer peripheral side surface 113p of the first outermost circumferential turn 113 and the outer side surface 14p of the lead-out, respectively.

[0065] (First characteristic) In the coil conductor portion 20 included in the coil component 100 related to this embodiment, a first feature is that the first lead-out portion 14, which serves as the lead-out conductor portion, has non-parallel portions on its two sides (inner side 14i and outer side 14p) along a second direction (X1-X2 direction) intersecting the first direction (Z1-Z2 direction) when viewed along the first direction. Specifically, as Figure 5 As shown, both the inner surface 14i and the outer surface 14p of the lead-out portion are sides along the X1-X2 direction. However, compared to the inner surface 14i, which is almost parallel to the X1-X2 direction, the outer surface 14p is inclined towards the Y1-Y2 direction (Y2 side) relative to the X1-X2 direction on the X1 side. Therefore, the inner surface 14i and the outer surface 14p of the lead-out portion are not parallel.

[0066] In this way, the inner side 14i and the outer side 14p of the lead-out portion have non-parallel portions. Specifically, the portion with a width W that is wider the closer it is to the boundary with the first spiral conductor portion 11, i.e., the outer peripheral end 13.

[0067] Because the coil conductor portion 20 has this structure, interference between the magnetic field generated by the first helical conductor portion 11 and the magnetic field generated by the first lead-out portion 14 can be reduced, thereby potentially improving the characteristics of the coil component 100. Furthermore, the outer peripheral end portion 13 has the maximum bending point Pb of the virtual conductive center line Lf. Therefore, when the coil component 100 is energized, the local electron flow in this part is prone to turbulence. However, because the width Wb of the outer peripheral end portion 13 of the coil conductor portion 20 is relatively wide, the turbulence of electron flow does not easily lead to an increase in resistance. Therefore, the DC resistance value DCR is less likely to increase, and the coil characteristics of the coil component 100 are less likely to decrease.

[0068] like Figure 6B As shown, in the coil conductor section 20 of the comparative example, the inner surface 14i of the lead-out section and the outer surface 14p of the lead-out section are parallel, but... Figures 7B to 13B In the coil conductor portion 20 of the illustrated embodiment, the inner surface 14i of the lead-out portion and the outer surface 14p of the lead-out portion are not parallel. Furthermore, in Figure 7B In the coil conductor portion 20 of Embodiment 1 shown, the portion where the inner side surface 14i of the lead-out portion is not parallel to the outer side surface 14p of the lead-out portion is only a small portion near the outer peripheral end 13. On the other hand, in Figure 13B In the coil conductor portion 20 of Embodiment 7, the outer peripheral end point of the width Wb of the outer peripheral end 13 is located at the outer peripheral end point Pe of the line formed by the first lead-out end face 14E, therefore the outer surface 14p of the lead-out portion does not exist. Therefore, in Embodiment 7, since the outer surface 14p of the lead-out portion does not exist, it is determined that the inner surface 14i of the lead-out portion is not parallel to the outer surface 14p of the lead-out portion.

[0069] (Second characteristic) Next, the first tangent Lt of the coil conductor portion 20 is defined. When viewed along the first direction, the first tangent Lt is a tangent drawn from the midpoint Pm of the line formed by the end face 14E of the first lead-out portion to the inner circumference of the outermost turn 113, one of the multiple turns of the first spiral conductor portion 11. The first tangent Lt is... Figure 5 The middle part is represented by a dashed line.

[0070] In the coil conductor portion 20 of the coil component 100 related to this embodiment, the second feature is that, when viewed along the first direction, in the entire region between the tangent point Pc on the inner periphery of the first outermost circumference turn 113 and the midpoint Pm, the first tangent line Lt overlaps with the first outermost circumference turn 113 and the first lead-out portion 14, which is the lead-out conductor portion.

[0071] In this configuration, interference between the magnetic field generated by the first helical conductor portion 11 and the magnetic field generated by the first lead-out portion 14 is stably reduced, thus improving the characteristics of the coil component 100. Furthermore, since conductive material exists entirely between the midpoint Pm and the tangent point Pc, electrons can move between these two points without needing to detour when the coil component 100 is energized. Therefore, the resistance value of the coil conductor portion 20, located further outward than the tangent point Pc, is less likely to increase. Consequently, the DC resistance value DCR is less likely to increase, and the coil characteristics of the coil component 100 are less likely to deteriorate.

[0072] like Figure 6B As shown, in the coil conductor portion 20 of the comparative example, the first tangent Lt intersects the line formed by the outer surface 14p of the lead-out portion and / or the outer surface 113p of the first outermost peripheral turn 113. Therefore, the first tangent Lt, between the tangent point Pc with the inner circumference of the first outermost peripheral turn 113 and the midpoint Pm, has a portion that does not overlap with the first outermost peripheral turn 113 and the first lead-out portion 14 when viewed along the first direction. Figure 7B As shown, in the coil conductor portion 20 related to Embodiment 1, the first tangent Lt does not intersect the line formed by the outer surface 14p of the lead-out portion, but intersects the line formed by the outer surface 113p of the first outermost peripheral turn 113. Therefore, the coil conductor portion 20 related to Embodiment 1 does not include the second feature. On the other hand, the coil conductor portions 20 related to Embodiments 2 to 7 all include the second feature.

[0073] (Third characteristic) In the coil conductor portion 20 of the coil component 100 related to this embodiment, the third feature is that, when viewed along the first direction, in the line formed by the outer peripheral side surface 113p of the first outermost peripheral turn 113 and the outer side surface 14p of the lead portion that is continuous with the outer peripheral side surface 113p, the distance Tt from the nearest point Pt to the first tangent Lt satisfies that the width Wc passing through the tangent point Pc is more than 1 / 4 and less than 3 / 4.

[0074] In this configuration, interference between the magnetic field generated by the first helical conductor portion 11 and the magnetic field generated by the first lead portion 14 is reduced particularly stably, and the bend in the current flow from the first helical conductor portion 11 to the first lead portion 14 is also made particularly easy to smooth out. Moreover, the effect of the decrease in self-inductance L caused by the widening of the width W of the first outermost peripheral turn 113 and the width of the first lead portion 14 can be suppressed, and the overall characteristic L×Isat / DCR of the coil component 100 can be easily improved.

[0075] In the comparative example ( Figure 6B ) and Example 1 ( Figure 7BIn the related coil conductor portion 20, when viewed along the first direction, the first tangent Lt intersects the line formed by the outer surface 14p of the lead-out portion and / or the outer surface 113p of the first outermost peripheral turn 113, and the intersection point is the nearest point Pt. The aforementioned distance Tt is not defined. On the other hand, in Embodiment 2 ( Figure 8B ) to Example 7 ( Figure 13B In the related coil conductor section 20, when viewed along the first direction, the first tangent Lt intersects neither the line formed by the outer surface 14p of the lead-out portion nor the line formed by the outer surface 113p of the first outermost circumferential turn 113, therefore a distance Tt is set. In Embodiment 2 ( Figure 8B In the related coil conductor section 20, the distance Tt is less than 1 / 4 of the width Wc passing through the tangent point Pc, but in embodiment 3 ( Figure 9B ) to Example 7 ( Figure 13B In the related coil conductor portion 20, the distance Tt satisfies a width Wc passing through the tangent point Pc that is more than 1 / 4 and less than 3 / 4, including the third feature. Furthermore, in Embodiment 6 ( Figure 12B ) and Example 7 ( Figure 13B In the related coil conductor section 20, the nearest point Pt overlaps with the outer peripheral end point Pe of the line formed by the first lead end face 14E.

[0076] (Fourth characteristic) In the coil conductor portion 20 of the coil component 100 related to this embodiment, the fourth feature is: when viewed along the first direction, when the portion from the tangent point Pc to the end of the first lead-out portion 14 side of the line (inner circumference) formed by the inner circumferential side surface 113i of the first outermost circumferential turn 113 is approximated by an arc Ca, the line segment L1 connecting the center Po and the midpoint Pm of the arc Ca (in) Figure 5 (Represented by a single-dot dash) Parallel to the side surface of the first lead-out portion 14 (inner side surface 14i) connecting the inner circumference of the first outermost circumferential turn 113. This results in a particularly stable reduction of magnetic field interference near the connection point between the first lead-out portion 14 and the first helical conductor portion 11. Furthermore, it suppresses the decrease in self-inductance L caused by the widening of the first lead-out portion 14, easily improving the overall characteristic L×Isat / DCR of the coil component 100. Example 1 ( Figure 7B ) to Example 7 ( Figure 13B The related coil conductor section 20 all include the fourth feature.

[0077] (Fifth characteristic) In the coil conductor portion 20 of the coil component 100 related to this embodiment, a fifth feature is that, when viewed along the first direction, the first line Lp obtained by connecting the outer peripheral endpoint Pp of the line formed by the width Wc passing through the tangent point Pc and the outer peripheral endpoint Pe of the line formed by the end face 14E of the first lead portion can have a portion located further inward than the outer peripheral side (outer periphery) of the line formed by the outer peripheral side surface 113p of the first outermost peripheral turn 113. This results in a particularly stable reduction of magnetic field interference near the connection portion of the first lead portion 14 and the first helical conductor portion 11. Furthermore, it can suppress the effect of the decrease in self-inductance L caused by the widening of the width W of the first lead portion 14, easily improving the overall characteristic L×Isat / DCR of the coil component 100.

[0078] When viewed along the first direction, if the portion of the line formed by the outer peripheral side surface 113p of the first outermost circumferential turn 113 and the outer peripheral side surface 14p of the lead-out portion that is closer to the outer periphery than the first line Lp is defined as the outer peripheral side portion, if the distance Tp from the farthest point Pp1 of the outer peripheral side portion to the first line Lp is greater than 1 / 10 of the width Wc of the first outermost circumferential turn 113 passing through the tangent point Pc, then the overall characteristic L×Isat / DCR of the coil component 100 can be particularly improved.

[0079] Comparative example ( Figure 6B ) and Example 1 ( Figure 7B ) and Example 2 ( Figure 8B Since the coil conductor portion 20 lacks an outer peripheral portion, the furthest point Pp1 is not defined. Example 3 ( Figure 8B ) to Example 7 ( Figure 13B The related coil conductor portion 20 has an outer peripheral side portion, but in embodiment 3 ( Figure 8B ) to Example 6 ( Figure 12B The distance Tp in the related coil conductor section 20 is extremely short. Therefore, in Figures 8B to 12B The farthest point Pp1 and its distance Tp are not shown in the diagram. In Example 7 (… Figure 13B In the related coil conductor section 20, the first outermost circumferential turn 113 has a portion that protrudes outward at the tangent point Pc compared to the outer circumferential end 13, thus fully forming the outer circumferential portion, and the distance from Tp reaches more than 1 / 10 of the width Wc.

[0080] (simulation) Here, for the comparative example ( Figure 6B ) and Example 1 ( Figure 7B ) to Example 7 ( Figure 13B The shape characteristics of the relevant coil conductor portion 20 were confirmed. Comparative Example ( Figure 6B ) and Example 1 ( Figure 7B ) to Example 6 ( Figure 12BIn the related coil conductor portion 20, in the line formed by the outer peripheral side surface 113p of the first outermost peripheral turn 113 and the outer side surface 14p of the lead-out portion, the boundary between the outer peripheral side surface 113p of the first outermost peripheral turn 113 and the outer side surface 14p of the lead-out portion, that is, the portion including the outer peripheral end point of the line formed by the outer peripheral end 13, when viewed along the first direction, is an approximate arc with its center located on the outer periphery and including a specific radius, and this radius varies in various examples. Specifically, based on the coil conductor portion 20 related to the comparative example, the radius is 2.5 times in the coil conductor portion 20 related to Embodiment 1, 5 times in the coil conductor portion 20 related to Embodiment 2, 15 times in the coil conductor portion 20 related to Embodiment 3, 25 times in the coil conductor portion 20 related to Embodiment 4, 50 times in the coil conductor portion 20 related to Embodiment 6, and 250 times in the coil conductor portion 20 related to Embodiment 6.

[0081] Example 7 (excluding the outer surface 14p of the lead-out portion) Figure 13B In the related coil conductor section 20, unlike the coil conductor section 20 in other examples, the shape of the portion between the outer peripheral end point Pe of the line formed by the first lead end face 14E and the outer peripheral end point Pp of the width Wc passing through the tangent point Pc when viewed along the first direction is an approximate arc with its center located on the inner peripheral side and including a predetermined radius, and its radius is 30 times that of the coil conductor section 20 in the comparative example.

[0082] For the comparative example ( Figure 6B ) and Example 1 ( Figure 7B ) to Example 7 ( Figure 13B The relevant coil component 100 was simulated to obtain the self-inductance L, DC resistance value DCR, and DC superimposed rated current Isat. The comprehensive characteristic L×Isat / DCR was then calculated from these values. The results are shown in Table 1. Table 1 also shows the calculated growth rate of each result relative to the comparative example reference. Furthermore, the shape feature column in Table 1 shows the multiples of the approximate arc radius of the aforementioned comparative example reference. Because the approximate arc center position of Comparative Example 7 is different, it is marked with "※".

[0083] [Table 1] As shown in Table 1, the general trend is that the larger the embodiment number, the higher the overall performance characteristic L×Isat / DCR. Embodiment 7, whose outer peripheral side surface 113p of the first outermost circumferential ring 113 has an approximately arc-shaped shape with its center located on the inner peripheral side when viewed along the first direction, has a particularly high overall performance characteristic L×Isat / DCR. Embodiment 7 has the following features A to C when viewed along the first direction.

[0084] Feature A: In the line formed by the outer peripheral side surface 113p of the first outermost circumferential ring 113, the portion closer to the end face 14E of the first lead-out portion than the outer peripheral side endpoint Pp of the width Wc passing through the tangent point Pc has an approximately arc shape with its center located on the inner peripheral side.

[0085] Feature B: The outer peripheral end point of the outer peripheral end 13 overlaps with the outer peripheral end point Pe of the line formed by the first lead-out end face 14E.

[0086] Feature C: In the line formed by the outer peripheral side surface 113p of the first outermost circumferential turn 113 and the outer peripheral side surface 14p of the lead-out portion that is continuous with the outer peripheral side surface 113p, the point Pt closest to the first tangent Lt overlaps with the outer peripheral end point Pe of the line formed by the end face 14E of the first lead-out portion.

[0087] Detailed simulation results show that the self-inductance L and DC resistance DCR are the highest in the comparative example, and tend to decrease as the example number increases. On the other hand, the DC superimposed rated current Isat is the lowest in the comparative example, and tends to increase as the example number increases. Therefore, in the comprehensive characteristic L×Isat / DCR, the effects of self-inductance L and DC resistance DCR cancel each other out, and it can be said that the comprehensive characteristic L×Isat / DCR roughly reflects the trend of the DC superimposed rated current Isat.

[0088] (First Insulation Section) The coil insulation portion has a first insulation portion 80, such as Figure 4 As shown, the first insulating portion 80 is disposed on at least a portion of the surface of the first spiral conductor portion 11 and at least a portion of the surface of the second spiral conductor portion 21.

[0089] In this embodiment, the first insulating portion 80 is thermoplastic and comprises a thermoplastic resin containing a p-xylene-based polymer. Other examples of thermoplastic resins include polyethylene, polypropylene, polyamide, polyester, polyamide-imide, polyimide, polysulfone, polycarbonate, liquid crystal polymer, polyvinylidene fluoride, and polytetrafluoroethylene. The first insulating portion 80 only needs to be thermoplastic in its entirety; in addition to the aforementioned thermoplastic resins, it may also contain, for example, inorganic insulating particles.

[0090] The first insulating portion 80 preferably has excellent insulation properties; specifically, its volume resistivity, obtained according to ASTM D257, is preferably 1.0 × 10⁻⁶. 11 Ωcm or higher. More preferably, the volume resistivity is 1.0 × 10⁻⁶. 15 Ωcm or more, more preferably 1.0 × 10 Ωcm 16 Above Ωcm. There is no specific upper limit to the volume resistivity. The volume resistivity can be 1.0 × 10⁻⁶. 20The relative permittivity is less than Ωcm. Furthermore, the first insulating portion 80 preferably has excellent dielectric properties; specifically, the relative permittivity at 60 Hz, obtained according to ASTM D150, is preferably 4.0 or less. More preferably, the relative permittivity is 3.5 or less, and even more preferably 3.0 or less. There is no particular upper limit to the relative permittivity. The relative permittivity can be 1.0 or more. The methods for measuring the volume resistivity and relative permittivity of the first insulating portion 80 are not limited as long as it is expected to yield results equivalent to those described in ASTM D257 and D150. For example, a measuring specimen equivalent to the material of the first insulating portion 80 can be prepared separately, and the constituent materials can be identified using analytical methods such as compositional analysis or FT-IR, and the properties such as the volume resistivity of the material can be evaluated.

[0091] (Second Insulation Section) The coil insulation portion has a second insulation portion 90, such as Figure 4 As shown, the second insulating portion 90 contacts at least one of the first helical conductor portion 11 and the second helical conductor portion 21. This ensures insulation between the first helical conductor portion 11 and the second helical conductor portion 21. Furthermore, by simultaneously contacting both the first helical conductor portion 11 and the second helical conductor portion 21 with the second insulating portion 90, short circuits between the first helical conductor portion 11 and the second helical conductor portion 21 can be reliably prevented.

[0092] The material constituting the second insulating part 90 is not limited, as long as it has suitable insulating properties. The volume resistivity of the second insulating part 90, as obtained according to ASTM D257, is preferably 1.0 × 10⁻⁶. 11 Ωcm or higher. More preferably, the volume resistivity is 1.0 × 10⁻⁶. 15 Ωcm or more, more preferably 1.0 × 10 Ωcm 16 Above Ωcm. There is no specific upper limit to the volume resistivity. The volume resistivity can be 1.0 × 10⁻⁶. 20 The relative permittivity is less than Ωcm. Furthermore, the second insulating portion 90 preferably has excellent dielectric properties; specifically, the relative permittivity at 60 Hz, obtained according to ASTM D150, is preferably 4.0 or less. More preferably, the relative permittivity is 3.5 or less, and even more preferably 3.0 or less. There is no particular upper limit to the relative permittivity. The relative permittivity can be 1.0 or more. The methods for measuring the volume resistivity and relative permittivity of the second insulating portion 90 are not limited as long as it is expected to yield results equivalent to those described in ASTM D257 and D150. For example, a measuring specimen of the material equivalent to the second insulating portion 90 can be prepared separately, and the constituent materials can be identified using analytical methods such as compositional analysis or FT-IR, and the properties such as the volume resistivity of the material can be evaluated.

[0093] The material constituting the second insulating part 90 can be an organic material, an inorganic material, or a composite material of organic and inorganic materials. When the second insulating part 90 is composed of a composite material, the inorganic material has a particle shape and can be dispersed in a matrix composed of an organic material. In this case, the inorganic material can be insulating particles. Specific examples of organic materials include polyimide resin, polyethylene resin, polypropylene resin, polyamide resin, polyester resin, polyamide-imide resin, polysulfone resin, polycarbonate resin, liquid crystal polymer resin, polyvinylidene fluoride resin, polytetrafluoroethylene resin, etc. Specific examples of inorganic materials, especially in composite materials, include inorganic materials such as oxides, carbides, nitrides, and inorganic salts. For example, oxides include silicon dioxide, alumina, and zirconium oxide. In addition, for example, carbides and nitrides include inorganic materials such as silicon carbide and boron nitride, respectively. Inorganic salts include minerals such as wollastonite, kaolin, and mica. From the perspective of cost and insulation, oxide-based materials such as oxides, silicates, and phosphates are preferred. For example, inorganic materials preferably contain at least one selected from the group consisting of silicon (Si), phosphorus (P), boron (B), and calcium (Ca).

[0094] (Core Body Department) The core body portion 30 contains magnetic powder and includes a portion of the coil portion 10. In this embodiment, the core body portion 30 is generally rectangular in shape and covers the portion other than the first lead-out end face 14E and the second lead-out end face 24E located at the ends of the coil portion 10.

[0095] The microstructure of magnetic powders is not limited. This microstructure can contain either a crystalline or amorphous phase. Here, crystalline materials are defined as materials composed of a crystalline phase, amorphous materials are defined as materials composed of an amorphous phase, and composite materials are defined as materials composed of both crystalline and amorphous phases. If a diffraction pattern obtained by conventional X-ray diffraction contains sharp diffraction peaks that can identify the type of crystalline phase, then the material contains a crystalline phase. Furthermore, if a diffraction pattern obtained by conventional X-ray diffraction contains broad peaks representing an amorphous phase, then the material contains an amorphous phase. DSC curves obtained by differential thermal analysis showing peaks of crystallization, i.e., containing the exothermic phase transition from an amorphous to a crystalline phase, also indicate that the material contains an amorphous phase.

[0096] The material system of the magnetic powder is unrestricted. Specific examples of crystalline materials include Fe-Si-Cr alloys, Fe-Ni alloys, Fe-Co alloys, Fe-V alloys, Fe-Al alloys, Fe-Si alloys, Fe-Si-Al alloys, pure iron, and ferrites. Pure iron powder is preferably carbonyl iron powder. Furthermore, specific examples of amorphous materials include Fe-Si-B alloys, Fe-PC alloys, and Co-Fe-Si-B alloys. Specific examples of composite materials include Fe-Zr alloys, Fe-Zr-B alloys, Fe-Si-B-Nb-Cu alloys, and Fe-Si-BP-Cu alloys. If the magnetic powder is an Fe-containing metal powder, the synergistic effect in improving magnetic properties is particularly significant.

[0097] The chemical composition of the magnetic powder is not limited. For example, an Fe-Si-Cr alloy may consist of 1.0 to 10.0% by mass of Si, 1.0 to 10.0% by mass of Cr, and the remainder consisting of Fe and impurities. Similarly, an Fe-Ni alloy may consist of 1.0 to 99.0% by mass of Ni, and the remainder consisting of Fe and impurities. Furthermore, an Fe-PC alloy may consist of 1.0 to 13.0 atomic% of P, 1.0 to 13.0 atomic% of C, and Fe and impurities. This Fe-PC alloy may optionally contain one or more elements selected from the group consisting of Ni, Sn, Cr, B, and Si. In this case, for example, the Ni content may be 0 to 10.0 atomic%, the Sn content may be 0 to 3.0 atomic%, the Cr content may be 0 to 6.0 atomic%, the B content may be 0 to 9.0 atomic%, and the Si content may be 0 to 7.0 atomic%. The Fe content is preferably 65 atomic% or more. Furthermore, for example, Fe-Si-B-Nb-Cu alloys can consist of 1.0 to 16.0 atomic% Si, 1.0 to 15.0 atomic% B, 0.50 to 5.0 atomic% Nb, 0.50 to 5.0 atomic% Cu, and the remainder consisting of Fe and impurities. In this case, the Fe content is preferably 65 atomic% or more.

[0098] The shape of the magnetic powder is not limited. Magnetic powder can be spherical, elliptical, flake-like, or irregular in shape. The manufacturing methods to obtain these shapes are also not limited.

[0099] The particle size distribution of the magnetic powder is not limited. The particle size distribution can be obtained by analyzing images (secondary electron images) obtained by imaging a cross-section of the core body using a scanning electron microscope. For example, the average equivalent circle diameter of the magnetic powder can be between 0.50 and 50.0 μm. The distribution of the equivalent circle diameter can contain multiple peaks.

[0100] Magnetic powder can undergo surface insulation treatment. If the magnetic powder undergoes surface insulation treatment, the insulation resistance of the core body 30 will increase. The type of surface insulation treatment applied to the magnetic powder is not limited. Examples include phosphoric acid treatment, phosphate treatment, and oxidation treatment. The surface of the magnetic particles of the magnetic powder may have an insulating coating layer. This insulating coating layer may contain at least one substance selected from Si, P, and B, as well as O (oxygen).

[0101] Magnetic powder can also be a mixture of multiple powder materials. The magnetic powder is preferably a ferromagnetic material, and more preferably a soft magnetic material.

[0102] The core body portion 30 may also include optional auxiliary materials. Optional auxiliary materials include, for example, adhesives or modifiers. The adhesive binds together particles such as magnetic powder contained in the core body portion 30. To impart insulation resistance to the core body portion 30, the adhesive is preferably an insulating material.

[0103] Adhesive materials can be either organic or inorganic. Organic materials can be resins. Examples of resins include acrylic resins, silicone resins, epoxy resins, phenolic resins, urea resins, melamine resins, and polyester resins. Inorganic materials can be glass-like materials such as water glass. Adhesive materials can be products of reactions such as thermal decomposition, or mixtures of various materials.

[0104] Modifiers are used, for example, to improve the flowability of powders or to adjust the curing speed of adhesive materials. Modifiers can be glass-like materials.

[0105] The size of the core body 30 is not limited. For example, the maximum size of the core body 30 can be 3.2 mm or less.

[0106] (External electrode) like Figure 2 As shown, the first lead-out end face 14E and the second lead-out end face 24E located at the end of the coil portion 10 are exposed from the core body portion 30 at the side of the core body portion 30 in the X1-X2 direction. The first external electrode 41 is configured to make electrical contact with the first lead-out end face 14E, and the second external electrode 42 is configured to make electrical contact with the second lead-out end face 24E.

[0107] like Figure 1As shown, the first external electrode 41 has a side portion 41a covering the X2 side of the core body 30 in the X1-X2 direction, and a bottom portion 41b provided to cover a portion of the bottom surface (Z2 side of the Z1-Z2 direction) of the core body 30. The bottom portion 41b is the portion facing the substrate during use. The second external electrode 42 has a side portion 42a covering the X1 side of the core body 30 in the X1-X2 direction, and a bottom portion 42b separated from the bottom portion 41b on the bottom surface of the core body 30 and provided to cover a portion of its bottom surface. The bottom portion 42b is also the portion facing the substrate during use.

[0108] The positions of the first external electrode 41 and the second external electrode 42 are not limited to the positions described above. The first external electrode 41 and the second external electrode 42 can be formed to cover a portion of the upper surface (the surface on the Z1 side in the Z1-Z2 direction) of the core body portion 30. Alternatively, the first external electrode 41 and the second external electrode 42 may only be provided on a portion of the bottom surface (the surface on the Z2 side in the Z1-Z2 direction) of the core body portion 30. In this case, the coil conductor portion 20 may have a connecting conductor portion (not shown) that extends from both ends of the coil portion 10 (the first lead-out portion 14 and the second lead-out portion 24) through the interior of the core body portion 30 and connects to the bottom surface of the core body portion 30. In this case, the two ends of the coil portion 10 (the end face 14E of the first lead-out portion and the end face 24E of the second lead-out portion) may not be exposed to the side of the core body portion 30, but the connecting conductor portion may be exposed to the bottom surface of the core body portion 30.

[0109] The materials and structures of the first external electrode 41 and the second external electrode 42 are not limited, as long as they have suitable conductivity. As a non-limiting example of the first external electrode 41 and the second external electrode 42, a layer with a Cu / Ni / Sn plating structure is included, extending from the surface side near the core body portion 30. The first external electrode 41 and the second external electrode 42 can be composed of coating-type electrodes made by dispersing a conductive material such as silver in a resin or the like. Furthermore, the first external electrode 41 and the second external electrode 42 can also be a combination of electroplated and coating-type electrodes.

[0110] (Outer packaging) Insulating outer covers 50 and 60 are respectively provided on the upper surface (the surface on the Z1 side in the Z1-Z2 direction) and the side surface parallel to each other in the Y1-Y2 direction of the core body 30. The portion of the bottom surface of the core body 30 where the bottom portions 41b and 42b are not provided may also be provided with insulating outer covers. Furthermore, the coil component 100 may not include the outer covers 50 and 60. The outer covers 50 and 60 can be provided at any position on the surface of the core body 30 as needed.

[0111] (Electronic / Electrical Machinery) The electronic / electrical device according to one embodiment of the present invention is an electronic / electrical device equipped with the coil component 100 described above, and the coil component 100 is connected to a substrate via a first external electrode 41 and a second external electrode 42. Because the coil component 100 of the present invention is installed in the electronic / electrical device according to one embodiment of the present invention, the size of the device can be easily reduced. Furthermore, even if a large current flows or a high frequency is applied inside this device, malfunctions caused by a decrease in the function of the coil component 100 or overheating are less likely to occur.

[0112] The embodiments and examples described above are provided for ease of understanding of the present invention and are not intended to limit the present invention. Therefore, the elements disclosed in the above embodiments are intended to include all design changes or equivalents that fall within the scope of protection of the present invention.

[0113] Explanation of reference numerals in the attached figures 100: Coil component 10: Coil section 11: First helical conductor section 11A, 14A, 21A, 24A: First conductor section 11B, 14B, 21B, 24B: Second conductor section 11C, 14C, 21C, 24C: Third conductor section 12, 22: Inner circumferential side end 13, 23: Outer peripheral side end 14: First Introduction 14E: First lead-out end face 14i: Inner side of the lead-out section 14p: Outer side of the lead-out section 20: Coil conductor section 21: Second spiral conductor section 24: Second Introduction 24E: Second lead-out end face 30: Core Body Section 41: First external electrode 41a, 42a: Side view 41b, 42b: Bottom surface 42: Second external electrode 50, 60: Outer packaging 80: First Insulation Section 90: Second Insulation Section 111: First inner peripheral side turn 112: First Central Turns 113: First outermost circumference turn 113i: Inner peripheral side 113p: Outer periphery 211: Second inner circumferential side turn 212: Second Central Turns 213: Second outermost circumference turn 900: Coil component 913a: First coil pattern 913b: Terminal pattern 914: External terminal Ca: Arc Lf, Lfa, Lfb: Virtual conductive center lines L1: Line segment Lp: First line Lt: First tangent line Mia, Mib: Induced magnetic field O: Central axis Pb: Maximum bending point Pc: Tangent point Pe, Pp: Endpoints Pm: Midpoint Po: Center Pp1: Farthest point Pt: nearest location R1, R2: Regions Tp, Tt: Distance VP: Through-hole section W, Wb: Width

Claims

1. A coil component, comprising: The coil portion has a spiral conductor portion with a central axis along a first direction and having a plurality of turns, and an outgoing conductor portion extending from the outer peripheral end of the spiral conductor portion in a second direction intersecting the first direction; as well as The core body comprises magnetic powder and adhesive material, covering the spiral conductor and the lead-out conductor, and exposing the end face of the lead-out conductor. The feature is that the two side surfaces of the lead-out conductor portion along the second direction have non-parallel portions when viewed along the first direction.

2. The coil component as claimed in claim 1, wherein, The lead-out conductor portion has a wider portion that is closer to the boundary with the spiral conductor portion.

3. The coil component as claimed in claim 1, wherein, When viewed along the first direction, a tangent drawn from the midpoint of the line formed by the end faces of the lead-out conductor portion to the inner periphery of the outermost turn of the plurality of turns overlaps with the outermost turn and the lead-out conductor portion between the tangent point and the midpoint of the tangent.

4. The coil component as claimed in claim 1, wherein, When viewed along the first direction, when a tangent is drawn from the midpoint of the line formed by the end faces of the lead-out conductor portion to the inner periphery of the outermost turn among the plurality of turns, the point closest to the tangent in the line formed by the outer peripheral side surface of the outermost turn and the side surface of the lead-out conductor portion that is continuous with the outer peripheral side surface is between the tangent point and the midpoint, and the distance from the tangent point is such that the distance from the tangent is greater than 1 / 4 and less than 3 / 4 of the width of the outermost turn at the tangent point.

5. The coil component as claimed in claim 1, wherein, When viewed along the first direction, a tangent is drawn from the midpoint of the line formed by the end faces of the lead conductor portion to the inner periphery of the outermost of the plurality of turns. When the portion of the inner periphery of the outermost turn from the point of tangency of the tangent to the end of the lead conductor portion is approximated by an arc, the line segment connecting the center of the arc and the midpoint is parallel to the side of the lead conductor portion connecting the inner periphery of the outermost turn.

6. The coil component as claimed in claim 1, wherein, When viewed along the first direction, when a tangent is drawn from the midpoint of the line formed by the end faces of the lead conductor portion to the inner periphery of the outermost turn among the plurality of turns, the first line obtained by connecting the outer periphery endpoint of the width at the tangent point of the tangent and the outer periphery endpoint of the line formed by the end faces of the lead conductor portion has a portion located on the inner periphery side of the outermost turn than the outer periphery of the outermost turn.

7. The coil component as claimed in claim 6, wherein, When viewed along the first direction, when the portion of the line formed by the outer peripheral side surface of the outermost circumferential turn and the side surface of the lead-out conductor portion that is continuous with the outer peripheral side surface is defined as the outer peripheral side portion, the distance from the farthest point of the outer peripheral side portion to the first line is more than 1 / 10 of the width of the outermost circumferential turn at the tangent point.

8. The coil component as claimed in claim 1, wherein, When viewed along the first direction, a tangent is drawn from the midpoint of the line formed by the end face of the lead conductor portion to the inner periphery of the outermost outermost turn among the plurality of turns. In the line formed by the outer periphery side surface of the outermost outermost turn, the portion closer to the end face of the lead conductor portion than the outer periphery endpoint of the width passing through the tangent point has an approximately arc shape with the center located on the inner periphery side.

9. The coil component as claimed in claim 1, wherein, When viewed along the first direction, the virtual conductive center line is obtained by connecting the outermost outermost turn among the plurality of turns to the midpoint of the width of the lead conductor portion. When the outer end is set along the width including the most bent point in the virtual conductive center line, the outer peripheral end of the line formed by the outer end overlaps with the outer peripheral end of the outermost turn among the lines formed by the exposed end faces of the lead conductor portion.

10. The coil component as claimed in claim 1, wherein, When viewed along the first direction, a tangent is drawn from the midpoint of the line formed by the end faces of the lead conductor portion to the inner periphery of the outermost outermost turn among the plurality of turns. When the side face of the lead conductor portion that is continuous with the outer periphery side face of the outermost outermost turn is taken as the outer side face of the lead portion, the point closest to the tangent in the line formed by the outer periphery side face of the outermost outermost turn and the outer side face of the lead portion overlaps with the outer periphery end point of the outermost outermost turn in the line formed by the end faces of the lead conductor portion that are exposed.

11. The coil component as claimed in any one of claims 1 to 10, further comprising: An external electrode is disposed on the core body and electrically connected to the end face of the lead-out conductor portion exposed from the core body.

12. An electronic / electrical machine having a coil component as claimed in claim 11, wherein the coil component is connected to a substrate at the external electrode.

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