Coil components

Abstract

The present invention relates to a coil component. The coil component comprises: a core body having a winding core and a pair of flanges; a terminal electrode provided on each of the pair of flanges; and a wire material wound on the winding core, and electrically connected to the terminal electrodes at both ends, the flange having an inner end face, an outer end face, a bottom face, a top face, and two side faces, the terminal electrode comprising: a bottom face electrode portion continuously provided on a face of the flange at least including the bottom face; and an outer end face electrode portion provided on the outer end face of the flange, the bottom face electrode portion having a side face extension portion extending toward the side face of the flange, in the height direction from the bottom face toward the top face, the side face extension portion exists at a position lower than the portion of the winding core closest to the bottom face, the outer end face electrode portion is connected to the bottom face electrode portion, and the two end edges of the outer end face electrode portion on both sides of the width direction of the two side faces of the flange portion are present at a position separated from the two side faces of the flange portion.

Description

Technical Field

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

[0002] In the past, as a coil component, there is a coil component described in Japanese Patent Publication No. 2019-134040 (Patent Document 1). The coil component has: a core body having a winding core and a pair of flanges provided at both ends of the winding core; a terminal electrode provided at each of the pair of flanges; and a wire wound around the winding core, and the two ends of the wire are electrically connected to the terminal electrodes.

[0003] The flange portion has: an inner end face facing the core portion; an outer end face facing the side opposite to the inner end face; a bottom face connecting the inner end face and the outer end face and facing the mounting substrate side when installed; a top face facing the side opposite to the bottom face; and two side faces connecting the inner end face and the outer end face and connecting the bottom face and the top face.

[0004] The terminal electrode includes a bottom electrode provided on the bottom surface of the flange, an outer end electrode provided on the outer end surface of the flange, and a side electrode provided on the side surface of the flange. The bottom electrode, the outer end electrode, and the side electrode are connected to each other.

[0005] Patent Document 1: Japanese Patent Application Publication No. 2019-134040

[0006] However, it is known that when the above-mentioned conventional coil components are actually manufactured and used, there are the following problems.

[0007] The two end edges of the outer end face electrode in the width direction are located at positions that contact the two side surfaces of the flange. Therefore, when the two side surfaces of the flange of the core are clamped by the chuck fixture of the winding device and the wire is wound around the core (hereinafter referred to as the winding process), there is a concern that the chuck fixture and the outer end face electrode may interfere with each other, causing the outer end face electrode to peel off or be damaged. As a result, there is a concern that the wetting of the solder to the outer end face electrode may be hindered.

[0008] In addition, the side electrodes extend to a position higher than the bottom surface of the winding core. Therefore, when observed from a direction orthogonal to the side of the flange, there are side electrodes in the area of ​​the side of the flange that extends the winding core (hereinafter referred to as the extended area of ​​the side of the flange). Moreover, when a chuck fixture is used to hold the extended area of ​​the side of the flange in the winding process, the chuck fixture interferes with the side electrodes, and therefore the chuck fixture cannot be used to hold the extended area of ​​the side of the flange. Therefore, the existing coil components are clamped by a chuck fixture designed not to interfere with the side electrodes to cope with the above-mentioned problem, but if the size of the core body becomes smaller, the area of ​​the core body clamped by the chuck fixture becomes smaller, making it difficult to rotate the core body around the axis of the core body by the chuck fixture, and it is difficult to stably wind the wire around the core body. Summary of the invention

[0009] Therefore, an object of the present disclosure is to provide a coil component that can reduce damage to terminal electrodes caused by a chuck jig in a winding process and stabilize winding of a wire around a core in the winding process.

[0010] In order to solve the above-mentioned problems, a coil component as one embodiment of the present disclosure includes:

[0011] A core body having a winding core portion and a pair of flange portions provided at both ends of the winding core portion;

[0012] a terminal electrode provided on each of the pair of flange portions; and

[0013] The wire is wound on the winding core, and both ends are electrically connected to the terminal electrodes.

[0014] The flange portion has: an inner end surface facing the winding core; an outer end surface facing the opposite side of the inner end surface; a bottom surface connecting the inner end surface and the outer end surface and facing the mounting substrate side when mounted; a top surface facing the opposite side of the bottom surface; and two side surfaces connecting the inner end surface and the outer end surface and connecting the bottom surface and the top surface.

[0015] The terminal electrode comprises: a bottom surface electrode portion provided continuously on a surface of the flange portion including at least the bottom surface; and an outer end surface electrode portion provided on the outer end surface of the flange portion.

[0016] The bottom electrode portion has a side extension portion extending toward the side surface of the flange portion, and in the height direction from the bottom surface toward the top surface, the side extension portion is located at a position lower than a portion of the winding core portion closest to the bottom surface.

[0017] The outer end surface electrode portion is connected to the bottom surface electrode portion, and both end edges of the outer end surface electrode portion on both sides of the opposite width direction of both side surfaces of the flange portion are located at positions separated from both side surfaces of the flange portion.

[0018] According to the above method, the two end edges of the outer end surface electrode portion exist in a position separated from the two side surfaces of the flange portion. Therefore, when the two side surfaces of the flange portion of the core body are clamped by the chuck fixture of the winding device and the wire is wound around the core body (hereinafter referred to as the winding process), the chuck fixture does not interfere with the outer end surface electrode portion, and the outer end surface electrode portion will not be peeled off or damaged.

[0019] In addition, the side extension of the bottom electrode portion exists at a position lower than the portion of the winding core portion that is closest to the bottom surface, so that when observed from a direction orthogonal to the side of the flange portion, there is no side extension in the area of ​​the side of the flange portion that extends the winding core portion (hereinafter referred to as the extended area of ​​the side of the flange portion). Therefore, when the two side surfaces of the flange portion of the core body are clamped by a chuck fixture, even if the extended area of ​​the side of the flange portion is held by the chuck fixture, the chuck fixture will not interfere with the side extension. As a result, the core body can be rotated around the axis of the core body by the chuck fixture, so that the wire can be stably wound around the core body.

[0020] Therefore, damage to the terminal electrode by the chuck jig in the winding step can be reduced, and winding of the wire material around the core in the winding step can be stabilized.

[0021] Preferably, in one embodiment of the coil component,

[0022] The terminal electrodes include a first terminal electrode and a second terminal electrode provided on one flange portion, and a third terminal electrode and a fourth terminal electrode provided on the other flange portion.

[0023] The wire material includes a first wire material electrically connected to the first terminal electrode and the third terminal electrode, and a second wire material electrically connected to the second terminal electrode and the fourth terminal electrode.

[0024] According to the above embodiment, the coil component functions as a common mode choke coil.

[0025] Preferably, in one embodiment of the coil component, a size of the outer end surface electrode portion in the width direction decreases from the bottom surface toward the top surface.

[0026] According to the above-mentioned embodiment, the inter-electrode gap between the outer end surface electrode portion of the first terminal electrode and the outer end surface electrode portion of the second terminal electrode can be widened from the bottom surface toward the top surface. That is, when viewed from the axial direction of the winding core portion, the inter-electrode gap can be ensured at a position where the outer end surface of the flange portion overlaps with the axis of the winding core portion. Therefore, the chuck fixture can also contact the inter-electrode gap of the outer end surface of the flange portion without interfering with the outer end surface electrode portion. Thus, the core body can be maintained in a more stable posture using the chuck fixture. In addition, the same is true for the third terminal electrode and the fourth terminal electrode.

[0027] Furthermore, since the width of the bottom surface side of the outer end surface electrode portion is wide, the width of the solder fillet after solder wetting is wide, and visibility is improved during inspection of the solder fillet after the coil component is mounted on the mounting substrate.

[0028] Preferably, in one embodiment of the coil component, the outer end surface electrode portion does not overlap with an axis of the winding core portion when viewed in an axial direction of the winding core portion.

[0029] According to the above embodiment, when viewed from the axial direction of the winding core, the inter-electrode gap between the outer end surface electrode portion of the first terminal electrode and the outer end surface electrode portion of the second terminal electrode can be ensured at the position where the outer end surface of the flange portion overlaps with the axis of the winding core. Therefore, the chuck fixture can also contact the inter-electrode gap of the outer end surface of the flange portion without interfering with the outer end surface electrode portion. Thus, the core body can be maintained in a more stable posture using the chuck fixture. In addition, the same is true for the third terminal electrode and the fourth terminal electrode.

[0030] Preferably, in one embodiment of the coil component, the size in the width direction of the connection portion of the outer end surface electrode portion connected to the bottom surface electrode portion is greater than 75% and less than 100% of the size in the width direction of the bottom surface electrode portion.

[0031] According to the above embodiment, the width of the connection portion of the outer end surface electrode portion connected to the bottom surface electrode portion is wide, so that the width of the solder fillet after solder wetting is wide, thereby improving visibility during inspection of the solder fillet after the coil component is mounted on the mounting substrate.

[0032] Preferably, in one embodiment of the coil component, the outer end surface electrode portion is present at a position lower than half of a size of the flange portion in the height direction.

[0033] According to the above embodiment, when viewed from the axial direction of the winding core, the chuck jig can be brought into contact with the outer end surface of the flange portion at a position overlapping the axis of the winding core portion without interfering with the outer end surface electrode portion.

[0034] Preferably, in one embodiment of the coil component, the outer end surface electrode portion is present at a position lower than 1 / 3 of a size of the flange portion in the height direction.

[0035] According to the above embodiment, the chuck jig can be brought into contact with the outer end surface of the flange portion more widely, and the core body can be held in a more stable posture by the chuck jig.

[0036] Preferably, in one embodiment of the coil component, in the height direction of the outer end surface electrode portion, a central portion in the width direction of the outer end surface electrode portion is highest.

[0037] According to the above embodiment, a natural fillet can be formed on the outer end surface electrode portion.

[0038] Preferably, in one embodiment of the coil component, a corner of the outer end surface electrode portion located on the top surface side and the side surface side is in an arc shape.

[0039] According to the above embodiment, a natural fillet can be formed on the outer end surface electrode portion.

[0040] Preferably, in one embodiment of the coil component, a magnetic plate is provided and fixed so as to straddle the pair of flange portions.

[0041] According to the above embodiment, the magnetic efficiency is improved and a desired inductance value can be obtained with a small number of wires.

[0042] Preferably, in one embodiment of the coil component,

[0043] The flange portion of one of the above-mentioned parts has two legs on the above-mentioned bottom surface side, the bottom surface electrode portion of the above-mentioned first terminal electrode is provided on one of the legs, and the bottom surface electrode portion of the above-mentioned second terminal electrode is provided on the other of the legs,

[0044] The other flange portion has two leg portions on the bottom surface side, the bottom surface electrode portion of the third terminal electrode is provided on one leg portion, and the bottom surface electrode portion of the fourth terminal electrode is provided on the other leg portion.

[0045] According to the above embodiment, the bottom surface electrode portions respectively provided on the two leg portions of the flange portion can be easily separated by the dipping method.

[0046] Preferably, in one embodiment of the coil component, an inner edge of the outer end surface electrode portion in the width direction is connected to an inner edge of the bottom surface electrode portion in the width direction.

[0047] Here, the inner side refers to the center side in the width direction of the flange portion.

[0048] According to the above embodiment, the outer end surface electrode portion can be provided offset inwardly with respect to the bottom surface electrode portion, thereby ensuring the width of the outer end surface electrode portion and making the outer edge of the outer end surface electrode portion further away from the side surface of the flange portion.

[0049] Preferably, in one embodiment of the coil component, the inner edge of the outer end surface electrode portion and the inner edge of the bottom surface electrode portion are located on the same line.

[0050] According to the above embodiment, the width of the outer end surface electrode portion can be further ensured, and the outer edge of the outer end surface electrode portion can be further away from the side surface of the flange portion.

[0051] Preferably, in one embodiment of the coil component, among the thickness of the outer end surface electrode portion, a central portion of the outer end surface electrode portion in the height direction and the width direction is the thickest.

[0052] According to the above embodiment, the thickness of the central portion of the outer end surface electrode portion is relatively thick, thereby preventing the weld leg from being formed too high. In addition, the thickness of the outer peripheral edge of the outer end surface electrode portion is relatively thin, thereby the weld leg smoothly extends in the vertical direction, and when the outer end surface of the flange portion is clamped by a chuck fixture, the outer end surface electrode portion does not become an obstacle to the chuck fixture.

[0053] Preferably, in one embodiment of the coil component, the flange portion has a first convex curved surface between the outer end surface and the side surface.

[0054] According to the above embodiment, the core body can be prevented from being broken when the two side surfaces of the flange portion of the core body are clamped by the chuck fixture. In addition, the solder legs can be formed at the same time so as to span both the outer end surface and the side surface of the flange portion. Specifically, since the solder legs on the outer end surface are higher, the molten solder can easily go around to the side surface along the first convex curved surface.

[0055] Preferably, in one embodiment of the coil component, the flange portion has a second convex curved surface between the outer end surface and the bottom surface.

[0056] According to the above embodiment, the melted solder can easily flow around the outer end surface and the bottom surface along the second convex curved surface, so that the fillet can be formed so as to straddle both the outer end surface and the bottom surface.

[0057] Preferably, in one embodiment of the coil component,

[0058] The flange portion has a third convex surface between the side surface and the bottom surface,

[0059] The side surface extension portion is located on the third convex curved surface in the height direction, and does not exist at a position higher than the third convex curved surface.

[0060] According to the above embodiment, when the chuck clamps the two side surfaces of the flange portion of the core body, the range in which the chuck clamp can contact the side surfaces of the flange portion without interfering with the side extension portions can be expanded, so that the core body can be stably held by the chuck clamp.

[0061] Preferably, in one embodiment of the coil component, the outer end surface electrode portion is higher than the side surface extension portion in the height direction.

[0062] According to the above embodiment, visibility is improved in the inspection of the fillet formed on the outer end surface electrode portion.

[0063] According to the coil component as one aspect of the present disclosure, damage to the terminal electrode by the chuck jig in the winding step can be reduced, and winding of the wire material around the core in the winding step can be stabilized. BRIEF DESCRIPTION OF THE DRAWINGS

[0064] Figure 1 This is a perspective view showing the first embodiment of the coil component as seen from below.

[0065] Figure 2 This is a diagram of the coil component as viewed from the L direction.

[0066] Figure 3 This is a diagram of the coil component as viewed from the W direction.

[0067] Figure 4 yes Figure 2 AA section view.

[0068] Figure 5 yes Figure 3 BB cross-sectional view.

[0069] Figure 6 It is a perspective view showing a state where both side surfaces of the first flange portion of the core body are clamped by a chuck jig.

[0070] Figure 7 This is a perspective view showing a state where the coil component is mounted on a mounting substrate.

[0071] Figure 8 This is a diagram showing a second embodiment of the coil component when viewed from the L direction.

[0072] Fig.9A It is a LW cross-sectional view of a part of the coil component which shows the 3rd embodiment of the coil component.

[0073] Fig. 9B It is a TL cross-sectional view showing a part of the coil component according to the third embodiment of the coil component.

[0074] Fig. 9C It is a TW cross-sectional view of a part of the coil component showing the third embodiment of the coil component.

[0075] Description of Reference Numerals

[0076] 1…coil component; 10, 10A, 10B…core; 11, 11A, 11B…first flange; 116…first convex surface; 117…second convex surface; 118…third convex surface; 12…second flange; 13…winding core; 13a…axis; 15…magnetic plate; 21…first wire; 22…second wire; 31, 31A…first terminal electrode; 32, 32A…second terminal electrode; 33…third terminal electrode; 34…fourth terminal electrode; 40…bottom Surface electrode portion; 41…bottom portion; 42…side extension portion; 43…external end surface extension portion; 44…inner end surface extension portion; 45a…inner end edge; 50…external end surface electrode portion; 51…end edge; 51a…inner end edge; 51b…outer end edge; 52…connecting portion; 53…corner; 60…chuck fixture; 70…mounting substrate; 80…solder; T11…height of the first flange portion; W40…width of the bottom electrode portion; W52…width of the connecting portion; Z…extension area. DETAILED DESCRIPTION

[0077] Hereinafter, a coil component as one embodiment of the present disclosure will be described in detail based on the illustrated embodiment. In addition, the drawings include some schematic components and may not reflect actual dimensions and ratios.

[0078] (First Embodiment)

[0079] Figure 1 1 is a perspective view showing a first embodiment of a coil component as viewed from below. Figure 1 As shown, the coil component 1 includes a core 10, a first wire 21 and a second wire 22 wound on the core 10, a first terminal electrode 31, a second terminal electrode 32, a third terminal electrode 33 and a fourth terminal electrode 34 arranged on the core 10 and electrically connected to the first wire 21 and the second wire 22, and a magnetic plate 15 mounted on the core 10.

[0080] The core 10 includes: a winding core 13, which is in a shape extending in a certain direction and is wound with a first wire 21 and a second wire 22; a first flange 11, which is provided at a first end of the extension direction of the winding core 13 and extends in a direction orthogonal to the direction; and a second flange 12, which is provided at a second end of the extension direction of the winding core 13 and extends in a direction orthogonal to the direction. The extension direction of the winding core 13 is also referred to as the axial direction of the winding core 13. The material of the core 10 is preferably a magnetic body such as a sintered body of ferrite or a molded body of a resin containing magnetic powder, and may also be a non-magnetic body such as alumina or resin.

[0081] In addition, hereinafter, the bottom surface of the core 10 is regarded as the surface mounted on the mounting substrate, and the surface of the core 10 opposite to the bottom surface is regarded as the top surface of the core 10. The axial direction of the winding core 13 is regarded as the L direction, the direction perpendicular to the L direction at the bottom surface of the core 10 is regarded as the W direction, and the direction opposite to the bottom surface and the top surface of the core 10 is regarded as the T direction. The T direction is perpendicular to the L direction and the W direction. The positive direction of the T direction is regarded as the top, and the negative direction of the T direction is regarded as the bottom. That is, the bottom surface of the core 10 corresponds to the bottom in the vertical direction, and the top surface of the core 10 corresponds to the top in the vertical direction. The L direction is also referred to as the length direction of the core 10, the W direction is referred to as the width direction of the core 10, and the T direction is referred to as the height direction of the core 10.

[0082] The first flange portion 11 has an inner end surface 111 facing the winding core portion 13, an outer end surface 112 facing the opposite side to the inner end surface 111, a bottom surface 113 connecting the inner end surface 111 and the outer end surface 112 and facing the mounting substrate side when mounted, a top surface 114 facing the opposite side to the bottom surface 113, and two side surfaces 115 connecting the inner end surface 111 and the outer end surface 112 and connecting the bottom surface 113 and the top surface 114. In addition, the inner end surface 111, the outer end surface 112, the bottom surface 113, the top surface 114, and the side surfaces 115 have ridges formed between adjacent surfaces.

[0083] Similarly, the second flange portion 12 has: an inner end face 121 facing the side of the winding core portion 13; an outer end face 122 facing the side opposite to the inner end face 121; a bottom face 123 facing the mounting substrate side during installation; a top face 124 facing the side opposite to the bottom face 123; and two side faces 125 connecting the inner end face 121 with the outer end face 122 and connecting the bottom face 123 with the top face 124.

[0084] The magnetic plate 15 is fixed across the pair of first flange portions 11 and second flange portions 12. The magnetic plate 15 is attached to the top surface 114 of the first flange portion 11 and the top surface 124 of the second flange portion 12 by an adhesive. The material of the magnetic plate 15 is, for example, the same as that of the core 10. The core 10 and the magnetic plate 15 are both magnetic bodies, so a closed magnetic circuit is formed, and the efficiency of obtaining the inductance value is improved. Therefore, the magnetic efficiency is improved, and the desired inductance value can be obtained with a smaller number of wires.

[0085] The first flange portion 11 has two legs on the bottom surface 113 side, and the first terminal electrode 31 is provided on one leg, and the second terminal electrode 32 is provided on the other leg. The second flange portion 12 has two legs on the bottom surface 123 side, and the third terminal electrode 33 is provided on the leg located on the same side as the leg located on the first terminal electrode 31, and the fourth terminal electrode 34 is provided on the other leg located on the same side as the leg located on the second terminal electrode 32. Figure 1As shown, the bottom surface 113 and the bottom surface 123 respectively refer to the portion from the bottom surface portion of the foot through the side portion of the crotch between the feet and including the bottom surface portion of the crotch.

[0086] The first wire 21 and the second wire 22 are wires with an insulating coating in which a wire made of a metal such as copper is covered with a coating made of a resin such as polyurethane or polyamide-imide. One end of the first wire 21 is electrically connected to the first terminal electrode 31, and the other end is electrically connected to the third terminal electrode 33. One end of the second wire 22 is electrically connected to the second terminal electrode 32, and the other end is electrically connected to the fourth terminal electrode 34. The first wire 21 and the second wire 22 are connected to the first terminal electrode 31 to the fourth terminal electrode 34, for example, by thermocompression bonding, soldering, welding, etc.

[0087] The first wire 21 and the second wire 22 are wound in the same direction relative to the winding core 13. Thus, in the coil component 1, if a signal of anti-phase such as a differential signal is input to the first wire 21 and the second wire 22, the magnetic fluxes generated by the first wire 21 and the second wire 22 cancel each other out, weakening the effect as an inductor and allowing the signal to pass. On the other hand, if a signal of the same phase such as external noise is input to the first wire 21 and the second wire 22, the magnetic fluxes generated by the first wire 21 and the second wire 22 reinforce each other, reinforcing the effect as an inductor and cutting off the passage of the noise. Therefore, the coil component 1 functions as a common mode choke coil, which reduces the passage loss of differential mode signals such as differential signals and attenuates common mode signals such as external noise.

[0088] like Figure 7 As shown, when the coil component 1 is mounted on the mounting substrate 70, the bottom surface 113 of the first flange portion 11 and the bottom surface 123 of the second flange portion 12 are opposite to the mounting substrate 70. At this time, the axial direction of the winding core portion 13 is parallel to the main surface of the mounting substrate. That is, the coil component 1 is a horizontal winding type in which the winding axes of the first wire 21 and the second wire 22 are parallel to the mounting substrate 70.

[0089] Figure 2 This is a diagram of the coil component as viewed from the L direction. Figure 3 This is a diagram of the coil component viewed from the W direction. Figure 2 and Figure 3 In the figure, for convenience, the wires 21 and 22 and the magnetic plate 15 are omitted.

[0090] like Figure 2 and Figure 3As shown, the first terminal electrode 31 includes a bottom electrode portion 40 continuously provided on a surface of the first flange portion 11 including at least the bottom surface 113, and an outer end surface electrode portion 50 provided on the outer end surface 112 of the first flange portion 11. Similarly, the second terminal electrode 32, the third terminal electrode 33, and the fourth terminal electrode 34 each include a bottom electrode portion 40 and an outer end surface electrode portion 50. Hereinafter, the first terminal electrode 31 will be described, and the description of the second terminal electrode 32, the third terminal electrode 33, and the fourth terminal electrode 34 will be omitted.

[0091] The bottom electrode portion 40 has a side extension portion 42 extending toward the side surface 115 of the first flange portion 11. In the height direction from the bottom surface 113 toward the top surface 114 (consistent with the T direction), the side extension portion 42 exists at a position lower than the portion of the core portion 13 closest to the bottom surface 113. Specifically, the core portion 13 is a quadrilateral in cross section, so the side extension portion 42 exists at a position lower than the bottom surface 131 of the core portion 13. In addition, the cross-sectional shape of the core portion may be a hexagon or an ellipse other than a quadrilateral. In this case, the portion of the core portion closest to the bottom surface corresponds to one side of the core portion, the generatrix.

[0092] The outer end surface electrode portion 50 is connected to the bottom surface electrode portion 40. The outer end surface electrode portion 50 has end edges 51 on both sides of the opposite width directions (which coincide with the W direction) of the two side surfaces 115 of the first flange portion 11. Both end edges 51 of the outer end surface electrode portion 50 exist at positions separated from the two side surfaces 115 of the first flange portion 11.

[0093] Figure 4 yes Figure 2 AA section view. Figure 5 yes Figure 3 BB cross-sectional view. Figure 4 and Figure 5 As shown, the bottom electrode portion 40 includes a bottom portion 41 facing the bottom surface 113 of the first flange portion 11, a side surface extension portion 42 extending from the bottom portion 41 toward the side surface 115 of the first flange portion 11, an outer end surface extension portion 43 extending from the bottom portion 41 toward the outer end surface 112 of the first flange portion 11, and an inner end surface extension portion 44 extending from the bottom portion 41 toward the inner end surface 111 of the first flange portion 11. In this embodiment, the side surface extension portion 42 faces the side surface 115, the outer end surface extension portion 43 faces the outer end surface 112, and the inner end surface extension portion 44 faces the inner end surface 111.

[0094] The bottom electrode portion 40 is composed of a first layer 40a in contact with the core 10 and a second layer 40b covering the first layer 40a. The first layer 40a is formed by, for example, applying an Ag paste containing Ag, Si and resin to the bottom surface 113 of the first flange portion 11 by a dipping method and firing it. The second layer 40b is formed by, for example, electroplating a film of Cu, Ni and Sn in the order of Cu, Ni and Sn on the first layer 40a. The bottom electrode portion 40 is provided at each of the two legs of the first flange portion 11, so that the bottom electrode portion 40 provided at each leg can be easily separated by a dipping method.

[0095] The outer end surface electrode portion 50 faces the outer end surface 112. The outer end surface electrode portion 50 has a connection portion 52 connected to the bottom surface electrode portion 40. Specifically, the connection portion 52 is connected to and overlaps with the outer end surface extension portion 43 so as to cover a part of the outer end surface extension portion 43.

[0096] The outer end surface electrode portion 50 is composed of a first layer 50a in contact with the core 10 and a second layer 50b covering the first layer 50a. The first layer 50a is formed by, for example, forming a film of Ni or Cu on the outer end surface 112 of the first flange portion 11 by sputtering. The second layer 50b is formed by, for example, forming a film of Cu, Ni, and Sn on the first layer 50a by electroplating.

[0097] The first layer 50a of the outer end surface electrode portion 50 is formed to cover a portion of the first layer 40a of the bottom surface electrode portion 40. That is, the first layer 50a of the connection portion 52 overlaps with a portion of the first layer 40a of the outer end surface extension portion 43 so as to cover it. This is because the first layer 40a of the bottom surface electrode portion 40 is formed first, and then the first layer 50a of the outer end surface electrode portion 50 is formed.

[0098] On the other hand, the second layer 50b of the outer end surface electrode portion 50 is integrally continuous with the second layer 40b of the bottom surface electrode portion 40. This is because the second layer 50b of the outer end surface electrode portion 50 and the second layer 40b of the bottom surface electrode portion 40 are formed simultaneously by plating. When the second layers 40b and 50b are integrally formed by plating, for convenience, the portion covering the first layer 50a of the outer end surface electrode portion 50 is used as the second layer 50b of the outer end surface electrode portion 50, and the portion covering the first layer 40a of the bottom surface electrode portion 40 other than this is used as the second layer 40b of the bottom surface electrode portion 40.

[0099] According to the above implementation, Figure 2 As shown, both end edges 51 of the outer end surface electrode portion 50 are located at positions separated from the two side surfaces 115 of the first flange portion 11, so as Figure 6As shown, when the chuck fixture 60 of the winding device clamps the two side surfaces 115 of the first flange portion 11 of the core body 10 and winds the wires 21 and 22 around the core body 10 (hereinafter referred to as the winding process), the chuck fixture 60 does not interfere with the outer end surface electrode portion 50 of each of the first terminal electrode 31 and the second terminal electrode 32, and the outer end surface electrode portion 50 is not peeled off or damaged. As a result, the wetting of the solder to the outer end surface electrode portion 50 is not hindered.

[0100] Specifically, the chuck fixture 60 includes a first chuck portion 61 and a second chuck portion 62. The first chuck portion 61 is fixed to the device, and the second chuck portion 62 is movably mounted to the device. Moreover, the front end claw portion of the first chuck portion 61 and the front end claw portion of the second chuck portion 62 clamp the core body 10. At this time, the front end claw portion of the first chuck portion 61 and the front end claw portion of the second chuck portion 62 do not interfere with the outer end surface electrode portion 50.

[0101] In addition, if Figure 3 As shown in FIG. 1 , the side extension portion 42 of the bottom electrode portion 40 is located at a position lower than the bottom surface 131 of the winding core portion 13, and thus, when viewed from a direction perpendicular to the side surface 115 of the first flange portion 11, a region of the side surface 115 of the first flange portion 11 where the winding core portion 13 is extended (hereinafter referred to as the extension region Z of the side surface 115 of the first flange portion 11) is located at a position lower than the bottom surface 131 of the winding core portion 13. Figure 3 In the figure, the extended area Z is indicated by the double-dashed line hatching, and there is no side extension portion 42. Similarly, there is no side extension portion 42 in the extended area Z of the side 125 of the second flange portion 12. Therefore, Figure 6 As shown, when the chuck fixture 60 is used to clamp the two side surfaces 115 of the first flange portion 11 of the core body 10, even if the chuck fixture 60 is used to hold the extended area Z of the side surface 115 of the first flange portion 11, the chuck fixture 60 will not interfere with the side extension portion 42. Thus, the core body 10 can be rotated around the axis of the core body 10 by the chuck fixture 60, so that the wires 21 and 22 can be stably wound around the core body 10.

[0102] Therefore, damage to the terminal electrodes 31 to 34 by the chuck jig 60 in the winding step can be reduced, and winding of the wires 21 and 22 around the core 10 in the winding step can be stabilized.

[0103] In addition, the coil component 1 has a bottom electrode portion 40 (side extension portion 42) and an outer end surface electrode portion 50, so that Figure 7 As shown, when the coil component 1 is mounted on the mounting substrate 70 , the solder 80 wets the side extension portion 42 and the outer end surface electrode portion 50 , thereby increasing the fixing force between the coil component 1 and the mounting substrate 70 .

[0104] Preferably, if Figure 2As shown, the width direction of the outer end surface electrode portion 50 decreases from the bottom surface 113 toward the top surface 114. That is, the distance between the two end edges 51 of the outer end surface electrode portion 50 narrows upward (T direction). The distance between the two end edges 51 may narrow stepwise or continuously.

[0105] Thus, the inter-electrode gap between the outer end surface electrode portion 50 of the first terminal electrode 31 and the outer end surface electrode portion 50 of the second terminal electrode 32 can be widened from the bottom surface 113 toward the top surface 114. That is, when viewed from the direction of the axis 13a of the winding core portion 13, the inter-electrode gap can be ensured at a position overlapping the axis 13a of the winding core portion 13 in the outer end surface 112 of the first flange portion 11. Therefore, the chuck fixture 60 can also contact the inter-electrode gap of the outer end surface 112 of the first flange portion 11 without interfering with the outer end surface electrode portion 50. Thus, the core body 10 can be maintained in a more stable posture using the chuck fixture 60. In addition, the same is true for the third terminal electrode 33 and the fourth terminal electrode 34.

[0106] In addition, since the width of the bottom surface 113 side of the outer end surface electrode portion 50 is large, the width of the solder fillet after solder wetting is large, and visibility is improved during inspection of the solder fillet after the coil component 1 is mounted on the mounting substrate.

[0107] Preferably, if Figure 2 As shown, when viewed from the direction of the axis 13a of the winding core portion 13, the outer end surface electrode portion 50 does not overlap with the axis 13a of the winding core portion 13. Therefore, when viewed from the direction of the axis 13a of the winding core portion 13, the inter-electrode gap between the outer end surface electrode portion 50 of the first terminal electrode 31 and the outer end surface electrode portion 50 of the second terminal electrode 32 can be ensured at a position overlapping with the axis 13a of the winding core portion 13 in the outer end surface 112 of the first flange portion 11. Therefore, the chuck fixture 60 can also be brought into contact with the inter-electrode gap of the outer end surface 112 of the first flange portion 11 without interfering with the outer end surface electrode portion 50. Thus, the core body 10 can be maintained in a more stable posture using the chuck fixture 60. In addition, the same is true for the third terminal electrode 33 and the fourth terminal electrode 34.

[0108] Preferably, if Figure 2As shown, the size of the connecting portion 52 of the outer end surface electrode portion 50 connected to the bottom surface electrode portion 40 in the width direction (hereinafter referred to as the width W52) is greater than 75% and less than 100% of the size of the bottom surface electrode portion 40 in the width direction (hereinafter referred to as the width W40). As a result, the width of the connecting portion 52 of the outer end surface electrode portion 50 is wider, so the width of the solder leg after the solder is wetted is wider, so that the visibility is improved in the inspection of the solder leg after the coil component 1 is mounted on the mounting substrate. In contrast, if the width W52 of the connecting portion 52 is less than 75% of the width W40 of the bottom surface electrode portion 40, the width of the solder leg becomes narrower. If the width W52 of the connecting portion 52 is the same as the width W40 of the bottom surface electrode portion 40, there is a concern that the chuck fixture 60 and the outer end surface electrode portion 50 will interfere with each other.

[0109] Preferably, if Figure 2 As shown, the outer end surface electrode portion 50 is present at a position lower than half of the size of the first flange portion 11 in the height direction (hereinafter referred to as the height T11). The height T11 of the first flange portion 11 refers to the maximum distance between the bottom surface 113 and the top surface 114 of the first flange portion 11. As a result, the chuck fixture 60 can be brought into contact with the position of the outer end surface 112 of the first flange portion 11 that overlaps with the axis 13a of the winding core portion 13 when viewed from the axis 13a of the winding core portion 13, without interfering with the outer end surface electrode portion 50. As a result, the core body 10 can be maintained in a more stable posture using the chuck fixture 60.

[0110] More preferably, the outer end surface electrode portion 50 is located at a position lower than 1 / 3 of the height T11 of the first flange portion 11. This allows the chuck jig 60 to contact the outer end surface 112 of the first flange portion 11 more widely, so that the chuck jig 60 can hold the core 10 in a more stable posture.

[0111] Preferably, if Figure 2 As shown in FIG. 1 , in the height direction of the outer end surface electrode portion 50, the center portion of the outer end surface electrode portion 50 in the width direction is the highest. That is, the center portion of the outer end surface electrode portion 50 in the width direction has the maximum height. In addition, in the two outer end surface electrode portions 50 provided on the first flange portion 11, each outer end surface electrode portion 50 has the maximum height in its center portion. Thus, when the solder wets to the upper part of the outer end surface electrode portion 50, a natural solder fillet can be formed on the outer end surface electrode portion 50.

[0112] Preferably, if Figure 2 As shown, the corner 53 of the outer end surface electrode portion 50 located on the top surface 114 side and the side surface 115 side is in an arc shape. Thus, when the solder wets above the outer end surface electrode portion 50, a natural fillet can be formed on the outer end surface electrode portion 50.

[0113] Preferably, if Figure 2As shown, among the thickness of the outer end surface electrode portion 50, the central portion of the outer end surface electrode portion 50 in the height direction and the width direction is the thickest. The thickness of the outer end surface electrode portion 50 refers to the size in the direction orthogonal to the outer end surface 112 of the first flange portion 11. Therefore, the thickness of the central portion of the outer end surface electrode portion 50 is relatively thick, so it is possible to prevent the weld leg from being formed too high. In addition, the thickness of the outer peripheral edge of the outer end surface electrode portion 50 is relatively thin, so the weld leg extends smoothly in the up-down direction, and when the outer end surface 112 of the first flange portion 11 is clamped by the chuck fixture 60, the outer end surface electrode portion 50 does not become an obstacle to the chuck fixture 60.

[0114] Preferably, if Figure 2 As shown, the outer end surface electrode portion 50 is higher in the height direction than the side surface extension portion 42 of the bottom surface electrode portion 40. This improves visibility when inspecting the fillet formed on the outer end surface electrode portion 50.

[0115] (Second Embodiment)

[0116] Figure 8 2 is a diagram showing a second embodiment of the coil component when viewed from the L direction. Figure 8 In the figure, for convenience, the wire and the magnetic plate are omitted. The difference between the second embodiment and the first embodiment lies in the shape of the core and the shape of the terminal electrode. The different structures are described below. The other structures are the same as those of the first embodiment, and are marked with the same figure marks as those of the first embodiment and their descriptions are omitted.

[0117] like Figure 8 As shown, in the core body 10A of the coil component of the second embodiment, the bottom surface 113 of the first flange portion 11A is flat, and does not have the two legs of the first embodiment. Although not shown, the same is true for the second flange portion.

[0118] In the first terminal electrode 31A, the inner edge 51a of the outer end surface electrode portion 50 in the width direction is connected to the inner edge 45a of the bottom surface electrode portion 40 in the width direction. The same is true for the second terminal electrode 32A. Although not shown in the figure, the same is true for the third terminal electrode and the fourth terminal electrode. Here, the inner side refers to the center side in the width direction of the first flange portion 11. Thus, the outer end surface electrode portion 50 can be set to be offset inward relative to the bottom surface electrode portion 40, so that the width of the outer end surface electrode portion 50 can be ensured, and the outer edge 51b of the outer end surface electrode portion 50 can be further away from the side surface 115 of the first flange portion 11.

[0119] Preferably, the inner edge 51a of the outer end surface electrode portion 50 is located on the same line as the inner edge 45a of the bottom surface electrode portion 40. Thus, the width of the outer end surface electrode portion 50 can be further ensured, and the outer edge 51b of the outer end surface electrode portion 50 can be further away from the side surface 115 of the first flange portion 11.

[0120] In addition, in the present embodiment, the inner edge 51a of the outer end surface electrode portion 50 is parallel to the outer edge 51b, and the width of the outer end surface electrode portion 50 is the same as it goes upward, but the width of the outer end surface electrode portion 50 may become smaller or larger as it goes upward. In addition, the inner edge 51a of the outer end surface electrode portion 50 and the inner edge 45a of the bottom surface electrode portion 40 are located on the same line, but the inner edge 51a of the outer end surface electrode portion 50 and the inner edge 45a of the bottom surface electrode portion 40 may intersect at one point.

[0121] (Third Embodiment)

[0122] Fig.9A It is a LW cross-sectional view of a part of the coil component which shows the third embodiment of the coil component. Fig. 9B It is a TL cross-sectional view showing a part of the coil component according to the third embodiment of the coil component. Fig. 9C 1 is a TW cross-sectional view of a portion of a coil component of the third embodiment of the coil component. The third embodiment differs from the first embodiment in the shape of the core. The following describes the different structures. The other structures are the same as those of the first embodiment, and are marked with the same figure marks as those of the first embodiment and their descriptions are omitted.

[0123] like Fig.9A As shown, in the core 10B of the coil component of the third embodiment, the first flange portion 11B has a first convex curved surface 116 between the outer end surface 112 and the side surface 115. In addition, although not shown, the same is true in the second flange portion. As a result, it is possible to prevent the core 10B from being broken when the two side surfaces 115 of the first flange portion 11B of the core 10B are clamped by a chuck fixture. In addition, solder legs can be formed at the same time so as to span both the outer end surface 112 and the side surface 115 of the first flange portion 11B. Specifically, since the solder leg of the outer end surface 112 is higher, the molten solder can easily go around to the side surface 115 along the first convex curved surface 116.

[0124] like Fig. 9B As shown in FIG. 1 , the first flange portion 11B has a second convex curved surface 117 between the outer end surface 112 and the bottom surface 113. Although not shown in the figure, the same is true for the second flange portion. Thus, the molten solder can easily flow along the second convex curved surface 117 to the outer end surface 112 and the bottom surface 113, and a solder fillet can be formed so as to span both the outer end surface 112 and the bottom surface 113.

[0125] like Fig. 9C As shown, the first flange portion 11B has a third convex surface 118 between the side surface 115 and the bottom surface 113. The side extension portion 42 is located on the third convex surface 118 in the height direction and does not exist at a position higher than the third convex surface 118. That is, the side extension portion 42 extends from the bottom surface 113 to the side surface 115, but does not reach the side surface 115. In addition, although not shown in the figure, the same is true for the second flange portion. As a result, when the two side surfaces 115 of the first flange portion 11B of the core body 10B are clamped by a chuck fixture, the range in which the chuck fixture can contact the side surface 115 of the first flange portion 11B without interfering with the side extension portion 42 can be expanded, so that the core body 10B can be stably held by the chuck fixture.

[0126] In addition, in this embodiment, the first flange portion 11B has a first convex surface 116, a second convex surface 117 and a third convex surface 118, but it is sufficient that at least one of the first flange portion and the second flange portion has at least one of the first convex surface, the second convex surface and the third convex surface.

[0127] In addition, the present disclosure is not limited to the above-mentioned embodiment, and the design can be changed within the scope not departing from the gist of the present disclosure. For example, various combinations of the respective features of the first to third embodiments are also possible.

[0128] In the first embodiment, the coil component has two wires, but may also have one or more than three wires. In addition, in the first embodiment, the coil component is used as a common mode choke coil, but may also be used as a winding type coil in which a wire is wound around a winding core, such as a transformer or a coupled inductor.

[0129] In the first embodiment described above, two terminal electrodes are provided on one flange portion, but one terminal electrode may be provided on one flange portion, in which case the terminal electrode also has a bottom electrode portion and an outer end surface electrode portion, the two end edges of the outer end surface electrode portion are present at positions separated from the two side surfaces of the flange portion, and the side extension portion of the bottom surface electrode portion is present at a position lower than the portion of the winding core portion closest to the bottom surface. In addition, three or more terminal electrodes may be provided on one flange portion.

[0130] In the first embodiment, the coil component has a magnetic plate, but it may not have a magnetic plate. In the first embodiment, the width direction size of the outer end surface electrode portion (the distance between the two end edges of the outer end surface electrode portion) decreases from the bottom surface toward the top surface, but it may increase, or it may be the same.

Claims

1. A coil component, wherein: have: A core body having a winding core portion and a pair of flange portions provided at both ends of the winding core portion; a terminal electrode provided on each of the pair of flange portions; and The wire is wound on the winding core, and both ends are electrically connected to the terminal electrodes. The flange portion has: an inner end surface facing the winding core portion; an outer end surface facing the opposite side of the inner end surface; and a bottom surface connecting the inner end surface and the outer end surface and facing the mounting substrate side when mounted; a top surface facing the opposite side of the bottom surface; and two side surfaces connecting the inner end surface to the outer end surface and connecting the bottom surface to the top surface, The terminal electrode comprises: a bottom surface electrode portion provided continuously on a surface of the flange portion including at least the bottom surface; and an outer end surface electrode portion provided on the outer end surface of the flange portion. The bottom electrode portion has a side extension portion extending along the side surface of the flange portion, and in the height direction from the bottom surface toward the top surface, the side extension portion is located at a position lower than a portion of the winding core portion closest to the bottom surface, The outer end surface electrode portion is connected to the bottom surface electrode portion, and both end edges of the outer end surface electrode portion on both sides of the opposite width direction of the two side surfaces of the flange portion are located at positions separated from the two side surfaces of the flange portion. The terminal electrodes include a first terminal electrode and a second terminal electrode provided at one flange portion, and a third terminal electrode and a fourth terminal electrode provided at the other flange portion. The wire material includes a first wire material electrically connected to the first terminal electrode and the third terminal electrode, and a second wire material electrically connected to the second terminal electrode and the fourth terminal electrode. The size of the outer end surface electrode portion in the width direction decreases from the bottom surface toward the top surface.

2. The coil component according to claim 1, wherein The outer end surface electrode portion is located at a position lower than half of the size of the flange portion in the height direction.

3. A coil component, wherein: have: A core body having a winding core portion and a pair of flange portions provided at both ends of the winding core portion; a terminal electrode provided on each of the pair of flange portions; and The wire is wound on the winding core, and both ends are electrically connected to the terminal electrodes. The flange portion has: an inner end surface facing the winding core portion; an outer end surface facing the opposite side of the inner end surface; and a bottom surface connecting the inner end surface and the outer end surface and facing the mounting substrate side when mounted; a top surface facing the opposite side of the bottom surface; and two side surfaces connecting the inner end surface to the outer end surface and connecting the bottom surface to the top surface, The terminal electrode comprises: a bottom surface electrode portion provided continuously on a surface of the flange portion including at least the bottom surface; and an outer end surface electrode portion provided on the outer end surface of the flange portion. The bottom electrode portion has a side extension portion extending along the side surface of the flange portion, and in the height direction from the bottom surface toward the top surface, the side extension portion is located at a position lower than a portion of the winding core portion closest to the bottom surface, The outer end surface electrode portion is connected to the bottom surface electrode portion, and both end edges of the outer end surface electrode portion on both sides of the opposite width direction of the two side surfaces of the flange portion are located at positions separated from the two side surfaces of the flange portion. The terminal electrodes include a first terminal electrode and a second terminal electrode provided at one flange portion, and a third terminal electrode and a fourth terminal electrode provided at the other flange portion. The wire material includes a first wire material electrically connected to the first terminal electrode and the third terminal electrode, and a second wire material electrically connected to the second terminal electrode and the fourth terminal electrode. The outer end surface electrode portion is located at a position lower than half of the size of the flange portion in the height direction.

4. The coil component according to claim 1 or 3, wherein: When viewed from the axial direction of the winding core, the outer end surface electrode portion does not overlap with the axis of the winding core.

5. The coil component according to claim 1 or 3, wherein: The size of the connection portion of the outer end surface electrode portion connected to the bottom surface electrode portion in the width direction is not less than 75% and less than 100% of the size of the bottom surface electrode portion in the width direction.

6. The coil component according to claim 1 or 3, wherein: The outer end surface electrode portion is located at a position lower than 1 / 3 of the size of the flange portion in the height direction.

7. The coil component according to claim 1 or 3, wherein: In the height direction of the outer end surface electrode portion, a central portion of the outer end surface electrode portion in the width direction is highest.

8. The coil component according to claim 1 or 3, wherein: The shape of the corner of the outer end surface electrode portion located on the top surface side and the side surface side is an arc shape.

9. The coil component according to claim 1 or 3, wherein: The coil component includes a magnetic plate fixed to the pair of flange portions so as to straddle the pair of flange portions.

10. The coil component according to claim 1 or 3, wherein: The flange portion of one side has two legs on the bottom side, the bottom electrode portion of the first terminal electrode is provided on one leg, and the bottom electrode portion of the second terminal electrode is provided on the other leg. The other flange portion has two leg portions on the bottom surface side, the bottom surface electrode portion of the third terminal electrode is provided on one leg portion, and the bottom surface electrode portion of the fourth terminal electrode is provided on the other leg portion.

11. The coil component according to claim 1 or 3, wherein: An inner edge of the outer end surface electrode portion in the width direction is connected to an inner edge of the bottom surface electrode portion in the width direction.

12. The coil component according to claim 11, wherein The inner edge of the outer end surface electrode portion and the inner edge of the bottom surface electrode portion are located on the same line.

13. The coil component according to claim 1 or 3, wherein: Among the thickness of the outer end surface electrode portion, the center portion of the outer end surface electrode portion in the height direction and the width direction is the thickest.

14. The coil component according to claim 1 or 3, wherein: The flange portion has a first convex curved surface between the outer end surface and the side surface.

15. The coil component according to claim 1 or 3, wherein: The flange portion has a second convex curved surface between the outer end surface and the bottom surface.

16. The coil component according to claim 1 or 3, wherein: The flange portion has a third convex surface between the side surface and the bottom surface, The side surface extension portion is located on the third convex curved surface in the height direction, and does not exist at a position higher than the third convex curved surface.

17. The coil component according to claim 1 or 3, wherein: The outer end surface electrode portion is higher than the side surface extension portion in the height direction.

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