Coil component and method for manufacturing coil component

Abstract

The present invention relates to a coil component and a method for manufacturing a coil component. The coil component (1) comprises: a drum-shaped core (10) having a winding core (11) extending in the length direction of the coil component (1) and a first flange (12) provided at a first end of the winding core (11) in the length direction; and first and second terminal electrodes provided at the first flange (12). The first terminal electrode (61) and the second terminal electrode (62) respectively comprise a base electrode (71) formed on the surface of the first flange (12) and a plating layer (72) covering the base electrode (71), the base electrode (71) comprising a bottom base electrode (71d) formed on the bottom surface (22d), an end base electrode (71b) formed on the end surface (12b), and a side base electrode (71e) formed on the first side surface (12e), the height of the end base electrode (71b) being higher than the height of the first crotch (24), and the height of the side base electrode (71e) being lower than the height of the first crotch (24).

Description

Technical Field

[0001] The present disclosure relates to a coil component and a method for manufacturing the coil component. Background Art

[0002] In the past, there was a winding type coil component as a coil component. The winding type coil component includes: a drum-shaped core having a winding core portion extending in the axial direction and flange portions provided at both ends of the winding core portion; a terminal electrode provided at the flange portion; and a plurality of wires connected to the terminal electrode and wound around the winding core portion (for example, refer to Patent Document 1). The terminal electrode is composed of, for example, a base electrode formed on the surface of the flange portion by an immersion method, and a plated electrode covering the base electrode. A groove-shaped crotch portion is formed on the flange portion, extending from the lower surface of the side where the terminal electrode is formed toward the upper surface on the opposite side to the lower surface. With the aid of the crotch portion, insulation between the plurality of terminal electrodes formed on the edge portion is ensured.

[0003] Patent Document 1: Japanese Patent Application Publication No. 2020-57637

[0004] The coil component is mounted on the circuit substrate by soldering. The installation state of the coil component is inspected by, for example, an appearance inspection device (such as AOI). The appearance inspection device identifies the solder fillet formed between the terminal electrode and the circuit substrate to inspect the installation state of the coil component. Therefore, for identification, it is preferred that the solder fillet is higher, that is, the terminal electrode is higher. However, if a higher terminal electrode is formed by a dipping method, a plurality of terminal electrodes may be electrically connected to each other. Summary of the invention

[0005] An object of the present disclosure is to provide a coil component capable of forming a solder fillet with higher visibility and a method for manufacturing the coil component.

[0006] As one embodiment of the present invention, a coil component comprises: a drum-shaped core body having a winding core portion extending along the length direction of the above-mentioned coil component, and a first flange portion arranged at a first end portion of the above-mentioned winding core portion in the above-mentioned length direction; a first wire and a second wire respectively have a first end and a second end, and are wound on the above-mentioned winding core portion; a first terminal electrode is arranged on the above-mentioned first flange portion and is connected to the above-mentioned first end of the above-mentioned first wire; and a second terminal electrode is arranged on the above-mentioned first flange portion and is connected to the above-mentioned first end of the above-mentioned second wire, the above-mentioned first flange portion has: an inner surface facing one side of the above-mentioned winding core portion; an end surface facing the opposite side of the above-mentioned inner surface; a bottom surface and a top surface facing opposite sides to each other in a height direction orthogonal to the above-mentioned length direction; and a pair of side surfaces facing opposite sides to each other in a width direction orthogonal to the above-mentioned length direction and the above-mentioned height direction, the above-mentioned first flange portion has: a first A main body; a first leg and a second leg protruding from the first main body along the height direction; the main body bottom surface of the first main body facing the side of the bottom surface; and a pair of inner side surfaces opposite to each other at the first leg and the second leg, when observed from the side of the end surface, a first crotch portion surrounded by the first main body, the first leg and the second leg is formed, the bottom surface includes the first bottom surface of the first leg and the second bottom surface of the second leg, the first terminal electrode and the second terminal electrode respectively have a base electrode formed on the surface of the first flange portion and a plating layer covering the base electrode, the base electrode includes a bottom base electrode formed on the bottom surface, an end base electrode formed on the end surface, and a side base electrode formed on the side surface, the height of the end base electrode is higher than the height of the first crotch portion, and the height of the side base electrode is lower than the height of the first crotch portion.

[0007] According to this structure, at the end face of the first flange portion, the height of the first terminal electrode and the second terminal electrode including the base electrode and the plating covering the base electrode is higher than the crotch height. Therefore, when installing the coil component, by attaching the solder to the first terminal electrode and the second terminal electrode at the end face, a solder foot with high recognition compared with the coil component with the same height as the crotch can be formed. Therefore, identification by the appearance inspection device becomes easy.

[0008] With regard to a method for manufacturing a coil component as one embodiment of the present invention, the coil component comprises: a drum-shaped core body having a winding core portion extending in the length direction of the coil component, a first flange portion arranged at a first end portion of the winding core portion in the length direction, and a second flange portion arranged at a second end portion of the winding core portion in the length direction; a first terminal electrode and a second terminal electrode arranged on the first flange portion; and a third terminal electrode and a fourth terminal electrode arranged on the second flange portion, the first terminal electrode to the fourth terminal electrode having a base electrode formed on the surface of the drum-shaped core body and a plating layer covering the base electrode, the first flange portion having a first main body portion arranged at the first end portion of the winding core portion and a first leg portion and a second leg portion protruding from the first main body portion in the height direction, a first crotch portion surrounded by the first main body portion, the first leg portion and the second leg portion being formed on the first flange portion, The second flange portion comprises a second main body portion arranged at the second end portion of the winding core portion, and a third leg portion and a fourth leg portion protruding from the second main body portion along the height direction, and a second crotch portion surrounded by the second main body portion, the third leg portion and the fourth leg portion is formed on the second flange portion, and the manufacturing method of the coil component comprises: a first step of lowering the drum-shaped core with the bottom surface of the drum-shaped core kept facing the conductive paste toward the upper surface of the platform storing the conductive paste forming the base electrode so as to immerse a part of the drum-shaped core in the conductive paste; a second step of moving the drum-shaped core along the length direction by a first distance; a third step of moving the drum-shaped core in a direction opposite to the moving direction of the second step by a distance twice the first distance; a fourth step of moving the drum-shaped core in the moving direction of the second step by the first distance; and a fifth step of lifting the drum-shaped core from the conductive paste.

[0009] According to this configuration, by swinging the drum-shaped core in the longitudinal direction of the drum-shaped core, the height of the base electrode at the end surface of the drum-shaped core can be easily made higher than the crotch height.

[0010] According to one aspect of the present disclosure, it is possible to provide a coil component capable of forming a solder fillet with higher visibility. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 This is a perspective view of the coil component according to one embodiment as viewed from above.

[0012] Figure 2 This is a perspective view of the coil component according to one embodiment as viewed from below.

[0013] Figure 3 This is a three-dimensional view of the drum-shaped core viewed from above.

[0014] Figure 4 This is a perspective view of the drum-shaped core as viewed from below.

[0015] Figure 5 FIG. 1 is an end view of a drum-shaped core body on which a base electrode is formed.

[0016] Figure 6 This is an end view of a drum-shaped core body on which a plated electrode is formed.

[0017] Figure 7 It is a side view showing the drum-shaped core and terminal electrodes.

[0018] Figure 8 It is a bottom view showing the drum-shaped core and terminal electrodes.

[0019] Fig. 9 yes Figure 8 Sectional view along line 9-9.

[0020] Fig.10 yes Figure 8 10-10 line cross-sectional view.

[0021] Fig.11 It is an explanatory diagram showing the steps of forming a base electrode.

[0022] Fig.12 It is an explanatory diagram showing the steps of forming a base electrode.

[0023] Fig.13 It is an explanatory diagram showing the formation process of the base electrode.

[0024] Fig.14 It is an explanatory diagram showing the formation process of the base electrode.

[0025] Fig.15 It is an explanatory diagram showing the steps of forming a base electrode.

[0026] Fig.16 It is an explanatory diagram showing the steps of forming a base electrode.

[0027] Fig.17 This is a flowchart showing an example of a method for manufacturing a coil component.

[0028] Fig.18 It is a graph showing the heights of the terminal electrodes of the example and the terminal electrodes of the comparative example.

[0029] Fig.19 This is a flowchart showing a method for manufacturing a coil component according to a modified example.

[0030] Description of Reference Numerals

[0031] 1…coil component; 10…drum-shaped core; 11…winding core; 11b…top surface; 12…first flange; 12a…inner surface; 12c…top surface; 12d…bottom surface; 13…second flange; 13a…inner surface; 13c…top surface; 13d…bottom surface; 21…first main body; 21d…bottom surface of main body; 22…first leg; 22a…inner surface; 22d…bottom surface; 22f…first inner side surface (inner side surface); 23…second leg; 23a…inner surface; 23d…bottom surface; 23e…second inner side surface (inner side surface); 24…first crotch; 31…second main body; 31d…bottom surface of main body; 32…third leg; 32a…inner surface; 32 d…bottom surface; 32f…first inner side surface (inner side surface); 33…fourth leg portion; 33a…inner surface; 33d…bottom surface; 33e…second inner side surface (inner side surface); 34…second crotch portion; 41~44…ridge portion; 51~54…ridge portion; 61~64…first terminal electrode~fourth terminal electrode; 71…base electrode; 71a…inner surface base electrode; 71b…end surface base electrode; 71d…bottom surface base electrode; 71e…side surface base electrode; 71f…inner surface base electrode; 72…plating; 81…first wire; 82…second wire; 113…platform; 114…conductive paste; D1…first distance; T1~T6…height; T24…height. DETAILED DESCRIPTION

[0032] Hereinafter, one embodiment will be described.

[0033] In addition, the drawings sometimes enlarge the components for easy understanding. The size ratio of the components is sometimes different from the actual size ratio or the size ratio in other drawings. In addition, in the cross-sectional view, the hatching of some components is sometimes omitted for easy understanding.

[0034] like Figure 1 , Figure 2 As shown, the coil component 1 includes a drum-shaped core 10 and a coil 80 wound around the drum-shaped core 10. The coil component 1 is, for example, a surface mount type coil component. The coil component 1 of the present embodiment is, for example, a common mode choke coil.

[0035] [Drum core]

[0036] The drum-shaped core 10 is made of a non-conductive material, specifically, a non-magnetic body such as alumina, a magnetic body such as nickel (Ni)-zinc (Zn) ferrite, etc. The drum-shaped core 10 is formed, for example, by firing a molded body formed by compressing a non-conductive material. In addition, the drum-shaped core 10 is not limited to being formed by firing a molded body formed by compressing a non-conductive material, and can also be formed by, for example, thermally curing a resin containing magnetic powder such as metal powder or ferrite powder, a resin containing non-magnetic powder such as silicon powder, or a resin without filler.

[0037] like Figure 3 , Figure 4 As shown, the drum-shaped core 10 has: a winding core 11 extending along the length direction Ld of the coil component 1; a first flange 12, a first end portion of the winding core 11 arranged in the length direction Ld; and a second flange 13, a second end portion of the winding core 11 arranged in the length direction Ld. In the present embodiment, the winding core 11, the first flange 12 and the second flange 13 are formed integrally. In this specification, the length direction Ld can also be changed to the arrangement direction of the first flange 12 and the second flange 13. In addition, in this specification, the "height direction Td" and "width direction Wd" of the coil component 1 are defined as follows. That is, the height direction Td is a direction perpendicular to the main surface of the circuit substrate in the state where the coil component 1 is mounted on the circuit substrate in the direction perpendicular to the length direction Ld. The width direction Wd is a direction parallel to the main surface of the circuit substrate in the state where the coil component 1 is mounted on the circuit substrate in the direction perpendicular to the length direction Ld.

[0038] [Core]

[0039] The shape of the cross section of the core portion 11 that is orthogonal to the length direction Ld is a polygonal shape. In the present embodiment, the cross section of the core portion 11 is a quadrilateral shape. In addition, in the present specification, "polygonal shape" includes shapes with chamfered corners, shapes with rounded corners, shapes with curved sides, etc. In addition, the shape of the cross section of the core portion 11 is not limited to a polygonal shape and can be changed arbitrarily. In one example, the shape of the cross section of the core portion 11 can also be a circular shape, an elliptical shape, or a shape that is a combination of these and a polygonal shape.

[0040] In the present embodiment, the winding core 11 has: a bottom surface 11a and a top surface 11b facing the height direction Td; and a pair of side surfaces 11c and 11d facing the width direction Wd. In the present embodiment, the bottom surface 11a is parallel to the top surface 11b, and the side surface 11c is parallel to the side surface 11d. The bottom surface 11a is the surface facing the circuit substrate side when the coil component 1 is mounted on the circuit substrate.

[0041] [First flange portion, second flange portion]

[0042] like Figure 3 , Figure 4 As shown, the first flange portion 12 has an inner surface 12a, an end surface 12b, a top surface 12c, a bottom surface 12d, a first side surface 12e and a second side surface 12f. The inner surface 12a is a surface on the side of the winding core portion 11 in the length direction Ld. The end surface 12b is a surface facing the opposite side of the inner surface 12a in the length direction Ld. The top surface 12c and the bottom surface 12d are surfaces facing the height direction Td, and are surfaces connecting the inner surface 12a and the end surface 12b. The bottom surface 12d is a surface facing the circuit substrate side in the height direction Td when the coil component 1 is mounted on the circuit substrate. The top surface 12c is a surface facing the opposite side of the bottom surface 12d in the height direction Td. The first side surface 12e and the second side surface 12f are surfaces facing the width direction Wd, and are surfaces connecting the inner surface 12a, the end surface 12b, the top surface 12c and the bottom surface 12d. The second side surface 12f is a surface facing the opposite side to the first side surface 12e in the width direction Wd.

[0043] The second flange portion 13 has an inner surface 13a, an end surface 13b, a top surface 13c, a bottom surface 13d, a first side surface 13e and a second side surface 13f. The inner surface 13a is a surface on the side of the winding core portion 11 in the length direction Ld. The end surface 13b is a surface facing the opposite side of the inner surface 13a in the length direction Ld. The top surface 13c and the bottom surface 13d are surfaces facing the height direction Td, and are surfaces connecting the inner surface 13a and the end surface 13b. The bottom surface 13d is a surface facing the circuit substrate side in the height direction Td when the coil component 1 is mounted on the circuit substrate. The top surface 13c is a surface facing the opposite side of the bottom surface 13d in the height direction Td. The first side surface 13e and the second side surface 13f are surfaces facing the width direction Wd, and are surfaces connecting the inner surface 13a, the end surface 13b, the top surface 13c and the bottom surface 13d. The second side surface 13f is a surface facing the opposite side to the first side surface 13e in the width direction Wd.

[0044] Thus, the bottom surface 11a of the winding core 11 is a surface on the same side as the bottom surface 12d of the first flange 12 and the bottom surface 13d of the second flange 13 in the height direction Td. In addition, the top surface 11b of the winding core 11 is a surface on the same side as the top surface 12c of the first flange 12 and the top surface 13c of the second flange 13 in the height direction Td.

[0045] [Feet, hips]

[0046] like Figure 3 , Figure 4As shown, the first flange portion 12 includes a first main body portion 21, and a first leg portion 22 and a second leg portion 23 protruding from the first main body portion 21 in the height direction Td. The first main body portion 21 includes a main body bottom surface 21d facing one side of the bottom surface 12d of the first flange portion 12, and the first leg portion 22 and the second leg portion 23 protrude from the main body bottom surface 21d in the height direction Td. The first leg portion 22 and the second leg portion 23 are arranged with a gap in the width direction Wd. In the width direction Wd, the first leg portion 22 is arranged on one side of the first side surface 12e of the first flange portion 12. The second leg portion 23 is arranged on one side of the second side surface 12f of the first flange portion 12. Therefore, the bottom surface 12d of the first flange portion 12 includes the first bottom surface 22d of the first leg portion 22 and the second bottom surface 23d of the second leg portion 23.

[0047] The first leg portion 22 and the second leg portion 23 are arranged at a predetermined interval in the width direction Wd. The first flange portion 12 has a first inner side surface 22f on the first leg portion 22 facing the second leg portion 23, and has a second inner side surface 23e on the second leg portion 23 facing the first leg portion 22. That is, the first flange portion 12 has a first inner side surface 22f and a second inner side surface 23e facing each other in the width direction Wd. The first crotch portion 24 surrounded by the main body bottom surface 21d, the first leg portion 22, and the second leg portion 23 is formed in the first flange portion 12. The main body bottom surface 21d can be said to be the crotch upper surface of the first crotch portion 24.

[0048] In the present embodiment, the end face 12b, the first side face 12e, and the second side face 12f are continuous faces from the first main body 21 to the first leg 22 and the second leg 23. The length of the bottom face 12d (22d, 23d) in the length direction Ld is shorter than the length of the top face 12c. The inner surface 12a of the first flange portion 12 includes the main body inner surface 21a of the first main body 21, the inner surfaces 22a and 23a of the first leg 22 and the second leg 23, and the first connecting face 25a and the second connecting face 25b between the main body inner surface 21a and the inner surfaces 22a and 23a. The first connecting face 25a is formed in a concave shape that is recessed toward the inside of the first flange portion 12. The second connecting face 25b is formed in a plane shape that is inclined relative to the main body inner surface 21a and the inner surfaces 22a and 23a.

[0049] like Figure 3 , Figure 4As shown, the second flange portion 13 includes a second main body portion 31, and a third leg portion 32 and a fourth leg portion 33 protruding from the second main body portion 31 in the height direction Td. The second main body portion 31 includes a main body bottom surface 31d facing one side of the bottom surface 13d of the second flange portion 13, and the third leg portion 32 and the fourth leg portion 33 protrude from the main body bottom surface 31d in the height direction Td. The third leg portion 32 and the fourth leg portion 33 are arranged with a gap in the width direction Wd. In the width direction Wd, the third leg portion 32 is arranged on one side of the first side surface 13e of the second flange portion 13. The fourth leg portion 33 is arranged on one side of the second side surface 13f of the second flange portion 13. Therefore, the bottom surface 13d of the second flange portion 13 includes the third bottom surface 32d of the third leg portion 32 and the fourth bottom surface 33d of the fourth leg portion 33.

[0050] The third leg portion 32 and the fourth leg portion 33 are arranged at a predetermined interval in the width direction Wd. The second flange portion 13 has a first inner side surface 32f on the third leg portion 32 facing the fourth leg portion 33, and has a second inner side surface 33e on the fourth leg portion 33 facing the third leg portion 32. That is, the second flange portion 13 has a first inner side surface 32f and a second inner side surface 33e facing each other in the width direction Wd. The second crotch portion 34 surrounded by the bottom surface 31d of the main body, the third leg portion 32, and the fourth leg portion 33 is formed in the second flange portion 13. The bottom surface 31d of the main body can be said to be the upper surface of the crotch portion of the second crotch portion 34.

[0051] In the present embodiment, the end surface 13b, the first side surface 13e, and the second side surface 13f are continuous surfaces from the second main body 31 to the third leg 32 and the fourth leg 33. The length of the bottom surface 13d (32d, 33d) in the length direction Ld is shorter than the length of the top surface 13c. The inner surface 13a of the second flange portion 13 includes the main body inner surface 31a of the second main body 31, the inner surfaces 32a and 33a of the third leg 32 and the fourth leg 33, and the first connecting surface 35a and the second connecting surface 35b between the main body inner surface 31a and the inner surfaces 32a and 33a. The first connecting surface 35a is formed in a concave shape that is recessed toward the inside of the first flange portion 12. The second connecting surface 35b is formed in a plane shape that is inclined relative to the main body inner surface 31a and the inner surfaces 32a and 33a.

[0052] like Figure 8As shown, the first leg portion 22 has a ridge portion 41 that forms a boundary between the end surface 12b, the first side surface 12e, the inner surface 22a, and the first inner side surface 22f that are the peripheral surfaces of the first leg portion 22 facing either the length direction Ld or the width direction Wd. The ridge portion 41 is formed in a curved surface shape that is convex toward the outside of the first leg portion 22. The second leg portion 23 has a ridge portion 42 that forms a boundary between the end surface 12b, the second side surface 12f, the inner surface 22a, and the second inner side surface 23e that are the peripheral surfaces of the second leg portion 23 facing either the length direction Ld or the width direction Wd. The ridge portion 42 is formed in a curved surface shape that is convex toward the outside of the second leg portion 23.

[0053] The third leg portion 32 has a ridge portion 51 that forms a boundary between the end surface 13b, the first side surface 13e, the inner surface 32a, and the first inner surface 32f that are the peripheral surfaces of the third leg portion 32 facing either the length direction Ld or the width direction Wd. The ridge portion 51 is formed in a curved surface shape that is convex toward the outside of the third leg portion 32. The fourth leg portion 33 has a ridge portion 52 that forms a boundary between the end surface 13b, the second side surface 12f, the inner surface 33a, and the second inner surface 33e that are the peripheral surfaces of the fourth leg portion 33 facing either the length direction Ld or the width direction Wd. The ridge portion 52 is formed in a curved surface shape that is convex toward the outside of the fourth leg portion 33.

[0054] like Figure 3 , Figure 4 As shown, the first leg portion 22 has a ridge portion 43, which forms the boundaries between the end face 12b, the first side face 12e, the inner surface 12a, the first inner side face 22f, and the first bottom face 22d. The ridge portion 43 is formed into a curved surface convex toward the outside of the first leg portion 22. The second leg portion 23 has a curved ridge portion 44, which forms the boundaries between the end face 12b, the second side face 12f, the inner surface 12a, the second inner side face 23e, and the second bottom face 23d. The ridge portion 44 is formed into a curved surface convex toward the outside of the second leg portion 23.

[0055] The third leg portion 32 has a curved ridge portion 53, which forms the boundaries between the end surface 13b, the first side surface 13e, the inner surface 13a, and the first inner side surface 32f and the third bottom surface 32d. The ridge portion 53 is formed in a curved shape that bulges toward the outside of the third leg portion 32. The fourth leg portion 33 has a curved ridge portion 54, which forms the boundaries between the end surface 13b, the second side surface 13f, the inner surface 13a, and the second inner side surface 33e and the fourth bottom surface 33d. The ridge portion 54 is formed in a curved shape that bulges toward the outside of the fourth leg portion 33.

[0056] [Terminal electrode]

[0057] like Figure 1 , Figure 2 As shown, a first terminal electrode 61 and a second terminal electrode 62 are provided in the first flange portion 12. The first terminal electrode 61 is provided in the first leg portion 22, and the second terminal electrode 62 is provided in the second leg portion 23. The first crotch portion 24 is interposed between the first terminal electrode 61 and the second terminal electrode 62. Therefore, the first terminal electrode 61 and the second terminal electrode 62 are not electrically connected to each other. The surface of the first terminal electrode 61 has a curved ridge portion due to the ridge portions 41 and 43 of the first leg portion 22. The surface of the second terminal electrode 62 has a curved ridge portion due to the ridge portions 42 and 44 of the second leg portion 23.

[0058] like Figure 1 , Figure 2 As shown, the third terminal electrode 63 and the fourth terminal electrode 64 are provided in the second flange portion 13. The third terminal electrode 63 is provided in the third leg portion 32, and the third leg portion 32 is located on the same side as the first leg portion 22 of the first flange portion 12 on which the first terminal electrode 61 is provided in the width direction Wd. The fourth terminal electrode 64 is provided in the fourth leg portion 33, and the fourth leg portion 33 is located on the same side as the second leg portion 23 of the first flange portion 12 on which the second terminal electrode 62 is provided in the width direction Wd. The second crotch portion 34 is interposed between the third terminal electrode 63 and the fourth terminal electrode 64. Therefore, the third terminal electrode 63 and the fourth terminal electrode 64 are not electrically connected to each other. The surface of the third terminal electrode 63 has a curved ridge portion due to the ridge portions 51 and 53 of the third leg portion 32. The surface of the fourth terminal electrode 64 has a curved ridge portion due to the ridge portions 52 and 54 of the fourth leg portion 33.

[0059] [Wire]

[0060] like Figure 1 , Figure 2 As shown, the coil 80 includes a first wire 81 and a second wire 82 wound around the winding core 11 .

[0061] The first wire 81 has a first end 81a and a second end 81b. For example, the first end 81a of the first wire 81 constitutes an end portion on the winding start side of the first wire 81, and the second end 81b of the first wire 81 constitutes an end portion on the winding end side of the first wire 81. The first end 81a of the first wire 81 is connected to the first terminal electrode 61, and the second end 81b of the first wire 81 is connected to the third terminal electrode 63.

[0062] The second wire 82 has a first end 82a and a second end 82b. For example, the first end 82a of the second wire 82 constitutes an end portion of the winding start end side of the second wire 82, and the second end 82b of the second wire 82 constitutes an end portion of the winding end end side of the second wire 82. The first end 82a of the second wire 82 is connected to the second terminal electrode 62, and the second end 82b of the second wire 82 is connected to the fourth terminal electrode 64.

[0063] [Terminal electrode details]

[0064] like Figure 7 , Figure 8 As shown, the first terminal electrode 61 includes a bottom electrode 61d of the first bottom surface 22d of the first leg portion 22, an end surface electrode 61b of the end surface 12b of the first flange portion 12, an inner surface electrode 61a of the inner surface 12a of the first flange portion 12, a side surface electrode 61e of the first side surface 12e of the first flange portion 12, and an inner surface electrode 61f of the first inner surface 22f of the first leg portion 22. The bottom surface electrode 61d, the end surface electrode 61b, the inner surface electrode 61a, the side surface electrode 61e, and the inner surface electrode 61f are formed continuously.

[0065] The second terminal electrode 62 includes a bottom electrode 62d of the second bottom surface 23d of the second leg portion 23, an end surface electrode 62b of the end surface 12b of the first flange portion 12, an inner surface electrode 62a of the inner surface 12a of the first flange portion 12, a side surface electrode 62f of the second side surface 12f of the first flange portion 12, and an inner surface electrode 62e of the second inner surface 23e of the second leg portion 23. The bottom surface electrode 62d, the end surface electrode 62b, the inner surface electrode 62a, the side surface electrode 62f, and the inner surface electrode 62e are formed continuously.

[0066] The third terminal electrode 63 includes a bottom electrode 63d of the third bottom surface 32d of the third leg portion 32, an end surface electrode 63b of the end surface 13b of the second flange portion 13, an inner surface electrode 63a of the inner surface 13a of the second flange portion 13, a side surface electrode 63e of the first side surface 13e of the second flange portion 13, and an inner surface electrode 63f of the first inner surface 32f of the third leg portion 32. The bottom surface electrode 63d, the end surface electrode 63b, the inner surface electrode 63a, the side surface electrode 63e, and the inner surface electrode 63f are formed continuously.

[0067] The fourth terminal electrode 64 includes a bottom electrode 64d of the fourth bottom surface 33d of the fourth leg portion 33, an end surface electrode 64b of the end surface 13b of the second flange portion 13, an inner surface electrode 64a of the inner surface 13a of the second flange portion 13, a side surface electrode 64f of the second side surface 13f of the second flange portion 13, and an inner surface electrode 64e of the second inner surface 33e of the fourth leg portion 33. The bottom surface electrode 64d, the end surface electrode 64b, the side surface electrode 64f, the inner surface electrode 64a, and the inner surface electrode 64e are formed continuously as one.

[0068] The first terminal electrode 61, the second terminal electrode 62, the third terminal electrode 63, and the fourth terminal electrode 64 include a base electrode 71 and a plating layer 72 covering the base electrode 71. The base electrode 71 is, for example, a metal layer mainly composed of silver (Ag). Alternatively, the base electrode 71 may include silicon dioxide, resin, or the like.

[0069] Next, the base electrode 71 and the plating layer 72 constituting the first terminal electrode 61 to the fourth terminal electrode 64 will be described in detail. Fig. 9 and Fig.10 The components of the first terminal electrode 61 and the base electrode 71 and the plating layer 72 constituting the first terminal electrode 61 are shown. In addition, since the structures of the first terminal electrode 61 to the fourth terminal electrode 64 are the same, the relationship between the components of the first terminal electrode 61 and the base electrode 71 and the plating layer 72 is mainly described, and the drawings and descriptions of the structures of the second terminal electrode 62 to the fourth terminal electrode 64 are omitted.

[0070] like Figure 5 , Figure 8 , Fig. 9 , Fig.10 As shown, the substrate electrode 71 has: a bottom substrate electrode 71d formed on the bottom surface 12d (22d); an end surface substrate electrode 71b formed on the end surface 12b; a side surface substrate electrode 71e formed on the first side surface 12e; an inner surface substrate electrode 71a formed on the inner surface 12a; and an inner surface substrate electrode 71f formed on the first inner side surface 22f. The bottom substrate electrode 71d and the end surface substrate electrode 71b, the bottom substrate electrode 71d and the inner surface substrate electrode 71a, the bottom substrate electrode 71d and the side surface substrate electrode 71e, and the bottom substrate electrode 71d and the inner surface substrate electrode 71f are formed as a whole and continuous. The end surface substrate electrode 71b, the side surface substrate electrode 71e, the inner surface substrate electrode 71a, and the inner surface substrate electrode 71f are formed as a whole and continuous. As shown Figure 5 , Figure 6 As shown, in the second leg portion 23, a base electrode 71f (side base electrode) is formed on the second side surface 12f of the first flange portion 12, and a second inner side surface 23e (see Figure 4) is formed with a base electrode 71e (inner side base electrode).

[0071] like Fig. 9 As shown, the height T1 of the end surface base electrode 71b is higher than the height T24 of the first crotch portion 24. In addition, in this specification, the surface that serves as a reference for the height is set to the bottom surface 12d (22d, 23d), 13d (32d, 33d). The height of the base electrode 71 is the highest maximum height in the direction from the reference surface (the first bottom surface 22d of the first leg portion 22) toward the top surface 12c of the first flange portion 12 in the height direction Td. The height (crotch height) T24 of the first crotch portion 24 is the height from the surface that serves as a reference for the height of the base electrode (the first bottom surface 22d of the first leg portion 22) to the crotch upper surface of the first crotch portion 24 (the main body bottom surface 21d of the main body) in the height direction Td. In addition, the height T3 of the inner surface base electrode 71a is higher than the height T24 of the first crotch portion 24.

[0072] like Fig.10 As shown, in the first leg portion 22, the height T5 of the side substrate electrode 71e is lower than the height T24 of the first crotch portion 24. In the first leg portion 22, the height T6 of the inner side substrate electrode 71f is lower than the height of the first inner side surface 22f. Figure 5 The same can be said for the second leg portion 23. That is, in the second leg portion 23, the height T5 of the side substrate electrode 71f is lower than the height T24 of the first crotch portion 24. In the second leg portion 23, the height T6 of the inner side substrate electrode 71e is lower than the second inner side surface 23e (see Figure 4 )Low.

[0073] like Figure 1 , Figure 5 As shown in the figure, at the end surface 12b of the first flange portion 12, the end surface base electrode 71b of the first terminal electrode 61 is formed so that the central portion is the highest in the width direction Wd. That is, the upper edge of the end surface base electrode 71b of the first terminal electrode 61 is formed in a curved shape that protrudes toward the side of the top surface 12c of the first flange portion 12. The end surface base electrode 71b of the second terminal electrode 62 is formed so that the central portion is the highest in the width direction Wd. The upper edge of the end surface base electrode 71b of the second terminal electrode 62 is formed in a curved shape that protrudes toward the side of the top surface 12c of the first flange portion 12.

[0074] like Figure 2As shown, at the end surface 13b of the second flange portion 13, the end surface base electrode 71b of the third terminal electrode 63 is formed so that the central portion is the highest in the width direction Wd. That is, the upper edge of the end surface base electrode 71b of the third terminal electrode 63 is formed in a curved shape that protrudes toward the side of the top surface 13c of the second flange portion 13. The end surface base electrode 71b of the fourth terminal electrode 64 is formed so that the central portion is the highest in the width direction Wd. The upper edge of the end surface base electrode 71b of the fourth terminal electrode 64 is formed in a curved shape that protrudes toward the side of the top surface 13c of the second flange portion 13.

[0075] like Fig. 9 As shown in FIG. 1 , the thickness of the end surface base electrode 71b of the end surface 12b of the first flange portion 12 is the same as the thickness of the inner surface base electrode 71a of the inner surface 12a. In addition, in this specification, "same" includes the case where the two values ​​are the same, and the difference between the two values ​​includes errors caused by manufacturing deviations, etc. The error caused by manufacturing deviations, etc. is less than ±10μm. Fig.10 As shown, the thickness of the side substrate electrode 71e of the first side surface 12e is the same as the thickness of the inner side substrate electrode 71f of the first inner side surface 22f. Moreover, the thickness of the end surface substrate electrode 71b is thicker than the thickness of the side substrate electrode 71e. In addition, in this specification, the thickness of the substrate electrode is the maximum thickness from the formed surface to the surface of the substrate electrode.

[0076] like Figure 6 , Figure 8 , Fig. 9 , Fig.10 As shown, the plating layer 72 includes a bottom plating layer 72d of the first bottom surface 22d (12d), an end plating layer 72b of the end surface 12b, a side plating layer 72e of the first side surface 12e, an inner surface plating layer 72a of the inner surface 12a (22a), and an inner side plating layer 72f of the first inner side surface 22f. The bottom plating layer 72d and the end plating layer 72b, the bottom plating layer 72d and the inner surface plating layer 72a, the bottom plating layer 72d and the side plating layer 72e, and the bottom plating layer 72d and the inner side plating layer 72f are formed as one continuous body. The end plating layer 72b, the side plating layer 72e, the inner surface plating layer 72a, and the inner side plating layer 72f are formed as one continuous body.

[0077] like Fig. 9 , Fig.10 As shown, the plating layer 72 of this embodiment includes a first plating layer 73 covering the base electrode 71 and a second plating layer 74 covering the first plating layer 73. The first plating layer 73 is formed of, for example, a metal such as nickel (Ni) or copper (Cu), or an alloy such as Ni-chromium (Cr) or Ni-Cu. The second plating layer 74 is formed of, for example, a metal such as tin (Sn). In addition, the plating layer 72 may be formed of one or more plating layers.

[0078] like Figure 1 , Figure 6 As shown, at the end face 12b of the first flange portion 12, the end face plating 72b of the first terminal electrode 61 is formed in a manner that is the same height in the width direction Wd. That is, the upper edge of the end face plating 72b of the first terminal electrode 61 is formed in a straight line extending in the width direction Wd. When viewed from the length direction Ld, the end face plating 72b of the first terminal electrode 61 is formed in a rectangular shape that is long in the width direction Wd. The end face plating 72b of the second terminal electrode 62 is formed so that the central part is the highest in the width direction Wd. The upper edge of the end face plating 72b of the second terminal electrode 62 is formed in a straight line extending in the width direction Wd. When viewed from the length direction Ld, the end face plating 72b of the second terminal electrode 62 is formed in a rectangular shape that is long in the width direction Wd.

[0079] like Figure 2 As shown, at the end face 13b of the second flange portion 13, the end face plating 72b of the third terminal electrode 63 is formed in a manner that becomes the same height in the width direction Wd. That is, the upper edge of the end face plating 72b of the third terminal electrode 63 is formed into a straight line extending in the width direction Wd. When viewed from the length direction Ld, the end face plating 72b of the third terminal electrode 63 is formed into a rectangular shape that is long in the width direction Wd. The end face plating 72b of the fourth terminal electrode 64 is formed in a manner that becomes the same height in the width direction Wd. The upper edge of the end face plating 72b of the fourth terminal electrode 64 is formed into a straight line extending in the width direction Wd. When viewed from the length direction Ld, the end face plating 72b of the fourth terminal electrode 64 is formed into a rectangular shape that is long in the width direction Wd.

[0080] [Plate-like member]

[0081] like Figure 1 , Figure 2 As shown, the coil component 1 has a plate-like member 90. The plate-like member 90 is a rectangular parallelepiped. The plate-like member 90 has a first surface 91 facing the drum-shaped core 10 in the height direction Td and a second surface 92 facing the opposite side of the first surface 91. The plate-like member 90 is arranged to connect the top surface 12c of the first flange portion 12 with the top surface 13c of the second flange portion 13. In the present embodiment, the plate-like member 90 is installed on the first flange portion 12 in a manner covering the entire surface of the top surface 12c of the first flange portion 12, and is installed on the second flange portion 13 in a manner covering the entire surface of the top surface 13c of the second flange portion 13.

[0082] The plate-like member 90 is made of a non-conductive material, such as a nickel (Ni)-zinc (Zn) ferrite, a magnetic body such as a non-magnetic body such as alumina, etc. The plate-like member 90 is formed, for example, by firing a molded body formed by compressing a non-conductive material. In addition, the plate-like member 90 is not limited to being formed by firing a molded body formed by compressing a non-conductive material, and can also be formed by, for example, thermally curing a resin containing magnetic powder such as metal powder or ferrite powder, a resin containing non-magnetic powder such as silicon powder, or a resin without filler.

[0083] The second surface 92 of the rectangular plate-like member 90 becomes an adsorption surface when the coil component 1 is moved. Therefore, for example, when the coil component 1 is mounted on a circuit substrate, it is easy to move the coil component 1 onto the circuit substrate by an adsorption conveying device. The plate-like member 90 can be made of a magnetic body like the drum-like core 10. When the plate-like member 90 is made of a magnetic body, the drum-like core 10 can cooperate with the plate-like member 90 to form a closed magnetic circuit, thereby improving the efficiency of obtaining the inductance value.

[0084] The plate-shaped member 90 is attached to the drum-shaped core 10 by an adhesive. As the adhesive, an epoxy resin adhesive is used. Preferably, an inorganic filler is added to the adhesive. As a result, the linear expansion coefficient of the adhesive is reduced, thereby improving the heat shock resistance.

[0085] (Method for manufacturing coil component)

[0086] Reference Figures 11 to 17 A method for manufacturing the coil component 1 will be described.

[0087] like Fig.17 As shown, the method for manufacturing the coil component 1 includes a core preparation step (step S11 ), an electrode formation step (step S12 ), a coil formation step (step S13 ), and a plate-like member mounting step (step S14 ).

[0088] [Core preparation process]

[0089] In the core preparation process, prepare Figure 3 , Figure 4 The drum-shaped core body 10 is shown. The drum-shaped core body 10 is formed by a process of compressing a non-conductive material with a mold to form a compact and a process of firing the compact.

[0090] [Electrode Formation Process]

[0091] The electrode forming process of step S12 includes a base electrode forming process (step S12a) and a plating layer forming process (step S12b).

[0092] In the base electrode forming step, Figures 11 to 17The illustrated dip coating apparatus 110 forms the base electrode 71 of each of the terminal electrodes 61 to 64 on the first flange portion 12 and the second flange portion 13 of the drum-shaped core 10 .

[0093] [Base electrode formation step]

[0094] In the base electrode forming process, Figures 11 to 17 As shown, the base electrode 71 of each of the terminal electrodes 61 to 64 is formed on the first flange portion 12 and the second flange portion 13 of the drum-shaped core 10 by a dip coating device 110 .

[0095] In detail, Fig.11 As shown, the dip coating device 110 has a holding device 111 and a coating tank 112. The coating tank 112 has a platform 113, and a conductive paste 114 is stored on the platform 113. The thickness of the conductive paste stored on the platform 113 is set according to the size of the first leg 22 to the fourth leg 33 of the drum-shaped core 10. The thickness of the conductive paste 114 is, for example, not less than 10 μm and not more than 20 μm. The conductive paste 114 is a paste containing silver (Ag), silicon dioxide, and a resin component.

[0096] The holding device 111 holds the drum-shaped core 10 so that the bottom surface 12 d of the first flange portion 12 and the bottom surface 13 d of the second flange portion 13 of the drum-shaped core 10 face the conductive paste 114 stored in the coating tank 112 .

[0097] like Fig.12 As shown, the drum-shaped core 10 is dip-coated with the conductive paste 114 (first step). The holding device 111 makes the bottom surfaces 12d and 13d of the drum-shaped core 10 abut against the upper surface of the platform 113 of the coating tank 112, and the drum-shaped core 10 is inserted into the coating tank 112 so that the first leg 22 and the second leg 23 of the first flange 12 of the drum-shaped core 10 and the third leg 32 and the fourth leg 33 of the second flange 13 are immersed in the conductive paste 114.

[0098] like Fig.13 As shown, the drum-shaped core 10 is moved by a predetermined first distance D1 in the length direction Ld of the drum-shaped core 10 (second process). At this time, the drum-shaped core 10 is not moved in the width direction Wd of the drum-shaped core 10. Through this second process, the end surface 12b of the first flange portion 12 and the inner surface 13a of the second flange portion 13 are wetted with the conductive paste 114. The first distance D1 is set, for example, based on the viscosity of the conductive paste 114 (for example, 20 Pa·S), the size of the drum-shaped core 10, etc. The first distance D1 is, for example, not less than 600 μm and not more than 750 μm.

[0099] like Fig.14As shown in FIG. 1 , the drum-shaped core 10 is moved in a direction opposite to the moving direction of the second step by a distance twice the predetermined first distance D1 (third step). At this time, the drum-shaped core 10 is not moved in the width direction Wd of the drum-shaped core 10. Through the third step, the end surface 13b of the second flange portion 13 and the inner surface 12a of the first flange portion 12 are wetted with the conductive paste 114.

[0100] like Fig.15 As shown, the drum-shaped core 10 is moved in the moving direction of the second step by a predetermined first distance D1 (fourth step). At this time, the drum-shaped core 10 is not moved in the width direction Wd of the drum-shaped core 10 .

[0101] That is, through the second to fourth steps, the drum core 10 is swung relative to the conductive paste 114. Thus, by swinging the drum core 10, the conductive paste 114 is attached to the end surfaces 12b, 13b and the inner surfaces 12a, 13a of the drum core 10.

[0102] like Fig.16 As shown, the holding device 111 is raised, and the drum-shaped core 10 held by the holding device 111 is lifted from the conductive paste 114 (fifth step).

[0103] The base electrode 71 is formed by firing the conductive paste 114 applied to the drum-shaped core 10 as described above. The firing temperature of the conductive paste 114 is, for example, 900 degrees. The resin component is volatilized by the firing process.

[0104] [Plating layer forming process]

[0105] In the plating layer forming step, the plating layer 72 is formed to cover the base electrode 71 formed on the drum-shaped core 10 as described above. The plating layer 72 is formed by, for example, an electrolytic barrel plating method. Fig. 9 , Fig.10 As shown, the plating layer 72 includes a first plating layer 73 and a second plating layer 74. The first plating layer 73 (eg, a Ni layer) and the second plating layer 74 (eg, a Sn layer) are sequentially formed by electrolytic barrel plating.

[0106] [Coil forming process]

[0107] In the coil forming process, a coil 80 is wound around a drum-shaped core 10 formed with terminal electrodes 61 to 64 using a winding machine. The coil 80 includes a first wire 81 and a second wire 82. First, the first end 81a of the first wire 81 is heat-pressed and bonded to the first terminal electrode 61, and the first end 82a of the second wire 82 is heat-pressed and bonded to the second terminal electrode 62. Next, the first wire 81 and the second wire 82 are simultaneously wound around the winding core 11 of the drum-shaped core 10. Next, the second end 81b of the first wire 81 is heat-pressed and bonded to the third terminal electrode 63, and the second end 82b of the second wire 82 is heat-pressed and bonded to the fourth terminal electrode 64. Then, the first wire 81 and the second wire 82 are cut between the winding machine and the drum-shaped core 10.

[0108] [Plate-like member installation process]

[0109] In the plate-shaped member mounting step, the plate-shaped member 90 is mounted on the drum-shaped core 10 by an adhesive.

[0110] Through the above steps, the coil component 1 is manufactured.

[0111] (effect)

[0112] Fig.18 : represents the height of the base electrode 71 in the coil component 1 of the present embodiment and the height of the base electrode in the coil component of the comparative example. Fig.18 In FIG. 1 , the hatched bars B11 to B14 represent the measurement results of the height of the base electrode 71 in the coil component 1 of the present embodiment, and the blank bars B21 to B24 represent the measurement results of the height of the base electrode in the coil component of the comparative example. Fig.18 In FIG. 1 , the solid line C1 indicates the crotch height T24 , and the solid line C2 indicates the winding core height T11 .

[0113] exist Fig.18 In FIG. 1 , bars B11 and B21 indicate the height T1 of the end surface base electrode 71b. Bars B12 and B22 indicate the height T3 of the inner surface base electrode 71a. Bars B13 and B23 indicate the height T5 of the side surface base electrode 71e. Bars B14 and B24 indicate the height T6 of the inner surface base electrode 71f.

[0114] The coil component of the comparative example uses a drum-shaped core body having the same size and shape as the drum-shaped core body 10 of the coil component 1 of the present embodiment. Fig.12 The first step (dip coating of the drum core with conductive paste) and Fig.16 The fifth step (lifting of the drum-shaped core body) shown in FIG. 1 is a coil component of the comparative example in which the base electrode is formed without swinging the drum-shaped core body.

[0115] Table 1 below shows the height of the base electrode 71 in the coil component 1 of the present embodiment and the height of the base electrode in the coil component of the comparative example. The height shown in Table 1 is the average value of the measurement results of the base electrode height of 10 samples of the coil component 1 of the present embodiment and the coil component of the comparative example.

[0116]

Table 1

[0117] sample End height Inner surface height Side height Inner side height Comparative Example 59.1 64.6 52.2 56.7 Example 118.8 111.3 56.1 57.9

[0118] like Fig.18 As shown in Table 1, in the coil component of the comparative example, the heights of the end surface base electrode 71b, the inner surface base electrode 71a, the side surface base electrode 71e, and the inner surface base electrode 71f are substantially the same.

[0119] In the coil component 1 of the present embodiment, the height T1 of the end surface base electrode 71b is higher than the crotch height T24. That is, in the process of forming the base electrode, by swinging the drum-shaped core 10 in the longitudinal direction of the drum-shaped core 10, the height T1 of the base electrode 71 (end surface base electrode 71b) at the end surfaces 12b and 13b of the drum-shaped core 10 can be made higher than the crotch height T24. Moreover, at the end surfaces 12b and 13b, the height T2 of each terminal electrode 61 to 64 including the base electrode 71 and the plating layer 72 covering the base electrode 71 is higher than the crotch height T24. The height T2 of the terminal electrodes 61 to 64 is the height from the bottom surface of each terminal electrode 61 to 64 to the highest part of each terminal electrode 61 to 64 at the end surfaces 12b and 13b. Therefore, when the coil component 1 is installed, the height of the solder fillet formed by the solder attached to each terminal electrode 61 to 64 on the end surfaces 12b and 13b is higher than that of the coil component of the comparative example. That is, the coil component 1 of the present embodiment can form a solder fillet with higher recognition than a coil component having the same height of the crotch portion. Therefore, recognition by a visual inspection device becomes easy.

[0120] In the coil component 1 of the present embodiment, the height T3 of the inner surface base electrode 71a is higher than the crotch height T24. That is, in the process of forming the base electrode, by swinging the drum-shaped core 10 along the length direction of the drum-shaped core 10, the height T3 of the base electrode 71 (inner surface base electrode 71a) at the inner surface 12a, 13a of the drum-shaped core 10 can be made higher than the crotch height T24. Moreover, the height T4 of each terminal electrode 61 to 64 including the base electrode 71 and the plating layer 72 covering the base electrode 71 is higher than the crotch height T24.

[0121] Thus, when the coil component 1 is installed, the height of the solder legs formed by the solder attached to each terminal electrode 61 to 64 on one side of the inner surface 12a, 13a of the drum-shaped core 10 of the coil component 1 becomes higher. That is, in the first flange portion 12, the height of the solder legs attached to one side of the end surface 12b and the height of the solder legs attached to one side of the inner surface 12a are higher than those of the coil component of the comparative example. Similarly, in the second flange portion 13, the height of the solder legs attached to one side of the end surface 13b and the height of the solder legs attached to one side of the inner surface 12a are higher than those of the coil component of the comparative example. Therefore, the heat shock resistance is improved.

[0122] In the process (first to fifth processes) of attaching the conductive paste 114 to the drum-shaped core 10, the drum-shaped core 10 is not moved in the width direction Wd of the drum-shaped core 10. Therefore, in the coil component 1 of the present embodiment, Fig.10 The height T6 of the inner side surface base electrode 71f at the first inner side surface 22f shown is substantially equal to the height of the inner side surface base electrode in the coil component of the comparative example and is lower than the crotch height T24. That is, the height T6 of the inner side surface base electrode 71f is lower than the height of the first inner side surface 22f constituting the first crotch portion 24. Therefore, in the coil component 1, the first terminal electrode 61 and the second terminal electrode 62 can be prevented from being connected to each other, thereby ensuring the insulation between the first terminal electrode 61 and the second terminal electrode 62. In addition, the third terminal electrode 63 and the fourth terminal electrode 64 can be prevented from being connected to each other, thereby ensuring the insulation between the third terminal electrode 63 and the fourth terminal electrode 64.

[0123] In the coil component 1 of the present embodiment, the height T3 of the inner surface base electrode 71a is lower than the core height T11 to the bottom surface 11a of the core portion 11. Moreover, on the inner surface 12a, the height T4 of each terminal electrode 61 to 64 including the base electrode 71 (inner surface base electrode 71a) and the plating layer 72 covering the base electrode 71 is lower than the core height T11. It is possible to prevent the first wire 81 and the second wire 82 wound on the core portion 11 from being connected to each terminal electrode 61 to 64 at an undesired position.

[0124] When the bottom surface substrate electrode 71d, the end surface substrate electrode 71b, the side surface substrate electrode 71e, the inner surface substrate electrode 71a and the inner side surface substrate electrode 71f are formed separately, it is necessary to connect each electrode, and the thickness of the connection part is thicker than other parts. In contrast, the coil component 1 of the present embodiment forms the bottom surface substrate electrode 71d, the end surface substrate electrode 71b, the side surface substrate electrode 71e, the inner surface substrate electrode 71a and the inner side surface substrate electrode 71f in unison. Therefore, the thickness of the substrate electrode 71 can be formed to be thinner. In addition, since the bottom surface substrate electrode 71d, the end surface substrate electrode 71b, the side surface substrate electrode 71e, the inner surface substrate electrode 71a and the inner side surface substrate electrode 71f can be formed at one time, the number of processes can be reduced compared with the case of making them separately.

[0125] The thickness of the end surface base electrode 71b is thicker than the thickness of the side surface base electrode 71e. The base electrode 71 contains silver (Ag) and silicon dioxide. Therefore, in the second step and the third step, by moving the drum-shaped core 10 along the length direction Ld, the end surface base electrode 71b can be thickened, and the close contact with the end surfaces 12b and 13b of the drum-shaped core 10 can be improved.

[0126] The first leg portion 22 has a ridge portion 41 that forms a boundary between the end face 12b, the first side face 12e, the inner surface 22a, and the first inner side face 22f that are the peripheral faces of the first leg portion 22 facing either the length direction Ld or the width direction Wd. The ridge portion 41 is formed into a curved surface that bulges outwardly toward the first leg portion 22. The second leg portion 23 has a ridge portion 42 that forms a boundary between the end face 12b, the second side face 12f, the inner surface 22a, and the second inner side face 23e that are the peripheral faces of the second leg portion 23 facing either the length direction Ld or the width direction Wd. The ridge portion 42 is formed into a curved surface that bulges outwardly toward the second leg portion 23.

[0127] The third leg portion 32 has a ridge portion 51 that forms a boundary between the end face 13b, the first side face 13e, the inner surface 32a, and the first inner surface 32f that are the peripheral surfaces of the third leg portion 32 facing either the length direction Ld or the width direction Wd. The ridge portion 51 is formed into a curved surface that bulges toward the outside of the third leg portion 32. The fourth leg portion 33 has a ridge portion 52 that forms a boundary between the end face 13b, the second side face 12f, the inner surface 33a, and the second inner surface 33e that are the peripheral surfaces of the fourth leg portion 33 facing either the length direction Ld or the width direction Wd. The ridge portion 52 is formed into a curved surface that bulges toward the outside of the fourth leg portion 33.

[0128] Therefore, when the drum-shaped core 10 is swung, the conductive paste 114 flows smoothly due to the ridges 41, 42, 51, 52, and the shape variation of the base electrode 71 can be suppressed. Thus, the quality variation of the coil component 1 can be suppressed.

[0129] The first flange portion 12 includes a first leg portion 22 and a second leg portion 23 .

[0130] The first leg portion 22 has a ridge portion 43 that forms the boundary between the end surface 12b, the first side surface 12e, the inner surface 12a, and the first inner side surface 22f and the first bottom surface 22d. The ridge portion 43 is formed into a curved surface convex toward the outside of the first leg portion 22. When the coil component 1 is mounted, solder enters between the mounting substrate and the curved ridge portion 43, thereby improving heat shock resistance.

[0131] The second leg portion 23 has a curved ridge portion 44 that forms the boundary between the end face 12b, the second side face 12f, the inner face 12a, and the second inner side face 23e and the second bottom face 23d. The ridge portion 44 is formed into a curved shape that is convex toward the outside of the second leg portion 23. When the coil component 1 is mounted, solder enters between the mounting substrate and the curved ridge portion 44, thereby improving heat shock resistance.

[0132] The second flange portion 13 includes a third leg portion 32 and a fourth leg portion 33 .

[0133] The third leg portion 32 has a curved ridge portion 53 that forms the boundary between the end surface 13b, the first side surface 13e, the inner surface 13a, and the first inner side surface 32f and the third bottom surface 32d. The ridge portion 53 is formed into a curved shape that protrudes toward the outside of the third leg portion 32. When the coil component 1 is mounted, solder enters between the mounting substrate and the curved ridge portion 53, thereby improving heat shock resistance.

[0134] The fourth leg portion 33 has a curved ridge portion 54 that forms the boundary between the end face 13b, the second side face 13f, the inner face 13a, and the second inner side face 33e and the fourth bottom face 33d. The ridge portion 54 is formed into a curved shape that is convex toward the outside of the fourth leg portion 33. When the coil component 1 is mounted, solder enters between the mounting substrate and the curved ridge portion 54, thereby improving heat shock resistance.

[0135] As described above, according to this embodiment, the following effects are achieved.

[0136] (1) The coil component 1 comprises: a drum-shaped core 10 having a winding core portion 11 extending in the length direction Ld of the coil component 1 and a first flange portion 12 provided at a first end portion of the winding core portion 11 in the length direction Ld; and a first terminal electrode 61 and a second terminal electrode 62 provided at the first flange portion 12. The first terminal electrode 61 and the second terminal electrode 62 respectively comprise a base electrode 71 formed on the surface of the first flange portion 12 and a plating layer 72 covering the base electrode 71, the base electrode 71 comprising a bottom base electrode 71d formed on the first bottom surface 22d, an end base electrode 71b formed on the end surface 12b, and a side base electrode 71e formed on the first side surface 12e, the height T1 of the end base electrode 71b being higher than the height T24 of the first crotch portion 24, and the height T5 of the side base electrode 71e being lower than the height T24 of the first crotch portion 24.

[0137] In the coil component 1 of the present embodiment, at the end faces 12b and 13b, the height T2 of each terminal electrode 61 to 64 including the base electrode 71 and the plating layer 72 covering the base electrode 71 is higher than the crotch height T24. The height T2 of the terminal electrodes 61 to 64 is the height from the bottom surface of each terminal electrode 61 to 64 to the highest part of each terminal electrode 61 to 64 on the end faces 12b and 13b. Therefore, when the coil component 1 is installed, the height of the solder fillet formed by the solder attached to each terminal electrode 61 to 64 at the end faces 12b and 13b is higher than that of the coil component of the comparative example. That is, it is possible to form a solder fillet with higher recognizability than a coil component with the same height of the crotch. Therefore, identification by the appearance inspection device becomes easy.

[0138] (2) In the coil component 1 of the present embodiment, the height T3 of the inner surface base electrode 71a is higher than the crotch height T24. The height T4 of each terminal electrode 61 to 64 including the base electrode 71 and the plating layer 72 covering the base electrode 71 is higher than the crotch height T24. As a result, when the coil component 1 is installed, the height of the solder leg formed by the solder attached to each terminal electrode 61 to 64 on one side of the inner surface 12a, 13a of the drum-shaped core 10 of the coil component 1 becomes higher. That is, in the first flange portion 12, the height of the solder leg attached to one side of the end surface 12b and the height of the solder leg attached to one side of the inner surface 12a are higher than those of the coil component of the comparative example. Similarly, in the second flange portion 13, the height of the solder leg attached to one side of the end surface 13b and the height of the solder leg attached to one side of the inner surface 12a are higher than those of the coil component of the comparative example. Therefore, the heat shock resistance is improved.

[0139] (3) In the step of forming the base electrode 71, by swinging the drum-shaped core 10 in the longitudinal direction of the drum-shaped core 10, the height T1 of the base electrode 71 (end surface base electrode 71b) at the end surfaces 12b and 13b of the drum-shaped core 10 can be easily made higher than the crotch height T24.

[0140] (4) In the process of forming the base electrode 71, by swinging the drum-shaped core 10 along the length direction of the drum-shaped core 10, the height T3 of the base electrode 71 (inner surface base electrode 71a) at the inner surfaces 12a and 13a of the drum-shaped core 10 can be easily made higher than the crotch height T24.

[0141] (5) In the process of attaching the conductive paste 114 to the drum-shaped core 10 (the first to fifth processes), the drum-shaped core 10 is not moved in the width direction Wd of the drum-shaped core 10. Therefore, in the coil component 1 of the present embodiment, Fig.10 The height T6 of the inner side surface base electrode 71f at the first inner side surface 22f shown is substantially equal to the height of the inner side surface base electrode in the coil component of the comparative example and is lower than the crotch height T24. That is, the height T6 of the inner side surface base electrode 71f is lower than the height of the first inner side surface 22f constituting the first crotch portion 24. Therefore, in the coil component 1, the first terminal electrode 61 and the second terminal electrode 62 can be prevented from being connected to each other, thereby ensuring the insulation between the first terminal electrode 61 and the second terminal electrode 62. In addition, the third terminal electrode 63 and the fourth terminal electrode 64 can be prevented from being connected to each other, thereby ensuring the insulation between the third terminal electrode 63 and the fourth terminal electrode 64.

[0142] (6) In the coil component 1 of the present embodiment, the height T3 of the inner surface base electrode 71a is lower than the core height T11 to the bottom surface 11a of the core portion 11. Moreover, on the inner surface 12a, the height T4 of each terminal electrode 61 to 64 including the base electrode 71 (inner surface base electrode 71a) and the plating layer 72 covering the base electrode 71 is lower than the core height T11. It is possible to prevent the first wire 81 and the second wire 82 wound on the core portion 11 from being connected to each terminal electrode 61 to 64 at an undesired position.

[0143] (7) When the bottom surface substrate electrode 71d, the end surface substrate electrode 71b, the side surface substrate electrode 71e, the inner surface substrate electrode 71a, and the inner side surface substrate electrode 71f are formed separately, it is necessary to connect each electrode, and the thickness of the connection part is thicker than other parts. In contrast, the coil component 1 of the present embodiment forms the bottom surface substrate electrode 71d, the end surface substrate electrode 71b, the side surface substrate electrode 71e, the inner surface substrate electrode 71a, and the inner side surface substrate electrode 71f in unison. Therefore, the thickness of the substrate electrode 71 can be formed to be thinner. In addition, the bottom surface substrate electrode 71d, the end surface substrate electrode 71b, the side surface substrate electrode 71e, the inner surface substrate electrode 71a, and the inner side surface substrate electrode 71f can be formed at one time, so the number of processes can be reduced compared to the case where they are made separately.

[0144] (8) The thickness of the end surface base electrode 71b is thicker than the thickness of the side surface base electrode 71e. The base electrode 71 contains silver (Ag) and silicon dioxide. Therefore, by making the end surface base electrode 71b thicker, the adhesion with the end surfaces 12b and 13b of the drum-shaped core 10 can be improved.

[0145] (9) The first leg portion 22 has a ridge portion 41 that forms a boundary between the end surface 12b, the first side surface 12e, the inner surface 22a, and the first inner surface 22f that are the peripheral surfaces of the first leg portion 22 facing either the length direction Ld or the width direction Wd. The ridge portion 41 is formed into a curved surface that bulges toward the outside of the first leg portion 22. The second leg portion 23 has a ridge portion 42 that forms a boundary between the end surface 12b, the second side surface 12f, the inner surface 22a, and the second inner surface 23e that are the peripheral surfaces of the second leg portion 23 facing either the length direction Ld or the width direction Wd. The ridge portion 42 is formed into a curved surface that bulges toward the outside of the second leg portion 23.

[0146] The third leg portion 32 has a ridge portion 51 that forms a boundary between the end face 13b, the first side face 13e, the inner surface 32a, and the first inner surface 32f that are the peripheral surfaces of the third leg portion 32 facing either the length direction Ld or the width direction Wd. The ridge portion 51 is formed into a curved surface that bulges toward the outside of the third leg portion 32. The fourth leg portion 33 has a ridge portion 52 that forms a boundary between the end face 13b, the second side face 12f, the inner surface 33a, and the second inner surface 33e that are the peripheral surfaces of the fourth leg portion 33 facing either the length direction Ld or the width direction Wd. The ridge portion 52 is formed into a curved surface that bulges toward the outside of the fourth leg portion 33.

[0147] Therefore, when the drum-shaped core 10 is swung, the conductive paste 114 flows smoothly due to the ridges 41, 42, 51, 52, and the shape variation of the base electrode 71 can be suppressed. Thus, the quality variation of the coil component 1 can be suppressed.

[0148] (10) The first leg portion 22 has a ridge portion 43 that forms the end surface 12b, the first side surface 12e, the inner surface 12a, and the respective boundaries between the first inner side surface 22f and the first bottom surface 22d. The ridge portion 43 is formed into a curved surface that protrudes toward the outside of the first leg portion 22. When the coil component 1 is mounted, solder enters between the mounting substrate and the curved ridge portion 43, thereby improving heat shock resistance.

[0149] (11) The second leg portion 23 has a curved ridge portion 44 that forms the boundary between the end surface 12b, the second side surface 12f, the inner surface 12a, and the second inner side surface 23e and the second bottom surface 23d. The ridge portion 44 is formed into a curved shape that protrudes toward the outside of the second leg portion 23. When the coil component 1 is mounted, solder enters between the mounting substrate and the curved ridge portion 44, thereby improving heat shock resistance.

[0150] (12) The third leg portion 32 has a curved ridge portion 53 that forms the end surface 13b, the first side surface 13e, the inner surface 13a, and the respective boundaries between the first inner side surface 32f and the third bottom surface 32d. The ridge portion 53 is formed into a curved shape that protrudes toward the outside of the third leg portion 32. When the coil component 1 is mounted, solder enters between the mounting substrate and the curved ridge portion 53, thereby improving heat shock resistance.

[0151] (13) The fourth leg portion 33 has a curved ridge portion 54 that forms the boundary between the end surface 13b, the second side surface 13f, the inner surface 13a, and the second inner side surface 33e and the fourth bottom surface 33d. The ridge portion 54 is formed into a curved shape that protrudes toward the outside of the fourth leg portion 33. When the coil component 1 is mounted, solder enters between the mounting substrate and the curved ridge portion 54, thereby improving heat shock resistance.

[0152] (Change Example)

[0153] The above-mentioned embodiment can be implemented by modification as follows. The above-mentioned embodiment and the following modification examples can be implemented in combination within the range that there is no technical contradiction.

[0154] · Fig.19 A modified example of the method for manufacturing the coil component 1 is shown. Fig.19 The method is manufactured by following steps S21 to S24 shown in the figure.

[0155] In the manufacturing method of this modified example, step S21 is the same as step S11 of the above-described embodiment.

[0156] The electrode forming process of step S22 includes a first base electrode forming process (step S22a), a second base electrode forming process (step S22b) and a plating layer forming process (step S22c). The first base electrode forming process (step S22a) is the same as step S12a of the above embodiment. That is, the first base electrode forming process includes the first to fifth processes shown in the above embodiment.

[0157] In the second base electrode forming step (step S22b), following the fifth step, the drum-shaped core 10 is dip-coated with the conductive paste 114 (sixth step). Then, the holding device 111 is raised, and the drum-shaped core 10 held by the holding device 111 is lifted from the conductive paste 114 (seventh step). Through this second base electrode forming step, the surface of the bottom base electrode 71d formed on the first bottom surface 22d, the second bottom surface 23d, the third bottom surface 32d, and the fourth bottom surface 33d can be smoothed.

[0158] The plating layer forming step (step S22c) is the same as step S12b of the above embodiment. Furthermore, steps S23 and S24 are the same as steps S13 and S14 of the above embodiment.

[0159] Through the above steps, the coil component 1 having the bottom base electrode 71d with a smooth surface is manufactured.

[0160] The above-described embodiment may be a coil component in which three or more wires are wound.

[0161] In the above embodiment, the main body inner surface 21a of the first main body 21 of the first flange 12 and the inner surfaces 22a and 23a of the first leg 22 and the second leg 23 may be on the same plane. In addition, the main body inner surface 31a of the second main body 31 of the second flange 13 and the inner surfaces 32a and 33a of the third leg 32 and the fourth leg 33 may be on the same plane.

Claims

1. A coil component, wherein: have: a drum-shaped core body having a winding core portion extending in the length direction of the coil component and a first flange portion provided at a first end portion of the winding core portion in the length direction; The first wire and the second wire respectively have a first end and a second end and are wound around the winding core; a first terminal electrode, disposed on the first flange portion and connected to the first end of the first wire; as well as a second terminal electrode, provided on the first flange portion and connected to the first end of the second wire, The first flange portion has: an inner surface facing one side of the winding core portion; an end surface facing the opposite side of the inner surface; a bottom surface and a top surface facing opposite sides in a height direction orthogonal to the length direction; and a pair of side surfaces facing opposite sides in a width direction orthogonal to the length direction and the height direction, The first flange portion comprises: a first main body portion provided at the first end portion of the winding core portion; a first leg portion and a second leg portion protruding from the first main body portion in the height direction; a main body bottom surface of the first main body portion facing one side of the bottom surface; and a pair of inner side surfaces of the first leg portion and the second leg portion facing each other, When viewed from one side of the end surface, a first crotch portion surrounded by the first main body portion, the first leg portion, and the second leg portion is formed. The bottom surface includes a first bottom surface of the first foot and a second bottom surface of the second foot, The first terminal electrode and the second terminal electrode each include a base electrode formed on a surface of the first flange portion and a plating layer covering the base electrode. The base electrode includes a bottom base electrode formed on the bottom surface, an end base electrode formed on the end surface, and a side base electrode formed on the side surface. The height of the end surface base electrode is higher than the height of the first crotch portion, The height of the side substrate electrode is lower than the height of the first crotch portion, The substrate electrode includes an inner surface substrate electrode formed on the inner surface, The height of the end surface base electrode is the same as the height of the inner surface base electrode, The height of the inner surface base electrode is higher than the height of the first crotch portion and lower than the height of the lower surface of the winding core portion. The drum-shaped core has a curved ridge portion that forms a boundary between each of the bottom surface, the end surface, the inner surface, the side surface, and the inner side surface and a surface adjacent to each surface.

2. The coil component according to claim 1, wherein The substrate electrode has an inner side substrate electrode formed on the inner side surface, The height of the inner side surface base electrode is lower than the height of the inner side surface.

3. The coil component according to claim 1 or 2, wherein: The bottom surface base electrode, the end surface base electrode, and the side surface base electrode are formed continuously.

4. The coil component according to claim 1 or 2, wherein: The end surface base electrode is thicker than the side surface base electrode.

5. A method for manufacturing a coil component, wherein: The coil component comprises: a drum-shaped core body having a winding core portion extending in the length direction of the coil component, a first flange portion provided at a first end portion of the winding core portion in the length direction, and a second flange portion provided at a second end portion of the winding core portion in the length direction; A first terminal electrode and a second terminal electrode are provided on the first flange portion; as well as The third terminal electrode and the fourth terminal electrode are provided on the second flange portion. The first terminal electrode to the fourth terminal electrode include a base electrode formed on the surface of the drum-shaped core and a plating layer covering the base electrode. The first flange portion includes a first main body portion provided at the first end portion of the winding core portion, a first leg portion and a second leg portion protruding from the first main body portion in a height direction perpendicular to the length direction, and a pair of inner side surfaces of the first leg portion and the second leg portion facing each other. The first flange portion includes a first crotch portion surrounded by the first body portion, the first leg portion, and the second leg portion. The second flange portion includes a second main body portion provided at the second end portion of the winding core portion, and a third leg portion and a fourth leg portion protruding from the second main body portion in the height direction. The second flange portion includes a second crotch portion surrounded by the second body portion, the third leg portion, and the fourth leg portion. The method for manufacturing the coil component comprises: In a first step, the drum-shaped core is held with its bottom surface facing toward the conductive paste, and is lowered toward the upper surface of a platform storing the conductive paste forming the base electrode so that a portion of the drum-shaped core is immersed in the conductive paste; The second step is to move the drum-shaped core body along the length direction by a first distance; A third step is to move the drum-shaped core body in a direction opposite to the moving direction of the second step by a distance twice as large as the first distance; a fourth step of moving the drum-shaped core body by the first distance in the moving direction of the second step; and The fifth step is to lift the drum-shaped core from the conductive paste. The first flange portion has: an inner surface facing one side of the winding core portion; an end surface facing the opposite side of the inner surface; and a pair of side surfaces facing opposite sides in a width direction orthogonal to the length direction and the height direction. The base electrode includes an inner surface base electrode formed on the inner surface and an end surface base electrode formed on the end surface. The height of the end surface base electrode is the same as the height of the inner surface base electrode, The height of the inner surface base electrode is higher than the height of the first crotch portion and lower than the height of the lower surface of the winding core portion. The drum-shaped core has a curved ridge portion that forms a boundary between each of the bottom surface, the end surface, the inner surface, the side surface, and the inner side surface and a surface adjacent to each surface.

6. The method for manufacturing a coil component according to claim 5, wherein: include: A sixth step, at least after the fourth step, lowering a portion of the drum-shaped core toward an upper surface of a platform storing the conductive paste to immerse the drum-shaped core in the conductive paste; and In a seventh step, the drum-shaped core is lifted from the conductive paste.

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