Coil device

Abstract

The present invention provides a coil device (1) capable of preventing short circuit failure, comprising: a core (10) including a winding core portion (12) and a flange portion (14) formed at an end portion of the winding core portion (12) in the X-axis direction; a coil portion (30) formed by winding wires (31, 32) around the winding core portion (12); and terminal electrodes (41, 42) provided on the flange portion (14) and connected to lead-out portions (310, 320) of the wires (31, 32) respectively. A main raised portion (144) having a raised shape is formed on the upper surface (14a) of the flange portion (14) on which at least a portion of the terminal electrodes (41, 42) are arranged, and a second lead-out portion (320) of a second wire (32) is connected to the second terminal electrode (42) on the outside of the main raised portion (144) in the X-axis direction.

Description

Technical Field

[0001] The invention relates to a coil device. Background Art

[0002] As a coil device for an inductor or the like, a common mode choke coil described in Patent Document 1 is known. In the common mode choke coil described in Patent Document 1, a flange portion is formed at an end portion of a winding core portion in a first direction (winding axial direction), and two legs are formed at both ends of the flange portion in a second direction (a direction orthogonal to the first direction). A terminal electrode is formed on each leg portion, and an end portion of each winding of two windings wound on the winding core portion is connected to each terminal electrode.

[0003] However, in the common mode choke coil described in Patent Document 1, the lead-out positions of the ends of the respective windings tend to become unstable, and the ends of the respective windings may come into contact with each other, thereby causing a short-circuit failure.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent Document 1: Japanese Patent Application Laid-Open No. 2006-49383 Summary of the invention

[0007] Problem that the invention aims to solve

[0008] The present invention has been made in view of such circumstances, and an object of the present invention is to provide a coil device capable of preventing a short-circuit failure from occurring.

[0009] Technical solutions to the problem

[0010] In order to achieve the above object, the coil device according to the present invention comprises:

[0011] a core including a winding core portion and a flange portion formed at an end portion of the winding core portion in a first direction;

[0012] A coil portion formed by winding a plurality of wires around the winding core portion; and

[0013] A plurality of terminal electrodes are provided on the flange portion and are connected to the lead-out portions of the plurality of wires respectively.

[0014] A main raised portion having a raised shape is formed on a first surface of the flange portion where at least a portion of any of the terminal electrodes is disposed.

[0015] The lead portion of the wire is connected to any of the terminal electrodes at an outer side in the first direction than the main protrusion.

[0016] In the coil device according to the present invention, a main ridge having a ridge shape is formed on the first surface of the flange portion where at least a portion of any terminal electrode is arranged. Therefore, at the position where the main ridge is formed, the height of the first surface of the flange portion is higher than the height of the surrounding area, and the lead-out portion of the wire located around it is difficult to reach the first surface of the flange portion. Therefore, the lead-out portions of multiple wires are difficult to contact each other around the main ridge, thereby preventing a short circuit fault from occurring.

[0017] Furthermore, generally, when the lead-out portion of the wire is loose (floated), when the terminal electrode of the first surface is connected to the mounting substrate in this state, a short circuit failure may occur due to the loose portion contacting the mounting substrate. However, for example, when a main raised portion is provided on the flange portion, when the terminal electrode of the first surface is connected to the mounting substrate, the position of the lead-out portion of the wire can be offset to a position separated from the mounting substrate by a distance corresponding to the raised amount of the main raised portion. Therefore, it is difficult for the loose portion to contact the mounting substrate, thereby preventing a short circuit failure from occurring.

[0018] In addition, in the coil device according to the present invention, the lead-out portion of the wire is connected to an arbitrary terminal electrode on the outside of the main protrusion in the first direction. In this case, the lead-out portion of the wire can be contacted (fixed) with the main protrusion or its surroundings, and can be led out to the terminal electrode while being positioned at this position. Therefore, the lead-out position of the lead-out portion of the wire can be stabilized, and the relaxation (floating) of the lead-out portion of the wire can be suppressed, making it difficult for the lead-out portion of the wire to reach the first surface of the flange portion. Therefore, contact between the lead-out portions of multiple wires can be avoided, preventing short-circuit failures.

[0019] Preferably, the main ridge is located inside the area sandwiched by the lead-out portion of any of the wires and the lead-out portion of another arbitrary wire. With such a structure, the lead-out portion of the wire led out on one side across the main ridge and the lead-out portion of the wire led out on the other side across the main ridge are difficult to reach the first surface of the flange, and contact between the lead-out portions of the wires can be avoided, effectively preventing short circuit failures.

[0020] Preferably, in addition to the main protrusion, a secondary protrusion is formed on the first surface, and the secondary protrusion is located at one end side of a second direction perpendicular to the first direction. With such a structure, the maximum height of the first surface of the flange portion can be made consistent at one end side of the second direction where the secondary protrusion is located and at a position where the main protrusion is formed (e.g., the other end side of the second direction of the first surface), so that the coil device can be stably connected to the mounting substrate.

[0021] Preferably, a first inclined portion is formed on the flange portion, and the first inclined portion extends obliquely to a third direction perpendicular to the first direction and the second direction relative to the second direction perpendicular to the first direction. With such a structure, the lead-out portion of the wire can be led out to the terminal electrode along the first inclined portion. In addition, at the position where the first inclined portion is formed, the inner corner of the flange portion is removed, so that when the lead-out portion of the wire is led out from the winding core side toward the terminal electrode, it can be prevented from being caught in the corner and causing damage to its insulation coating.

[0022] Preferably, the first inclined portion has an inclined surface that widens toward the first direction as it moves from the starting end toward the terminal end of the first inclined portion, and at the terminal end of the first inclined portion, the inclined surface is formed from the vicinity of the outer end surface of the flange portion to the inner end surface of the flange portion. With such a structure, a deeply inclined inclined surface is formed from the inner side to the outer side of the flange portion in the first direction, and the lead-out portion of the wire can be led out to the vicinity of the outer end surface of the flange portion along the first inclined portion.

[0023] By leading the lead-out portion of the wire to the vicinity of the outer end surface of the flange portion, as described above, the lead-out portion of the wire is brought into contact (fixed) with the main ridge or its periphery, and can be positioned at this position while being led out to the terminal electrode along the main ridge or its periphery. Therefore, the lead-out position of the lead-out portion of the wire can be stabilized, and the relaxation (floating) of the lead-out portion of the wire can be suppressed, making it difficult for the lead-out portion of the wire to reach the first surface of the flange portion. Therefore, contact between the lead-out portions of multiple wires can be avoided, preventing short-circuit failures.

[0024] Preferably, a second inclined portion extending at an angle different from that of the first inclined portion is formed on the flange portion, and the main ridge is located inside a region sandwiched between the first inclined portion and the second inclined portion. With such a configuration, the lead-out portion of the wire led out along the first inclined portion on one side of the main ridge and the lead-out portion of the wire led out along the second inclined portion on the other side of the main ridge are difficult to reach the first surface of the flange portion, and contact between the lead-out portions of the above wires can be avoided, effectively preventing a short circuit fault from occurring.

[0025] Preferably, the width of the flange portion along the first direction on the first surface side is greater than the width of the flange portion along the first direction on the second surface side located on the opposite side of the first surface. With such a structure, the volume of the flange portion can be increased compared to a case where the widths of the flange portion along the first direction on the first surface side and the second surface side are equal, and a coil device with good inductance characteristics can be obtained.

[0026] In addition, compared with the first surface side, on the second surface side, the inner end surface of the flange portion is arranged on the outside in the first direction, so that the lead-out position of the lead-out portion of the wire extending from the second surface side to any terminal electrode and the lead-out position of the lead-out portion of the wire extending from the second surface side to another arbitrary terminal electrode can be separated, thereby avoiding contact between the lead-out portions of the above-mentioned wires and effectively preventing short circuit failures.

[0027] In addition, for example, the lead-out portion of one wire can be fixed near the inner end surface of the flange portion on the first surface side, and the lead-out portion of another wire can be fixed near the inner end surface of the flange portion on the second surface side, so the lead-out portion of each wire can be easily positioned. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1A It is an overall perspective view of a coil device according to one embodiment of the present invention.

[0029] Figure 1B yes Figure 1A A plan view of the coil arrangement shown.

[0030] Figure 1C Observed from the IC direction Figure 1A Side view of the coil arrangement shown.

[0031] Figure 2A It shows the manufacturing Figure 1A A perspective view of the process of making a coil device is shown.

[0032] Figure 2B It is shown Figure 2A A three-dimensional diagram of the subsequent process.

[0033] Figure 2C It is shown Figure 2B A three-dimensional diagram of the subsequent process.

[0034] Figure 2D It is shown Figure 2C A three-dimensional diagram of the subsequent process.

[0035] Figure 2E It is shown Figure 2D A three-dimensional diagram of the subsequent process.

[0036] Figure 2F It is shown Figure 2E A three-dimensional diagram of the subsequent process.

[0037] Figure 2G It is shown Figure 2F A three-dimensional diagram of the subsequent process.

[0038] Figure 2H It is shown Figure 2G A three-dimensional diagram of the subsequent process.

[0039] Figure 3 It is shown Figure 2G A perspective view of a variation of the process shown.

[0040] Figure 4 It is used to illustrate observation from above and below. Figure 1A A diagram showing different points on the core of the coil device.

[0041] Figure 5 When Figure 1A The coil arrangement is shown as a side view when mounted on a mounting substrate. DETAILED DESCRIPTION

[0042] Hereinafter, the present invention will be described based on the embodiments shown in the drawings.

[0043] like Figure 1A As shown, the coil device 1 according to one embodiment of the present invention includes a drum core 10 and a coil portion 30 wound around a winding core portion 12 of the drum core 10 .

[0044] In the following description, the X-axis indicates a direction (first direction) parallel to the winding axis of the winding core portion 12 of the drum core 10 in a plane parallel to the mounting surface on which the coil device 1 is mounted. Like the X-axis, the Y-axis is in a plane parallel to the mounting surface and is a direction perpendicular to the X-axis (second direction). The Z-axis is a normal direction perpendicular to the mounting surface (third direction).

[0045] The drum core 10 has a winding core portion 12 and a pair of flange portions 14m, 14n provided at both ends of the winding core portion 12 in the X-axis direction. One of the flange portions (first flange portion) 14m is provided at one end portion of the axial direction (first direction) of the winding core portion 12. The other flange portion (second flange portion) 14n is provided at the other end portion of the axial direction of the winding core portion 12 and is opposite to the first flange portion 14m. The flange portions 14m, 14n have the same shape, but may also be different from each other. In this embodiment, the flange portions 14m, 14n are configured to be point symmetrical. In the following description, when there is no need to specifically distinguish the flange portions 14m, 14n, they are collectively referred to as "flange portions 14".

[0046] In the following description, the first flange portion 14m is referred to as the "inner side" on the positive X-axis direction and the "outer side" on the negative X-axis direction. The second flange portion 14n is referred to as the "inner side" on the negative X-axis direction and the "outer side" on the positive X-axis direction.

[0047] The size of the drum core 10 (coil device 1) is not particularly limited, but Figure 1B As shown, its length L0 in the X-axis direction is 1.46 to 1.86 mm, its width W2 in the Y-axis direction is 0.85 to 1.25 mm, and its height H1 in the Z-axis direction (refer to Figure 1C) is 0.45~0.53mm. Figure 2A The width W3 of the winding core 12 in the Y-axis direction is Figure 1B The ratio W3 / W2 of the width W2 of the flanges 14m and 14n in the Y-axis direction is preferably 0.6 to 0.9. Figure 1C , the height H1 does not include heights H2 of the main raised portion 144 and the sub-raised portion 145 described later.

[0048] The core portion 12 has a winding axis in the X-axis direction and an elongated, approximately hexagonal cross-section in the Y-axis direction. In the present embodiment, the cross-sectional shape of the core portion 12 is approximately hexagonal, but may also be rectangular, circular or approximately octagonal, and its cross-sectional shape is not particularly limited. A portion of the outer peripheral surface of the core portion 12 located in the approximately central portion in the Y-axis direction protrudes convexly outward. Thus, the cross-sectional area of ​​the core portion 12 can be ensured by the amount of its protrusion, and the inductance characteristics of the coil device 1 can be improved. In the following description, the outer peripheral surface located on the upper side of the core portion 12 is referred to as the upper surface, the outer peripheral surface located on the lower side of the core portion 12 is referred to as the lower surface, and the outer peripheral surface located on the lateral side of the core portion 12 is referred to as the side surface.

[0049] like Figure 1A As shown, the first wire 31 and the second wire 32 are wound on the winding core 12, and the wires 31 and 32 are wound into one or more layers (two layers in this embodiment) to form the coil portion 30. The wires 31 and 32 are composed of covered wires, for example, and have a structure in which a core material made of a good conductor is covered with an insulating coating. In this embodiment, the cross-sectional areas of the conductor parts of the wires 31 and 32 are the same, but they can also be different. In addition, the coil portion 30 can be constructed by winding one wire material in one or more layers, or by winding three or more wire materials in one or more layers.

[0050] In this embodiment, the winding times of the wires 31 and 32 are substantially the same, but may be different depending on the application. The winding times of the wires 31 and 32 being substantially the same means that the ratio of the winding times is in the range of 0.75 to 1 / 0.75, and is preferably 1.

[0051] The outer shape of the flange portion 14 is a substantially rectangular parallelepiped shape (substantially rectangular) that is long in the Y-axis direction, and the flange portions 14m and 14n are arranged substantially parallel to each other at a predetermined interval in the X-axis direction. Figure 1B As shown, when the flange 14 is viewed from the mounting surface side (in this embodiment, on the Z axis), the flange 14 is formed with rounded corners at its four corners. The cross-sectional shape (YZ cross-sectional shape) of the flange 14 may be circular or substantially octagonal, and the cross-sectional shape is not particularly limited.

[0052] The flange portion 14 has an upper surface (first surface) 14a, a lower surface (second surface) 14b, an inner end surface 14c, an outer end surface 14d, a first lateral side surface 14e, and a second lateral side surface 14f. The upper surface 14a is a surface located on the upper side of the flange portion 14. The lower surface 14b is a surface located on the opposite side of the upper surface 14a in the Z-axis direction. The inner end surface 14c is a surface located on the side of the winding core portion 12. The outer end surface 14d is a surface located on the opposite side of the inner end surface 14c in the X-axis direction. The first lateral side surface 14e is a surface that is orthogonal to the upper surface 14a and the inner end surface 14c and is a surface on the side where the first terminal electrode 41 described later is located. The second lateral side surface 14f is a surface that is orthogonal to the upper surface 14a and the inner end surface 14c and is a surface on the side where the second terminal electrode 42 described later is located.

[0053] In this embodiment, when the coil device 1 is mounted on a circuit board, etc., the upper surface 14a becomes a mounting surface (ground surface). In the illustrated example, the second lateral side surface 14f of the first flange portion 14m and the first lateral side surface 14e of the second flange portion 14n are the same surface, but there may also be a deviation in the Y-axis direction between the lateral side surfaces 14e and 14f.

[0054] like Figure 2A As shown in the figure, a concave corner portion 16 is formed at the intersection of the core portion 12 and the flange portion 14. The concave corner portion 16 is an angular portion formed by the outer peripheral surface of the core portion 12 and the inner end surface 14c of the flange portion 14, and is formed in a manner that goes around the core portion 12 in the outer peripheral direction of the core portion 12. Hereinafter, among the concave corner portions 16, the concave corner portion formed by the side surface of the core portion 12 (the side surface on the second lateral side surface 14f side) and the inner end surface 14c of the flange portion 14 is referred to as a first concave corner portion 161, the concave corner portion located on the opposite side of the first concave corner portion 161 across (interposed between) the core portion 12 is referred to as a second concave corner portion 162, and the concave corner portion formed by the upper surface of the core portion 12 and the inner end surface 14c of the flange portion 14 is referred to as a third concave corner portion 163.

[0055] The first concave corner portion 161 is located at a first lead-out portion 310 or a second lead-out portion 320 (see Figure 1A ) is away from the side of the winding core 12 (the side of the winding core 12). The second concave corner 162 corresponds to the concave corner formed by the side surface of the winding core 12 (the side surface on the first lateral side surface 14e side) and the inner end surface 14c of the flange portion 14.

[0056] The first and second concave corners 161 and 162 constitute the side portions of the concave corner 16 and are formed along the Z-axis direction (the height direction of the flange 14). The third concave corner 163 constitutes the upper portion of the concave corner 16 and is formed along the Y-axis direction.

[0057] In this embodiment, the width of the upper surface 14a of the flange portion 14 along the X-axis direction is different between one end side and the other end side of the flange portion 14 in the Y-axis direction. Figure 1B As shown, when the width along the X-axis direction at one end side of the upper surface 14a where the first terminal electrode 41 described later is located is set to W1A, and the width along the X-axis direction at the other end side of the upper surface 14a where the second terminal electrode 42 described later is located is set to W1B, the width W1B along the X-axis direction at the other end side of the upper surface 14a is smaller than the width W1A along the X-axis direction at one end side of the upper surface 14a (W1B<W1A).

[0058] Furthermore, the width W1A of the upper surface 14a along the X-axis direction at one end side in the Y-axis direction corresponds to the length between the outer end surface 14d of the flange portion 14 and the inner end surface 14c of the flange portion 14 located at one end side in the Y-axis direction. Furthermore, the width W1B of the flange portion 14 along the X-axis direction at the other end side in the Y-axis direction corresponds to the length between the outer end surface 14d of the flange portion 14 and the inner end surface 14c of the flange portion 14 located at the other end side in the Y-axis direction.

[0059] The width W1A along the X-axis direction at one end side of the upper surface 14a of the flange portion 14 in the Y-axis direction is preferably 0.45 cm to 0.51 cm. The width W1B along the X-axis direction at the other end side of the upper surface 14a of the flange portion 14 in the Y-axis direction is smaller than the width W1A, and is preferably 0.26 cm to 0.36 cm. The ratio W1B / W1A of the width W1B to the width W1A is preferably greater than or equal to 0.5 and less than 1, and more preferably greater than or equal to 0.7 and less than 0.9. When the diameter of the first line 31 or the second line 32 is d, the difference between the width W1A and the width W1B, that is, the size of the width W1C is preferably W1C ≥ d, and more preferably W1C ≥ 2d.

[0060] In the present embodiment, W1B<W1A, so a portion of the inner end surface 14c of the flange 14 located at the other end side in the Y-axis direction is arranged to be biased toward the outer end surface 14d of the flange 14 along the X-axis direction compared to a portion of the inner end surface 14c located at one end side in the Y-axis direction. The deviation width between a portion of the inner end surface 14c of the flange 14 located at the other end side in the Y-axis direction and a portion of the inner end surface 14c of the flange 14 located at one end side in the Y-axis direction corresponds to the difference between the widths W1A and W1B, i.e., W1C. In the example shown in the figure, the deviation width is 2 to 3 times the diameter of the second wire 32, but it may be larger than that.

[0061] The first concave corner 161 is offset toward the outer end surface 14d of the flange 14 along the X-axis direction compared to the second concave corner 162. The difference width between the first concave corner 161 and the second concave corner 162 corresponds to the difference W1C between the width W1A and the width W1B.

[0062] like Figure 4 As shown, in this embodiment, the width (maximum width) W2A along the X-axis direction on the upper surface 14a side of the flange portion 14 is different from the width (maximum width) W2B along the X-axis direction on the lower surface 14b side of the flange portion 14. More specifically, the width W2A is greater than the width W2B. The difference W2A-W2B between the width W2A and the width W2B is preferably W2A-W2B≥d, and more preferably W2A-W2B≥2d. Wherein, d is the diameter of the first wire 31 or the second wire 32.

[0063] Corresponding to the relationship between the widths W2A and W2B, the length L1A on the upper surface side of the winding core 12 along the X-axis direction is different from the length L1B on the lower surface side of the winding core 12 along the X-axis direction. More specifically, the length L1A is smaller than the length L1B. The difference L1B-L1A between the length L1B and the length L1A is preferably L1B-L1A≥d, and more preferably L1B-L1A≥2d.

[0064] like Figure 1B and Figure 1C As shown, a first terminal electrode 41 is formed on the upper surface 14a (mounting surface) of the flange portion 14. The first terminal electrode 41 formed on the first flange portion 14m and the first terminal electrode 41 formed on the second flange portion 14n have the same structure. The first terminal electrode 41 is composed of a first upper surface electrode portion 410 and a first side electrode portion 411, which are electrically connected. In more detail, the first upper surface electrode portion 410 has a surface parallel to the XY plane and is formed at one end in the Y-axis direction of the upper surface 14a of the flange portion 14. A portion of the first upper surface electrode portion 410 is formed in a manner that enters the first inclined portion 141 described later. In addition, the first side electrode portion 411 has a surface parallel to the YZ plane and is formed on the end surface 14d of the flange portion 14. By forming the first side electrode portion 411 on the flange portion 14, a sufficient solder fillet can be formed on the first terminal electrode 41.

[0065] The first upper surface electrode portion 410 formed on the first flange portion 14m is provided with a first connection portion 311, which is a connection portion with the first lead portion 310 of the first wire 31. The first upper surface electrode portion 410 formed on the second flange portion 14n is provided with a second connection portion 321, which is a connection portion with the second lead portion 320 of the second wire 32. The connection portions 311, 321 are formed by hot pressing the lead portions 310, 320 to the first upper surface electrode portion 410. In the present embodiment, the first upper surface electrode portion 410 also has a function as a mounting portion that is face-to-face connected to the surface of a circuit substrate (not shown). More specifically, the portion of the first upper surface electrode portion 410 where the connection portions 311, 321 are not formed functions as a good bonding surface for solder with the electrode (pad) of the circuit substrate.

[0066] In addition, generally speaking, the solder wettability is reduced in the portion that is thermally pressed. Therefore, it is preferred that the wiring portions 311 and 321 are not arranged in the center of the first upper surface electrode portion 410, but are arranged at the end. In the present embodiment, the wiring portions 311 and 321 are arranged near the outer end surface 14d of the flange portion 14. Thus, the area of ​​the portion of the first upper surface electrode portion 410 that has excellent solder wettability can be sufficiently ensured to be large, and the bonding strength (fixed installation strength) between the coil device and the circuit substrate can be improved. In addition, even when the coil device 1 is miniaturized, the fixed installation strength with the circuit substrate can be sufficiently ensured.

[0067] On the upper surface 14a of the flange portion 14, the second terminal electrode 42 is formed at a predetermined interval (separated) from the first terminal electrode 41 along the Y-axis direction. The second terminal electrode 42 formed on the first flange portion 14m and the second terminal electrode 42 formed on the second flange portion 14n have the same structure. In addition, the interval between the first terminal electrode 41 and the second terminal electrode 42 is not particularly limited as long as it is a distance that ensures insulation.

[0068] In the present embodiment, the second terminal electrode 42 is composed of a second upper surface electrode portion 420 and a second side electrode portion 421, which are electrically connected. In more detail, the second upper surface electrode portion 420 has a surface parallel to the XY plane and is formed at the other end in the Y-axis direction of the upper surface 14a of the flange portion 14 (the opposite side of the first upper surface electrode portion 410 in the Y-axis direction). A portion of the second upper surface electrode portion 420 is formed in a manner that enters the second inclined portion 142 described later. In addition, the second side electrode portion 421 has a surface parallel to the YZ plane and is formed on the end surface 14d of the flange portion 14. By forming the second side electrode portion 421 on the flange portion 14, a sufficient solder fillet can be formed on the second terminal electrode 42.

[0069] The second upper surface electrode portion 420 formed on the first flange portion 14m is provided with a second connection portion 321 as a connection portion with the second lead portion 320 of the second wire 32. The second upper surface electrode portion 420 formed on the second flange portion 14n is provided with a first connection portion 311 as a connection portion with the first lead portion 310 of the first wire 31. The connection portions 311 and 321 are formed by hot pressing the lead portions 310 and 320 to the second upper surface electrode portion 420. In the present embodiment, the second upper surface electrode portion 420 also has a function as a mounting portion connected face to face with the surface of a circuit substrate (not shown). More specifically, the portion of the second upper surface electrode portion 420 where the connection portions 311 and 321 are not formed functions as a good bonding surface for solder with the electrodes (pads) of the circuit substrate.

[0070] In addition, it is preferred that the wiring portions 311 and 321 are not arranged in the center of the second upper surface electrode portion 420, but are arranged at the end. In the present embodiment, the wiring portions 311 and 321 are arranged near the outer end surface 14d of the flange portion 14. Thus, the area of ​​the portion of the second upper surface electrode portion 420 with excellent solder wettability can be sufficiently large, and the fixing strength between the coil device and the circuit substrate can be improved. In addition, even when the coil device 1 is miniaturized, the fixing strength with the circuit substrate can be sufficiently ensured.

[0071] The first terminal electrode 41 and the second terminal electrode 42 are formed by, for example, a metal paste sintered film or a metal plating film. The terminal electrodes 41 and 42 are formed by applying, for example, Ag paste to the upper surface 14a and the outer end surface 14d of the flange portion 14 and sintering the surface, and then performing, for example, electric field plating or non-electric field plating on the surface to form a plating film.

[0072] In addition, the material of the metal paste is not particularly limited, and examples thereof include Cu paste or Ag paste. In addition, the plating film may be a single layer or a multilayer, and examples thereof include Cu plating, Ni plating, Sn plating, Ni-Sn plating, Cu-Ni-Sn plating, Ni-Au plating, Au plating, etc. The thickness of the terminal electrodes 41 and 42 is not particularly limited, but is preferably 0.1 to 15 μm.

[0073] like Figure 2AAs shown, the flange portion 14 is formed with a first inclined portion 141 and a second inclined portion 142. The first inclined portion 141 formed on the first flange portion 14m and the first inclined portion 141 formed on the second flange portion 14n are constituted by the same structure. In addition, the second inclined portion 142 formed on the first flange portion 14m and the second inclined portion 142 formed on the second flange portion 14n are constituted by the same structure. In the present embodiment, the inclined portions 141, 142 formed on the first flange portion 14m and the inclined portions 141, 142 formed on the second flange portion 14n are arranged in a point-symmetrical manner.

[0074] The first inclined portion 141 is formed in a range between the upper surface of the winding core 12 and the upper surface 14a of the flange 14, and extends obliquely in the Z-axis direction relative to the Y-axis direction. An extension line C1 of the central axis of the first inclined portion 141 intersects with the first lateral side surface 14e of the flange 14, and also intersects with the step surface 149 (see FIG. Figure 2B ) intersect with the peripheral edge 1490.

[0075] The first inclined portion 141 has a first inclined surface 1410 and a first wall-side side surface 1411. The first inclined surface 1410 is composed of an inclined surface inclined from one end side in the Y-axis direction of the flange portion 14 toward the other end side in the Y-axis direction. At the position of the first inclined portion 141, the inner end surface 14c of the flange portion 14 is cut by the first inclined surface 1410.

[0076] like Figure 2B As shown, the starting end 141s of the first inclined portion 141 is located closer to the other end side in the Y-axis direction than the center of the flange portion 14 in the Y-axis direction, and the terminal end 141e of the first inclined portion 141 is located closer to one end side in the Y-axis direction than the center of the flange portion 14 in the Y-axis direction.

[0077] The first inclined surface 1410 is formed so as to become wider in the X-axis direction from the starting end 141s toward the terminal end 141e of the first inclined portion 141, and is formed from the vicinity of the outer end surface 14d of the flange portion 14 to the inner end surface 14c of the flange portion 14 at the terminal end portion (the peripheral portion of the terminal end 141e) of the first inclined surface 1410. At the terminal end 141e of the first inclined surface 1410, when the distance between the end portion of the first inclined surface 1410 in the X-axis direction and the outer end surface 14d of the flange portion 14 is L, the ratio L / W1A of the distance L to the width W1A of one end side of the upper surface 14a of the flange portion 14 in the X-axis direction is preferably 0 to 0.2.

[0078] like Figure 2A As shown, the first wall side surface 1411 constitutes a part of the wall portion 143. The first wall side surface 1411 is formed by a rising wall surface and extends along one side of the first inclined surface 1410.

[0079] The second inclined portion 142 extends obliquely toward the outer side (outer end face 14d) of the flange portion 14 at an angle different from that of the first inclined portion 141, and is inclined in a gradually descending manner. An extension line C2 of the central axis of the second inclined portion 142 intersects the outer end face 14d of the flange portion 14, extends toward the first concave corner portion 161 to be described later, and intersects with the step surface 148 to be described later (see Figure 2B ) intersects the peripheral portion 1480 of the second inclined portion 142. The angle between the extended line C2 and the X-axis is preferably 18 to 24 degrees. The extending direction of the extended line C2 is substantially the same as the leading direction of the second lead portion 320 led out along the second inclined portion 142 (see Figure 1A ).

[0080] The second inclined portion 142 is formed in a groove shape (groove portion), and has a second inclined surface 1420, a second wall side surface 1421, and a second outer side surface 1422. The second inclined surface 1420 is arranged to be sandwiched between the second wall side surface 1421 and the second outer side surface 1422, and is formed of an inclined surface inclined from the outer end surface 14d of the flange portion 14 toward the inner end surface 14c.

[0081] The second wall-side side surface 1421 is formed adjacent to the wall portion 143, and constitutes a portion of the wall portion 143. The second outer side surface 1422 is formed on the opposite side of the second wall-side side surface 1421 with the second inclined surface 1420 interposed therebetween.

[0082] The flange portion 14 has a stepped surface 148 and a stepped surface 149. The stepped surface 148 is substantially flat and is formed near the other end of the third concave corner portion 163 in the Y-axis direction (the second lateral side surface 14f side) or the upper end of the first concave corner portion 161.

[0083] like Figure 2B As shown, in this embodiment, the second starting end 142s of the second inclined portion 142 is connected to the peripheral portion 1480 of the step surface 148. The second starting end 142s of the second inclined portion 142 corresponds to the intersection of the step surface 148 and the second inclined portion 142 (the second inclined surface 1420). The second terminal 142e of the second inclined portion 142 corresponds to the intersection of the upper surface 14a of the flange portion 14 and the second inclined portion 142 (the second inclined surface 1420).

[0084] The step surface 149 is formed of a substantially flat shape and is formed adjacent to the third concave corner portion 163 and the wall portion 143 on the other end side relative to the center portion in the Y-axis direction of the flange portion 14. The first starting end 141s of the first inclined portion 141 is connected to the peripheral edge portion 1490 of the step surface 149. The first starting end 141s of the first inclined portion 141 corresponds to the intersection of the step surface 149 and the first inclined portion 141 (first inclined surface 1410). The first terminal end 141e of the first inclined portion 141 corresponds to the intersection of the upper surface 14a of the flange portion 14 and the first inclined portion 141 (first inclined surface 1410).

[0085] like Figure 1A As shown, in this embodiment, the first lead portion 310 of the first wire 31 passes through the first inclined portion 141 of the first flange portion 14m, and the second lead portion 320 of the second wire 32 passes through the second inclined portion 142 of the first flange portion 14m. In addition, the second lead portion 320 of the second wire 32 passes through the first inclined portion 141 of the second flange portion 14n, and the first lead portion 310 of the first wire 31 passes through the second inclined portion 142 of the second flange portion 14n.

[0086] More specifically, if Figure 1A and Figure 2A As shown, on the first flange portion 14m side, the first lead portion 310 of the first wire 31 leaves the winding core 12 (or the coil portion 30) at the side of the winding core 12 and is led out toward the step surface 149. Then, the first lead portion 310 passes over the step surface 149 without contacting it, and is guided along the first inclined surface 1410 of the first inclined portion 141 (see Figure 2A ) is led out obliquely toward the first terminal electrode 41. More specifically, the first lead portion 310 is led out to the first terminal electrode 41 along the first wall side surface 1411 of the first inclined portion 141 or fixed on the first wall side surface 1411.

[0087] Furthermore, on the first flange portion 14m side, the second lead portion 320 of the second wire 32 is led out toward the step surface 148 after leaving the winding core portion 12 (or the coil portion 30) on the side surface of the winding core portion 12. Then, the second lead portion 320 passes over the step surface 148 without contacting it, and is led out along the second inclined surface 1420 of the second inclined portion 142 toward the second terminal electrode 42 (or the outer end surface 14d of the flange portion 14) at an angle different from that of the first lead portion 310.

[0088] On the second flange portion 14n side, the second lead portion 320 of the second wire 32 is led out toward the step surface 149 after leaving the winding core portion 12 (or the coil portion 30) on the side surface of the winding core portion 12. Then, the second lead portion 320 passes over the step surface 149 without contacting it, and is led out to the first terminal electrode 41 along the first inclined surface 1410 of the first inclined portion 141 or fixed to the first wall side surface 1411 at an angle.

[0089] On the side of the second flange portion 14n, the first lead portion 310 of the first wire 31 is led out toward the step surface 148 (not shown) after leaving the winding core portion 12 (or the coil portion 30) on the side of the winding core portion 12. Then, the first lead portion 310 passes over the step surface 148 without contacting it, and is led out along the second inclined surface 1420 of the second inclined portion 142 toward the second terminal electrode 42 (or the outer end surface 14d of the flange portion 14) at an angle different from that of the second lead portion 320.

[0090] As described above, in this embodiment, the first concave corner portion 161 is larger than the second concave corner portion 162 by the width W1C (see Figure 1B ) is offset toward the outer end surface 14d of the flange portion 14. Therefore, within the range between the end of the winding core portion 12 on the negative side in the X-axis direction and the stepped surface 148, the second lead-out portion 320 can be led out obliquely, and near the first concave corner portion 161, each of the first lead-out portion 310 and the second lead-out portion 320 can be arranged to be spaced apart along the X-axis direction.

[0091] The second wire 32 is wired in an overhead manner between the step surface 148 and the front portion of the second terminal 142 e of the second inclined portion 142 , and the front portion of the second terminal 142 e of the second inclined portion 142 may also contact the bottom of the second inclined portion 142 (the second inclined portion 1420 ).

[0092] The first inclined portion 141 and the second inclined portion 142 are separated by a wall portion 143 formed on the flange portion 14. The wall portion 143 is located between the first inclined portion 141 and the second inclined portion 142, and a portion of the wall portion 143 protrudes inwardly in the X-axis direction relative to the sub-protrusion 145 described later. Therefore, the first lead-out portion 310 is led out toward the first inclined portion 141 in a manner that bypasses a portion of the wall portion 143 protruding from the inner end surface 14c of the flange portion 14. Therefore, the first lead-out portion 310 and the second lead-out portion 320 can be sufficiently separated from each other, and contact between the first lead-out portion 310 and the second lead-out portion 320 can be effectively prevented.

[0093] like Figure 2AAs shown, the wall portion 143 has a front end face 1430, a first side face 1431, and a second side face 1432. The front end face 1430 is composed of a wall surface substantially parallel to the YZ plane, and constitutes a part of the inner end face 14c of the flange portion 14. The front end face 1430 constitutes the front end portion of the wall portion 143, and is connected to the first side face 1431 and the second side face 1432 on both sides thereof. The first side face 1431 is composed of a rising wall surface, and is connected to the first wall side face 1411 of the first inclined portion 141. The first side face 1431 is continuously connected to the first wall side face 1411, but may also be connected discontinuously. The second side face 1432 is composed of a wall surface substantially parallel to the XZ plane, and is discontinuously connected to the second wall side face 1421 of the second inclined portion of the flange portion 14.

[0094] In the present embodiment, a main ridge 144 having a protruding shape (convex or protruding shape) is formed on the upper surface (first surface) 14a of the flange portion 14. The main ridge 144 is formed on the other end side of the flange portion 14 in the Y-axis direction and is located inside the region sandwiched between the first inclined portion 141 and the second inclined portion 142. More specifically, the main ridge 144 is formed on the inside of the flange portion 14 in the X-axis direction in the region sandwiched by the first inclined portion 141 and the second inclined portion 142, constituting a portion of the upper surface of the wall portion 143.

[0095] At the position where the main raised portion 144 is formed on the upper surface 14a of the flange portion 14, the height of the upper surface 14a of the flange portion 14 is higher than the height of the surrounding positions of the position. The upper surface of the main raised portion 144 is a flat surface, and a step is formed between the position where the main raised portion 144 is formed on the upper surface 14a of the flange portion 14 and the position where the main raised portion 144 is not formed (the outer end of the main raised portion 144 in the X-axis direction).

[0096] like Figure 1C As shown, the ratio H2 / H1 of the height H2 of the main raised portion 144 (the height of the main raised portion 144 relative to the peripheral portion on the upper surface 14a of the flange portion 14) and the height H1 of the flange portion 14 (the height of the peripheral portion of the main raised portion 144 on the upper surface 14a of the flange portion 14) is preferably 0.01 to 0.08, and more preferably 0.03 to 0.06. In addition, the ratio H2 / d of the height H2 of the main raised portion 144 to the above-mentioned d is preferably 0.3 to 1.3, and more preferably 0.5 to 1.0. Here, d is the diameter of the first line 31 or the second line 32. In addition, in the example shown in the figure, the upper surface of the main raised portion 144 is a flat surface, but it can also be formed to be raised in a mountain shape, for example.

[0097] exist Figure 1CIn the figure, the height H2 of the main protrusion 144 is the height at which a portion of the second connection portion 321 of the second lead portion 320 protrudes upward compared to the upper surface of the main protrusion 144 when the second lead portion 320 of the second wire 32 is connected to the second upper surface electrode portion 420 of the second terminal electrode 42.

[0098] like Figure 2A As shown, the main raised portion 144 constitutes a part of the wall portion 143, and is formed by extending the upper surface of the wall portion 143 upward. The side surface of the main raised portion 144 is composed of the first wall side surface 1411 of the first inclined portion 141, the second wall side surface 1421 of the second inclined portion 142, the top end surface 1430 of the wall portion 143, the first side surface 1431, and the second side surface 1432. The upper surface of the main raised portion 144 is discontinuously (step-shaped) connected to its peripheral portion, but it can also be continuously connected.

[0099] like Figure 2A As shown in FIG. 1 , when viewed from above in the Z-axis direction, the main protrusion 144 has a polygonal shape (a pentagon in the example shown in the figure) and is formed so as to become wider as it goes outward in the X-axis direction. The maximum width W4 of the main protrusion 144 in the X-axis direction is equal to the width W1A of one end side of the upper surface 14a of the flange portion 14 in the X-axis direction (see FIG. 1 ). Figure 1B ) The ratio W4 / W1A is preferably 0.2 to 0.5, more preferably 0.3 to 0.4.

[0100] like Figure 2B As shown, in the present embodiment, the inner end of the second upper surface electrode portion 420 of the second terminal electrode 42 in the X-axis direction is located outside the outer end of the main protrusion 144 in the X-axis direction. The second upper surface electrode portion 420 and the main protrusion 144 are arranged side by side along the X-axis direction. That is, the second upper surface electrode portion 420 is not formed on the main protrusion 144, and the main protrusion 144 and the second upper surface electrode portion 420 are arranged independently (non-overlapping) from each other. In addition, the main protrusion 144 is partially arranged at a position corresponding to the second upper surface electrode portion 420 of the second terminal electrode 42.

[0101] like Figure 1A As shown, the second lead portion 320 of the second wire 32 is connected to the second upper surface electrode portion 420 of the second terminal electrode 42 at the outer side of the main ridge 144 in the X-axis direction, forming the second connection portion 321 at this position. Therefore, the main ridge 144 is arranged between the second connection portion 321 and the coil portion 30.

[0102] The main raised portion 144 is located inside the region sandwiched by the first lead portion 310 of the first line 31 led out along the first inclined portion 141 and the second lead portion 320 of the second line 32 led out along the second inclined portion 142. The main raised portion 144 has a predetermined width in the Y-axis direction (in the illustrated example, about 1 / 4 to 1 / 3 of the width of the flange portion 14 in the Y-axis direction), so that the first lead portion 310 and the second lead portion 320 passing around the main raised portion 144 can be sufficiently separated to prevent the first lead portion 310 and the second lead portion 320 from contacting each other.

[0103] like Figure 2A As shown, on the upper surface 14a of the flange portion 14, a sub-raised portion 145 is formed in addition to the main raised portion 144. The sub-raised portion 145 has a protruding shape (convex or protruding shape). The sub-raised portion 145 is formed on one end side of the flange portion 14 in the Y-axis direction and is located on the inner side of the flange portion 14 in the X-axis direction. The sub-raised portion 145 is located closer to one end side in the Y-axis direction than the first inclined portion 141, and the first inclined portion 141 is sandwiched between the main raised portion 144 and the sub-raised portion 145.

[0104] At the position where the secondary protrusion 145 is formed on the upper surface 14a of the flange 14, the height of the upper surface 14a of the flange 14 is higher than the height around the position. The upper surface of the secondary protrusion 145 is a flat surface, and a step is formed between the position where the secondary protrusion 145 is formed on the upper surface 14a of the flange 14 and the position where the secondary protrusion 145 is not formed (the outer end of the secondary protrusion 145 in the X-axis direction). The height of the secondary protrusion 145 is equal to the height H2 of the main protrusion 144 (refer to Figure 1C ) are substantially equal. In the example shown in the figure, the upper surface of the sub-protrusion 145 is a flat surface, but it can also be formed to be raised in a mountain shape, for example.

[0105] When viewed from above in the Z-axis direction, the sub-ridge 145 has a polygonal shape (a rectangular shape in the illustrated example), but the shape is not particularly limited.

[0106] like Figure 2B As shown, the inner end of the first upper surface electrode portion 410 in the X-axis direction is located outside the outer end of the sub-ridge portion 145 in the X-axis direction, and the first upper surface electrode portion 410 and the sub-ridge portion 145 are arranged side by side along the X-axis direction. That is, the first upper surface electrode portion 410 of the first terminal electrode 41 is not formed on the sub-ridge portion 145, and the sub-ridge portion 145 and the first upper surface electrode portion 410 are arranged independently of each other (not overlapping).

[0107] like Figure 1AAs shown, the first lead portion 310 of the first wire 31 is connected to the first upper surface electrode portion 410 of the first terminal electrode 41 at the outer side of the sub-protrusion 145 in the X-axis direction, forming the first connection portion 311 at this position. Therefore, the sub-protrusion 145 is arranged between the first connection portion 311 and the coil portion 30.

[0108] like Figure 5 As shown, the coil device 1 is fixed to the mounting substrate 80 via a connecting member 90 such as solder or a conductive adhesive. More specifically, on the first flange portion 14m side, the first upper surface electrode portion 410 of the first terminal electrode 41 is connected to the connection pad 81 of the mounting substrate 80 by the connecting member 90 at the outer side of the X-axis direction compared to the secondary protrusion 145. Although detailed illustration is omitted, the second upper surface electrode portion 420 of the second terminal electrode 42 is connected to the connection pad 81 of the mounting substrate 80 by the connecting member 90 at the outer side of the X-axis direction compared to the main protrusion 144.

[0109] On the second flange portion 14n side, the second upper surface electrode portion 420 of the second terminal electrode 42 is connected to the connection pad 81 of the mounting substrate 80 through the connecting member 90 at the outer side in the Z-axis direction compared with the main protrusion 144. Although the detailed illustration is omitted, the first upper surface electrode portion 410 of the first terminal electrode 41 is connected to the connection pad 81 of the mounting substrate 80 through the connecting member 90 at the outer side in the X-axis direction compared with the sub-protrusion 145.

[0110] When the upper surface electrode portions 410, 420 of the terminal electrodes 41, 42 are connected to the connection pads 81 of the mounting substrate 80, the upper surfaces of the main protrusion 144 and the sub-protrusion 145 do not contact the mounting substrate 80, but are arranged at a predetermined distance above the mounting substrate 80. The shape of the connection pads 81 of the mounting substrate 80 is preferably formed into the shape of the upper surface electrode portions 410, 420 of the terminal electrodes 41, 42.

[0111] In manufacturing the coil device 1, first, a drum-shaped drum core 10 and wires 31 and 32 are prepared. As the wires 31 and 32, wires obtained by, for example, covering a core material made of a good conductor such as copper (Cu) with an insulating material such as imide-modified polyurethane, and further covering the outermost surface with a thin resin film such as polyester, can be used.

[0112] As the magnetic material constituting the drum core 10, for example, a magnetic material with a high magnetic permeability, such as Ni-Zn ferrite and Mn-Zn ferrite, or a metal magnetic body, etc., the drum core 10 is manufactured by molding and sintering the powder of these magnetic materials. Figure 2AAs shown, the drum core 10 is manufactured in such a manner that the first inclined portion 141, the second inclined portion 142, the main raised portion 144, and the sub-raised portion 145 are formed on each portion of the flange portion 14. In addition, the drum core 10 is manufactured in such a manner that the winding core portion 12 and the pair of flange portions 14 are integrally formed, and the width of the flange portion 14 along the X-axis direction is different at one end side and the other end side of the flange portion 14 in the Y-axis direction.

[0113] Next, metal paste is applied to the flange portion 14 of the drum core 10 and sintered at a predetermined temperature. Then, the surface is subjected to electric field plating or electroless plating to form a Figure 2B The first terminal electrode 41 and the second terminal electrode 42 are as shown.

[0114] Next, the drum core 10 and the wires 31 and 32 formed with the terminal electrodes 41 and 42 are placed in a winding machine (not shown). Figure 2C As shown, the first wire 31 (first lead portion 310) is led out from the front end of the nozzle 50 and connected to the first upper surface electrode portion 410 of the first terminal electrode 41. Thus, the first connection portion 311 is formed at the connection portion between the first upper surface electrode portion 410 and the first wire 31.

[0115] At the same time (or thereafter), the second wire 32 (second lead portion 320) is led out from the front end of the nozzle 50 and connected to the second upper surface electrode portion 420 of the second terminal electrode 42. Thus, the second connection portion 321 is formed at the connection portion between the second upper surface electrode portion 420 and the second wire 32.

[0116] In addition, the connection method is not particularly limited, and for example, the wires 31 and 32 may be thermocompressed and bonded to the terminal electrodes 41 and 42 by pressing a thermocompressive heat press sheet so that the wires 31 and 32 are sandwiched between the terminal electrodes 41 and 42. As the insulating material covering the core wires of the wires 31 and 32 is thermally melted during thermocompressive bonding, it is not necessary to remove the coating from the wires 31 and 32.

[0117] In the present embodiment, each wire 31, 32 is thermocompressively bonded to the terminal electrodes 41, 42 at a position equidistant from the outer end surface 14d near the flange portion 14. As described above, by aligning the positions for thermocompressively bonding each wire 31, 32, it is possible to thermocompress each wire 31, 32 to the terminal electrodes 41, 42 at one time under appropriate welding conditions without the need to exchange thermocompressive sheets or prepare a plurality of thermocompressive sheets. Therefore, the reliability and workability of thermocompressive bonding can be improved.

[0118] Next, if Figure 2DAs shown, the unnecessary parts of the wires 31, 32 (lead-out parts 310, 320) extending from the upper surface electrode parts 410, 420 (terminal electrodes 41, 42) are cut off by a cutting tool 60. When the unnecessary parts of the lead-out parts 310, 320 are cut off, the cut-off parts of the lead-out parts 310, 320 are arranged at the peripheral part of the outer end surface 14d of the flange part 14, and the cutting tool 60 is arranged (positioned) in such a way that its side surface is substantially flush with the outer end surface 14d.

[0119] Then, at this position, the cutting tool 60 is lowered along the outer end surface 14d in the Z-axis direction. Thus, the cutting portion of the lead-out portions 310 and 320 can be cut without the cutting tool 60 contacting the corner between the upper surface 14a of the flange portion 14 and the outer end surface 14d, thereby preventing the flange portion 14 from being damaged.

[0120] In this embodiment, the lead-out portions 310 and 320 are each led out toward the outer end surface 14d of the flange portion 14. Therefore, the lead-out portions 310 and 320 can be cut at once using the cutting tool 60, and workability can be improved.

[0121] Next, if Figure 2E As shown, on the first flange portion 14m side, the first wire 31 (first lead portion 310) is led out obliquely toward the middle position of the third concave corner portion 163 in the Y-axis direction along the inclined surface of the first inclined portion 141 while passing above the step surface 149. Then, the led out first wire 31 is led out along the third concave corner portion 163 toward the other end side in the Y-axis direction. Figure 2A The first wall-side side surface 1411 of the first inclined portion 141 shown is led out while abutting against the first side surface 1431 of the wall portion 143 .

[0122] Furthermore, the second wire 32 (second lead portion 320) is led out obliquely downward toward the inside to the end portion on one side in the X-axis direction of the winding core portion 12 while passing above the step surface 148 along the inclined surface of the second inclined portion 142. Thereafter, the wires 31 and 32 are wound around the opposite side (the other end side) in the X-axis direction of the winding core portion 12 to form the coil portion 30.

[0123] Then, on the side of the second flange portion 14n, the second wire 32 (second lead-out portion 320) is led out from the end of the other side in the X-axis direction of the winding core portion 12 to the other end side in the Y-axis direction to the midway position in the Y-axis direction of the third concave corner portion 163 (not shown). Then, the led-out second wire 32 is led out obliquely along the inclined surface of the first inclined portion 141 toward the first upper surface electrode portion 410 of the first terminal electrode 41 while passing above the step surface 149. Then, the second wire 32 is hooked and fixed to the support 70 to prevent it from loosening. The second wire 32 is connected to the support 70 at the same time as the second wire 32 passes through the step surface 149. Figure 2AThe first wall-side side surface 1411 of the first inclined portion 141 shown is led out while abutting against the first side surface 1431 of the wall portion 143 .

[0124] At the same time (or afterwards), the first wire 31 (first lead-out portion 310) is led out obliquely upward from the other end side in the X-axis direction of the winding core portion 12 toward the outside in the X-axis direction, and while passing over the stepped surface 1148 (not shown), it is led out obliquely along the inclined surface of the second inclined portion 142 toward the second upper surface electrode portion 420 of the second terminal electrode 42. Then, the first wire 31 is hooked and fixed to the support 70 to prevent it from loosening.

[0125] Then, if Figure 2F As shown, the first wire 31 is connected to the second upper surface electrode portion 420 of the second terminal electrode 42. Thus, the first wiring portion 311 is formed at the connection portion between the second upper surface electrode portion 420 and the first wire 31.

[0126] At the same time (or thereafter), the second wire 32 is connected to the first upper surface electrode portion 410 of the first terminal electrode 41. Thus, the second wiring portion 321 is formed at the connection portion between the first upper surface electrode portion 410 and the second wire 32.

[0127] Then, if Figure 2G As shown, Figure 2D In the same manner as described above, unnecessary portions of the wires 31 and 32 (lead portions 310 and 320 ) extending from the upper surface electrode portions 410 and 420 (terminal electrodes 41 and 42 ) are cut off using the cutting tool 60 .

[0128] Then, if Figure 2H As shown, a plate-like core 20 is provided on the lower surface 14b of the flange portion 14. The lower surface 14b is formed by a flat surface, and the plate-like core 20 is easily provided. The plate-like core 20 is formed by a flat rectangular parallelepiped having a flat surface, and has a function of increasing the inductance of the coil device 1. The plate-like core 20 is preferably formed by the same magnetic body component as the drum core 10, but may also be formed by separate components. In addition, the plate-like core 20 does not necessarily need to be formed by a magnetic body, and may also be formed by a non-magnetic body such as a synthetic resin.

[0129] In the coil device 1 according to the present embodiment, as Figure 1A As shown in the figures, a main ridge 144 is formed on the upper surface 14a of the flange 14. Therefore, at the position where the main ridge 144 is formed, the height of the upper surface 14a of the flange 14 is higher than the height of the surrounding area, and the lead-out portions 310 and 320 of the wires 31 and 32 located around it are difficult to reach the upper surface 14a of the flange 14. Therefore, the lead-out portions 310 and 320 of the wires 31 and 32 are difficult to contact each other around the main ridge 144, so that a short circuit fault can be prevented from occurring.

[0130] Furthermore, generally, when the lead portions 310, 320 of the wires 31, 32 are slack (floated), when the terminal electrodes 41, 42 of the upper surface 14a are connected to the mounting substrate 80 in this state, a short circuit failure may occur due to the slack portion contacting the mounting substrate 80. However, for example, by setting the height of the main raised portion 144 to be greater than a predetermined length, when the terminal electrodes 41, 42 of the upper surface 14a are connected to the mounting substrate, the position of the lead portions 310, 320 of the wires 31, 32 can be shifted to a position separated from the substrate 80 by a distance corresponding to the raised amount of the main raised portion 144. Therefore, it is difficult for the slack portion to contact the mounting substrate 80, so that a short circuit failure can be prevented from occurring.

[0131] In addition, in the coil device 1 according to the present embodiment, the second lead-out portion 320 of the second wire 32 is connected to the second terminal electrode 42 at the outer side of the main protrusion 144 in the X-axis direction. In this case, the second lead-out portion 320 can be contacted (fixed) with the outer periphery (wall portion 143) of the main protrusion 144, and can be led to the second terminal electrode 42 while being positioned at this position. Therefore, the lead-out position of the second lead-out portion 320 can be stabilized, and the relaxation (floating) of the second lead-out portion 320 can be suppressed, making it difficult for the second lead-out portion 320 to reach the upper surface 14a of the flange portion 14. Therefore, the contact between the lead-out portions 310 and 320 of the wires 31 and 32 can be avoided, and a short circuit fault can be prevented.

[0132] Moreover, the main ridge 144 is located inside the region sandwiched between the first lead-out portion 310 of the first wire 31 and the second lead-out portion 320 of the second wire 32. Therefore, the first lead-out portion 310 led out on one side across the main ridge 144 and the second lead-out portion 320 led out on the other side across the main ridge 144 are difficult to reach the upper surface 14a of the flange portion 14, and the contact between the lead-out portions 310 and 320 can be avoided, effectively preventing the occurrence of a short circuit fault.

[0133] In addition, on the upper surface 14a, a sub-protrusion 145 is formed in addition to the main protrusion 144, and the sub-protrusion 145 is located at one end side in the Y-axis direction. Therefore, the maximum height of the upper surface 14a of the flange portion 14 can be made consistent at one end side in the Y-axis direction where the sub-protrusion 145 is located and at the other end side in the Y-axis direction where the main protrusion 144 is located, so that the coil device 1 can be stably connected to the mounting substrate 80.

[0134] In addition, a first inclined portion 141 extending obliquely in the Z-axis direction relative to the Y-axis direction is formed on the flange portion 14. Therefore, the first lead portion 310 of the first wire 31 can be led out to the first terminal electrode 41 along the first inclined portion 141. In addition, at the position where the first inclined portion 141 is formed, the inner corner (the corner formed by the upper surface 14a and the inner end surface 14c) of the flange portion 14 is removed, so that when the first lead portion 310 is led out from the winding core portion 12 side toward the first terminal electrode 41, it is possible to prevent the first lead portion 310 from being caught at the corner and causing its insulation coating to be damaged.

[0135] In addition, if Figure 2B As shown in FIG. 1 , the first inclined portion 141 has a first inclined surface 1410 that becomes wider in the X-axis direction as it moves from the starting end 141s of the first inclined portion 141 toward the terminal end 141e. At the terminal end 141e of the first inclined portion 141, the first inclined surface 1410 is formed from the vicinity of the outer end surface 14d of the flange portion 14 to the inner end surface 14c of the flange portion 14. Therefore, a deeply inclined inclined surface is formed from the inner side to the outer side of the flange portion 14 in the X-axis direction, as shown in FIG. Figure 1A As shown in FIGS. 1 and 14 , the first lead-out portion 310 of the first wire 31 can be led out along the first inclined portion 141 to the vicinity of the outer end surface 14 d of the flange portion 14 .

[0136] By leading the first lead portion 310 to the vicinity of the outer end surface 14d of the flange portion 14, as described above, the first lead portion 310 is brought into contact with (fixed to) the periphery (wall portion 143) of the main protrusion 144, and can be positioned at this location while being led out to the first terminal electrode 41 along the periphery (wall 143) of the main protrusion 144. Therefore, the lead position of the first lead portion 310 can be stabilized, and the slack (floating) of the first lead portion 310 can be suppressed, making it difficult for the first lead portion 310 to reach the upper surface 14a of the flange portion 14. Therefore, contact between the lead portions 310 and 320 of the wires 31 and 32 can be avoided, and a short circuit failure can be prevented.

[0137] In addition, the flange portion 14 is provided with a second inclined portion 142 extending at an angle different from that of the first inclined portion 141, and the main raised portion 144 is located inside the region sandwiched between the first inclined portion 141 and the second inclined portion 142. Therefore, the first lead-out portion 310 of the first wire 31 led out along the first inclined portion 141 located on one side of the main raised portion 144 and the second lead-out portion 320 of the second wire 32 led out along the second inclined portion 142 located on the other side of the main raised portion 144 are difficult to reach the upper surface 14a of the flange portion 14, and the contact between the lead-out portions 310 and 320 of the wires 31 and 32 can be avoided, thereby effectively preventing the occurrence of a short-circuit fault.

[0138] In addition, if Figure 4 As shown, the width W2A along the X-axis direction on the upper surface 14a side of the flange portion 14 is greater than the width W2B along the X-axis direction on the lower surface 14b side of the flange portion 14. Therefore, compared with the case where the widths along the X-axis direction on the upper surface 14a side and the lower surface 14b side of the flange portion 14 are equal, the volume of the flange portion 14 can be increased, and the coil device 1 with good inductance characteristics can be obtained.

[0139] In addition, the inner end surface 14c of the flange portion 14 is arranged on the outer side in the X-axis direction on the lower surface 14b side compared to the upper surface 14a side, as shown in FIG. Figure 1A As shown, the lead-out position of the first lead-out portion 310 of the first wire 31 extending from the upper surface 14a side toward the first terminal electrode 41 and the lead-out position of the second lead-out portion 320 of the second wire 32 extending from the lower surface 14b side toward the second terminal electrode 42 can be separated, thereby avoiding contact between the lead-out portions 310, 320 of the above-mentioned wires 31, 32 and effectively preventing short circuit failures.

[0140] In addition, for example, the first lead-out portion 310 can be fixed on the upper surface 14a side (the upper surface side of the winding core portion 12) near the inner end surface 14c of the flange portion 14, and the second lead-out portion 320 can be fixed on the lower surface 14b side (the lower surface side of the winding core portion 12) near the inner end surface 14c of the flange portion 14, so that the lead-out portions 310, 320 of each wire 31, 32 can be easily positioned.

[0141] The present invention is not limited to the above-described embodiment, and various changes can be made within the scope of the present invention.

[0142] In the above embodiment, the number of the main protrusion 144 is not limited to one, and may be two or more. For example, when the coil portion 30 is composed of three wires, the main protrusion may also be formed on the inner side of each area sandwiched by the lead-out portions of the three wires. The same is true for the secondary protrusion 145, and the number of the secondary protrusion 145 may be two or more.

[0143] In the above embodiment, the second terminal electrode 42 is not formed on the upper surface of the main protrusion 144, but the second terminal electrode 42 may be formed so as to straddle the main protrusion 144. In addition, in the above embodiment, the first terminal electrode 41 is not formed on the upper surface of the sub-protrusion 145, but the first terminal electrode 41 may be formed so as to straddle the sub-protrusion 145.

[0144] In the above embodiment, the terminal electrodes 41 and 42 may be formed by terminal metal fittings. For example, the terminal electrodes 41 and 42 may be formed by fixing an L-shaped terminal metal fitting across the upper surface 14a and the outer end surface 14d of the flange portion 14 with a connecting material such as an adhesive.

[0145] In the above embodiment, when the second lead portion 320 of the second wire 32 is connected to the second upper surface electrode portion 420, a portion of the second wiring portion 321 of the second lead portion 320 protrudes upward from the upper surface of the main protrusion 144. However, the second wiring portion 321 may be configured to be at the same height as the upper surface of the main protrusion 144 or below the upper surface. When the first lead portion 310 of the first wire 31 is connected to the first upper surface electrode portion 410, a portion of the first wiring portion 311 of the first lead portion 310 protrudes upward from the upper surface of the sub-protrusion 145. However, the first wiring portion 311 may be configured to be at the same height as the upper surface of the sub-protrusion 145 or below the upper surface.

[0146] In this case, Figure 5 In the embodiment, when the coil device 1 is mounted on the mounting substrate 80, the main protrusion 144 and the sub-protrusion 145 are in contact with the mounting substrate 80, and the wiring portions 311, 321 (upper surface electrode portions 410, 420) are arranged to be separated from the connection pad 81 of the mounting substrate 80 by a predetermined distance at a distance corresponding to the protrusion amount of the main protrusion 144 and the sub-protrusion 145. At this time, preferably, the height of the main protrusion 144 and the sub-protrusion 145 is set so that the wiring portions 311, 321 are not excessively separated from the connection pad 81 of the mounting substrate 80. Thus, the wiring portions 311, 321 can be well connected to the connection pad 81 of the mounting substrate 80 via the connecting member 90.

[0147] In the above embodiment, the first and second inclined portions 141 and 142 are not essential and may be omitted from the configuration of the core 10. Furthermore, the sub-ridges 145 are not essential and may be omitted from the configuration of the core 10.

[0148] In the above-described embodiment, each first lead portion 310 of the first wire 31 can be connected to the first terminal electrode 41 of the first flange portion 14m and the first terminal electrode 41 of the second flange portion 14n, respectively. Similarly, each second lead portion 320 of the second wire 32 can be connected to the second terminal electrode 42 of the first flange portion 14m and the second terminal electrode 42 of the second flange portion 14n, respectively. In this case, for example, before or after the coil portion 30 is formed, the positional relationship between the first wire 31 and the second wire 32 can be changed to the same as that of the first wire 31 and the second wire 32 by crossing the first wire 31 and the second wire 32 (twisting the pair of wires 31 and 32). Figure 1A The example shown is the opposite.

[0149] In the above embodiment, Figure 1BThe range of the first upper surface electrode portion 410 shown can be extended to the outer side of the flange portion 14 in the Y-axis direction, and the end of the upper surface 14a in the Y-axis direction can be covered by the first upper surface electrode portion 410. In addition, the range of the first side surface electrode portion 411 can be extended to the outer side of the flange portion 14 in the Y-axis direction, and the end of the outer end surface 14d in the Y-axis direction can be covered by the first side surface electrode portion 411.

[0150] Similarly, the range of the second upper surface electrode portion 420 can be extended to the outer side of the flange portion 14 in the Y-axis direction, and the end of the upper surface 14a in the Y-axis direction can be covered by the second upper surface electrode portion 420. In addition, the range of the second side electrode portion 421 can be extended to the outer side of the flange portion 14 in the Y-axis direction, and the end of the outer end surface 14d in the Y-axis direction can be covered by the second side electrode portion 421.

[0151] In the above embodiment, Figure 2G Compared with the position shown in FIG. 1 , the excess portion of the wires 31 and 32 (lead-out portions 310 and 320) may be cut at a position spaced outward from the outer end surface 14d of the flange portion 14 in the X-axis direction. Figure 3 As shown, the excess parts of the wires 31 and 32 may also remain at the ends of the connecting portions 311 and 321 .

[0152] In the above embodiment, if Figure 1A 1 , the coil device 1 having the coil part 30 composed of two layers is shown, but the number of layers of the coil part 30 may be three or more layers, or one layer.

[0153] In the above embodiment, if Figure 2A As shown, the step surface 148 is composed of a step surface having a substantially flat shape, but it may also be composed of a step surface formed of a curved surface.

[0154] In the above embodiment, if Figure 2B , the first terminal electrode 41 is constituted by the first upper surface electrode portion 410 and the first side surface electrode portion 411, but the first side surface electrode portion 411 may be omitted. Similarly, for the second terminal electrode 42, the second side surface electrode portion 421 may be omitted.

[0155] In the above embodiment, the upper surface 14 a of the flange portion 14 is the mounting surface, but the lower surface 14 b may be used as the mounting surface and the core 20 may be provided on the upper surface 14 a .

[0156] In the above embodiment, if Figure 2E As shown, the wires 31 and 32 are hooked and fixed to the outer peripheral surface of one side (toward the front side of the paper) of the pillars 70 and 70, but they can also be hooked and fixed to the outer peripheral surface of the other side (toward the back side of the paper) of the pillars 70 and 70.

[0157] Description of Reference Numerals

[0158] 1...Coil device

[0159] 10...Drum core

[0160] 12...Core

[0161] 14, 14m, 14n... flange

[0162] 14a...upper surface

[0163] 14b...lower surface

[0164] 14c...Inner end face

[0165] 14d...External end face

[0166] 14e...First horizontal side

[0167] 14f...Second horizontal side

[0168] 141...First inclined portion

[0169] 1410...First inclined surface

[0170] 1411...side of first wall

[0171] 142...Second inclined portion

[0172] 1420...Second inclined surface

[0173] 1421...side of the second wall

[0174] 1422...Second outer side

[0175] 143...Wall

[0176] 1430...Front end

[0177] 1431...First side

[0178] 1432...side 2

[0179] 144...Main ridge

[0180] 145...Sub-protuberance

[0181] 148, 149...Step surface

[0182] 1480, 1490...periphery

[0183] 16...Concave corner

[0184] 161...First concave corner

[0185] 162...Second concave corner

[0186] 163...The third concave corner

[0187] 20...Core

[0188] 30...Coil

[0189] 31...The front line

[0190] 310...First lead-out section

[0191] 311...First connection part

[0192] 32...Second Line

[0193] 320...Second lead-out section

[0194] 321...Second connection part

[0195] 41...First terminal electrode

[0196] 410...first upper surface electrode portion

[0197] 411...first side electrode portion

[0198] 42...Second terminal electrode

[0199] 420...Second upper surface electrode portion

[0200] 421...Second side electrode portion

[0201] 50...Nozzle

[0202] 60...Cutting tools

[0203] 70...Pillar

[0204] 80...Mounting base plate

[0205] 81...Connection pad (solder pad)

[0206] 90...Connecting components.

Claims

1. A coil device, characterized in that: include: a core including a winding core portion and a flange portion formed at an end portion of the winding core portion in a first direction; A coil portion formed by winding a plurality of wires around the winding core portion; and A plurality of terminal electrodes are provided on the flange portion and are connected to the lead-out portions of the plurality of wires respectively. A main raised portion having a raised shape is formed on a first surface of the flange portion where at least a portion of any of the terminal electrodes is disposed. The lead-out portion of the wire is connected to any of the terminal electrodes on the first surface of the flange portion, on the outside of the main protrusion in the first direction. The main protrusion is located inside a region sandwiched between an arbitrary lead-out portion of the wire and another arbitrary lead-out portion of the wire, and stands vertically from the first surface to which the lead-out portion is connected, inside the flange portion in the first direction.

2. The coil device according to claim 1, characterized in that In addition to the main ridge, a secondary ridge is formed on the first surface. The sub-protrusion is located on one end side in a second direction perpendicular to the first direction.

3. The coil device according to claim 1, characterized in that The flange portion has a first inclined portion formed therein, the first inclined portion extending obliquely toward a third direction perpendicular to the first direction and the second direction relative to a second direction perpendicular to the first direction.

4. The coil device according to claim 2, characterized in that The flange portion has a first inclined portion formed therein, the first inclined portion extending obliquely toward a third direction perpendicular to the first direction and the second direction relative to a second direction perpendicular to the first direction.

5. The coil device according to claim 3, characterized in that The first inclined portion has an inclined surface that becomes wider toward the first direction as it goes from the starting end toward the terminal end of the first inclined portion. The inclined surface is formed at a terminal end portion of the first inclined portion from the vicinity of the outer end surface of the flange portion to the inner end surface of the flange portion.

6. The coil device according to claim 4, characterized in that The first inclined portion has an inclined surface that becomes wider toward the first direction as it goes from the starting end toward the terminal end of the first inclined portion. The inclined surface is formed at a terminal end portion of the first inclined portion from the vicinity of the outer end surface of the flange portion to the inner end surface of the flange portion.

7. The coil device according to claim 3, characterized in that The flange portion is provided with a second inclined portion extending at an angle different from that of the first inclined portion. The main raised portion is located inside a region sandwiched between the first inclined portion and the second inclined portion.

8. The coil device according to claim 5, characterized in that The flange portion is provided with a second inclined portion extending at an angle different from that of the first inclined portion. The main raised portion is located inside a region sandwiched between the first inclined portion and the second inclined portion.

9. The coil device according to claim 1, characterized in that A width of the flange portion on a first surface side along the first direction is greater than a width of the flange portion on a second surface side located on an opposite side to the first surface of the flange portion along the first direction.

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