Coil components and methods for manufacturing coil components

Abstract

This invention relates to a coil component and a method for manufacturing a coil component, which prevents wire from detaching from a metal terminal. The coil component (10) has a rectangular cylindrical core portion (11). A flange portion (12) is provided at a first end and a second end in the direction of the central axis of the core portion (11). The flange portion (12) extends outward from the core portion (11) in a first direction orthogonal to the central axis. A first wire (30) and a second wire (40) are wound around the core portion (11). A metal terminal (20) is provided on the flange portion (12). The metal terminal (20) has a receiving portion (24) for fixing the ends of the first wire (30) and the second wire (40). The receiving portion (24) extends in the direction of the central axis toward the side away from the core portion (11). The receiving portion (24) extends such that the top end (Q) on the side away from the core portion (11) is farther from the central axis than the base end (P) on the side closer to the core portion (11).

Description

Technical Field

[0001] This invention relates to coil components and methods for manufacturing coil components. Background Technology

[0002] The coil component described in Patent Document 1 has a prism-shaped core portion. Flange portions are provided at both ends of the core portion along its axial direction. The core portion and the flange portions are made of a magnetic material. The aforementioned core portion and flange portions constitute the core of the coil component.

[0003] The flange extends outward from the core portion in the width direction orthogonal to the axis of the core. Furthermore, in the height direction orthogonal to both the axis of the core and the aforementioned width direction, the flange also extends outward from the core portion. Metal terminals are mounted at both ends of each flange portion in the aforementioned width direction. Two wires are spirally wound around the core portion. The ends of each wire are led out from the core portion and heat-pressed to the metal terminals.

[0004] Patent Document 1: Japanese Patent Application Publication No. 2019-009285

[0005] In the coil component described in Patent Document 1, wire misalignment occurs when the wire is heat-pressed onto the metal terminal. If the wire is misaligned, the fixing of the wire relative to the metal terminal in the coil component becomes incomplete, resulting in unstable quality of the coil component. Summary of the Invention

[0006] To address the aforementioned issues, the present invention provides a coil component comprising: a core having a columnar core portion and a pair of flange portions disposed at a first end and a second end in the direction of the central axis of the core portion and extending outward from the core portion in a first direction orthogonal to the central axis; a wire wound around the core portion; and a metal terminal mounted on the flange portions, the metal terminal having a plate-shaped receiving portion extending in the direction of the central axis toward a side away from the core portion and for fixing an end of the wire, wherein in the receiving portion, if the side close to the core portion is designated as the base end and the top end away from the core portion is designated as the top end, the receiving portion extends such that the top end is farther from the central axis than the base end.

[0007] In the above structure, when the wire wound on the core is fixed to the metal terminal, a force acts on the wire that desires to move outward toward the central axis. According to this structure, the receiving portion of the metal terminal extends such that its tip is further away from the central axis than its base, thereby fixing the wire further outward in the first direction. Therefore, the force that desires to move the wire outward toward the central axis is reduced, and the wire becomes less prone to misalignment relative to the metal terminal.

[0008] According to one method of this disclosure, misalignment of the wire relative to the metal terminal is suppressed. Attached Figure Description

[0009] Figure 1 This is a 3D view of the coil component.

[0010] Figure 2 This is a top view of the coil component.

[0011] Figure 3 It is a top view showing a partially enlarged portion of the coil component.

[0012] Figure 4 This is a partial side view of the coil component.

[0013] Explanation of reference numerals in the attached figures

[0014] 10…coil component; 11…core part; 12…flange part; 20…metal terminal; 24…receiving part; 30…first wire; 40…second wire. Detailed Implementation

[0015] Hereinafter, embodiments of the coil component will be described with reference to the accompanying drawings.

[0016] like Figure 1 As shown, the coil component 10 includes a rectangular cylindrical core portion 11. Furthermore, in the following description, a first direction is defined as the direction orthogonal to the central axis of the core portion 11 and along the long side of the rectangular cross-section of the core portion 11. A second direction is defined as the direction orthogonal to both the central axis and the first direction.

[0017] A flange portion 12 is provided at a first end in the direction of the central axis of the core portion 11. The flange portion 12 extends outward in both the first and second directions beyond the core portion 11. The flange portion 12 has a planar outer end face 121 facing the first end side in the direction of the central axis. Viewed from the direction of the central axis, the flange portion 12 is a rectangular shape with two adjacent corners recessed. That is, the flange portion 12 has recesses 13 at both ends in the first direction and at the first end in the second direction. When viewed from the direction of the central axis, the recesses 13 are quadrilateral. In addition, the recesses 13 are further outward in the first direction than the core portion 11, and further outward in the second direction than the core portion 11. Furthermore, the length of the flange portion 12 in the direction of the central axis is shorter than that of the core portion 11. The portion of the first end side of the flange portion 12 in the second direction where the recesses 13 are not provided is a planar mounting surface 120. Furthermore, the mounting surface 120 is the surface that faces the substrate when the coil component 10 is mounted on the substrate.

[0018] Furthermore, as described above, when viewed from the central axis direction, the recess 13 is quadrilateral in shape. Therefore, the inner surface of each recess 13 is composed of a setting surface 13X and a side surface 13Y. The setting surface 13X faces the first end side in the second direction. The side surface 13Y faces the side in the first direction opposite to the central axis of the core portion 11.

[0019] Similar to the first end, a flange portion 12 is provided at the second end in the direction of the central axis of the core portion 11. The flange portion 12 at the first end and the flange portion 12 at the second end of the core portion 11 are formed in a symmetrical shape in the direction of the central axis. Furthermore, in the following description, when it is necessary to distinguish each flange portion 12, the flange portion 12 at the first end in the direction of the central axis is referred to as the first flange portion 12L, and the flange portion 12 at the second end is referred to as the second flange portion 12R.

[0020] The core portion 11 and the flange portion 12 constitute the core of the coil component 10. The core is made of a non-conductive material. Specifically, the core material can be, for example, alumina, Ni-Zn ferrite, resin, or mixtures of these substances.

[0021] like Figure 1 and Figure 2 As shown, a metal terminal 20 is mounted on the first end side of the first flange portion 12L, closer to the center in the first direction. The base 21 of the metal terminal 20 extends from the outer end face 121 of the flange portion 12 to the mounting surface 120. That is, when viewed from the first direction, the base 21 is formed in an L-shape.

[0022] A connecting portion 22 extends from the outer edge of the portion of the base 21 that extends along the mounting surface 120 in the first direction toward the first end side in the first direction. The connecting portion 22 extends from the mounting surface 120 via the side surface 13Y of the recess 13 to the setting surface 13X.

[0023] like Figure 3 As shown, a fixing portion 23 extends from the edge of the mounting surface 13X of the connecting portion 22. The fixing portion 23 extends from the connecting portion 22 toward a first end in the direction of a generally central axis. When viewed from a second direction, the fixing portion 23 is formed into a generally rectangular shape. The long side of the fixing portion 23 is inclined relative to the direction of the central axis.

[0024] A first notch 25 is provided on the edge of the fixing part 23 near the core part 11 in the short side direction. The first notch 25 is formed into a semi-circular shape that protrudes from the center side of the fixing part 23 in the short side direction. In addition, the first notch 25 is located approximately at the center in the long side direction of the fixing part 23.

[0025] A second notch 26 is provided on the edge of the fixing part 23 at its base end along the long side, i.e., on the side connected to the connecting part 22. The second notch 26 is formed into a semi-circular shape that protrudes from the center side along the long side of the fixing part 23. The second notch 26 is located approximately at the center along the short side of the fixing part 23.

[0026] The receiving portion 24 is located on the long side of the fixing portion 23, closer to the top of the first notch 25. When viewed from a second direction, the receiving portion 24 is generally rectangular. In this embodiment, the long side of the receiving portion 24 is aligned with the long side of the fixing portion 23.

[0027] like Figure 1 As shown, similar to the first end side, a metal terminal 20 is mounted on the second end side of the first flange portion 12L, closer to the center in the first direction. This metal terminal 20 on the second end side in the first direction is formed in a substantially symmetrical shape with the metal terminal 20 on the first end side in the first direction. Furthermore, metal terminals 20 are mounted on the first end side and the second end side of the second flange portion 12R, closer to the center in the first direction. The metal terminal 20 on the first end side of the second flange portion 12R is formed in a substantially symmetrical shape with the metal terminal 20 on the first end side of the first flange portion 12L in the central axis direction. The metal terminal 20 on the second end side of the second flange portion 12R is formed in a substantially symmetrical shape with the metal terminal 20 on the second end side of the first flange portion 12L in the central axis direction. The extending directions of the receiving portions 24 of these four metal terminals 20 are different from each other. Details regarding the extending directions of these receiving portions 24 will be described later.

[0028] Furthermore, in the following description, when it is necessary to distinguish the metal terminals 20, the metal terminal 20 on the first end side of the first flange portion 12L in the first direction will be referred to as the first metal terminal 20A, and the metal terminal 20 on the second end side of the first flange portion 12L in the first direction will be referred to as the second metal terminal 20B. Additionally, the metal terminal 20 on the first end side of the second flange portion 12R in the first direction will be referred to as the third metal terminal 20C, and the metal terminal 20 on the second end side of the second flange portion 12R in the first direction will be referred to as the fourth metal terminal 20D.

[0029] Similarly, when it is necessary to distinguish the receiving portion 24 in each metal terminal 20, the receiving portion 24 of the first metal terminal 20A is referred to as the first receiving portion 24A, the receiving portion 24 of the second metal terminal 20B is referred to as the second receiving portion 24B, the receiving portion 24 of the third metal terminal 20C is referred to as the third receiving portion 24C, and the receiving portion 24 of the fourth metal terminal 20D is referred to as the fourth receiving portion 24D.

[0030] like Figure 2As shown, the coil component 10 includes a first wire 30. One end of the first wire 30 is fixed to a first receiving portion 24A of a first metal terminal 20A. The first wire 30 is fixed to a first end side surface in a second direction of the first receiving portion 24A. That is, the first wire 30 is fixed to the side of the first receiving portion 24A in a second direction that is away from the central axis of the core portion 11.

[0031] The first wire 30 extends from the first metal terminal 20A toward the ridge line closest to the second metal terminal 20B among the four ridge lines of the core portion 11, and is wound around the core portion 11. That is, when viewed from the first end side in the direction of the central axis, the first wire 30 is wound clockwise around the core portion 11.

[0032] Furthermore, the other end of the first wire 30 extends from the ridge furthest from the fourth metal terminal 20D among the four ridges of the core portion 11 toward the third metal terminal 20C near the second flange portion 12R of the core portion 11. The other end of the first wire 30 is fixed to the third receiving portion 24C of the third metal terminal 20C. The first wire 30 is fixed to the first end side surface in the second direction of the third receiving portion 24C.

[0033] Additionally, the coil component 10 includes a second wire 40. One end of the second wire 40 is fixed to the second receiving portion 24B of the second metal terminal 20B. The second wire 40 is fixed to the first end side of the second receiving portion 24B in a second direction.

[0034] The second wire 40 extends from the second metal terminal 20B toward the core portion 11 from the ridge line furthest from the first metal terminal 20A among the four ridge lines, and is wound around the core portion 11. That is, when viewed from the first end side in the direction of the central axis, the second wire 40 is wound around the core portion 11 in the same clockwise direction as the first wire 30.

[0035] Furthermore, another end of the second wire 40 extends from the ridge closest to the third metal terminal 20C among the four ridges of the core portion 11 toward the fourth metal terminal 20D near the second flange portion 12R of the core portion 11. The other end of the second wire 40 is fixed to the fourth receiving portion 24D of the fourth metal terminal 20D. The second wire 40 is fixed to the first end side surface in the second direction of the fourth receiving portion 24D.

[0036] like Figure 4 As shown, when viewed from the central axis direction, the second wire 40 is wound around the core portion 11 from the outer side of the central axis compared to the first wire 30. Therefore, near the second flange portion 12R, at the ridge line of the core portion 11 furthest from the fourth metal terminal 20D, the second wire 40 presses the first wire 30 from the outer side of the central axis of the core portion 11.

[0037] like Figure 1 As shown, the wires 30 and 40 and the receiving portion 24 are fixed by laser welding. Therefore, a hemispherical welding block 27, generated during laser welding, is formed at the fixing position on the receiving portion 24 where it is fixed to each wire 30 and 40. Furthermore, each welding block 27 is only shown in the figure. Figure 1 In Figure 2 , Figure 3 and Figure 4 The illustration is omitted.

[0038] Next, the direction in which the receiving portion 24 of the metal terminal 20 extends will be explained.

[0039] like Figure 2 and Figure 3 As shown, in the first metal terminal 20A, when the side of the first receiving portion 24A closest to the core portion 11 in the central axis direction is designated as the base end P, and the side furthest from the core portion 11 is designated as the tip end Q, the first receiving portion 24A extends such that the tip end Q side is farther from the central axis than the base end P side. The tip end Q of the first receiving portion 24A is closer to the central axis of the core portion 11 than both ends of the first flange portion 12L in the first direction. In other words, the first receiving portion 24A does not protrude outward in the first direction from the first flange portion 12L.

[0040] Here, the direction orthogonal to the direction in which the first receiving portion 24A extends and parallel to the mounting surface opposite the substrate during installation is defined as the width direction. Furthermore, in this embodiment, the short side direction of the first receiving portion 24A is aligned with the width direction. For example... Figure 3 As shown, the center line C1 of the first receiving portion 24A passes through the center of the first receiving portion 24A in the width direction. An imaginary straight line L1 extends along the central axis of the core portion 11 and intersects the center line C1 of the first receiving portion 24A at the base end P of the first receiving portion 24A. Furthermore, the angle between the first end side of the first direction of the angle formed by the center line C1 and the imaginary straight line L1 and the top end side of the first receiving portion 24A is defined as the terminal angle α1. In this embodiment, the direction in which the first receiving portion 24A extends is defined such that the terminal angle α1 is approximately 10 degrees. Furthermore, in this embodiment, the direction in which the fixing portion 23, including the first receiving portion 24A, extends as a whole is defined such that the terminal angle α1 is approximately 10 degrees.

[0041] like Figure 2As shown, in the second metal terminal 20B, when the side of the second receiving portion 24B closest to the core portion 11 in the central axis direction is designated as the base end P, and the side furthest from the core portion 11 is designated as the tip end Q, the second receiving portion 24B extends such that the tip end Q side is farther from the central axis than the base end P side. The tip end Q of the second receiving portion 24B is closer to the central axis of the core portion 11 than both ends of the first flange portion 12L in the first direction. In other words, the second receiving portion 24B does not protrude outward in the first direction from the first flange portion 12L.

[0042] Furthermore, similar to the first metal terminal 20A described above, a center line C2 of the second receiving portion 24B in the second metal terminal 20B and an imaginary straight line L2 intersecting the center line C2 are drawn out. Additionally, the angle between the center line C2 and the imaginary straight line L2, specifically the angle at the second end side in the first direction and the top end Q side of the second receiving portion 24B, is defined as the terminal angle α2. In this embodiment, the direction in which the second receiving portion 24B extends is specified, such that the terminal angle α2 is approximately 20 degrees. Furthermore, in this embodiment, the direction in which the fixing portion 23, including the second receiving portion 24B, extends as a whole is specified, such that the terminal angle α2 is approximately 20 degrees.

[0043] In the case where the third receiving portion 24C of the third metal terminal 20C has a base end P on the side closer to the core portion 11 in the central axis direction and a tip Q on the side farther from the core portion 11, the third receiving portion 24C extends such that the tip Q side is farther from the central axis than the base end P side. The tip Q of the third receiving portion 24C is closer to the central axis of the core portion 11 than both ends of the second flange portion 12R in the first direction. In other words, the third receiving portion 24C does not protrude outward in the first direction from the second flange portion 12R.

[0044] Furthermore, similar to the first metal terminal 20A described above, a center line C3 of the third receiving portion 24C in the third metal terminal 20C and an imaginary straight line L3 intersecting the center line C3 are drawn out. Additionally, the angle between the center line C3 and the imaginary straight line L3, specifically the angle from the first end side in the first direction to the top end Q side of the third receiving portion 24C, is defined as the terminal angle α3. In this embodiment, the direction in which the third receiving portion 24C extends is defined such that the terminal angle α3 is approximately 10 degrees. Furthermore, in this embodiment, the direction in which the fixing portion 23, including the third receiving portion 24C, extends as a whole is defined such that the terminal angle α3 is approximately 10 degrees.

[0045] In the fourth metal terminal 20D, the fourth receiving portion 24D extends such that the side closest to the core portion 11 in the central axis direction is designated as the base end P, and the side furthest from the core portion 11 is designated as the tip end Q. The tip end Q of the fourth receiving portion 24D is closer to the central axis of the core portion 11 than both ends of the second flange portion 12R in the first direction. In other words, the fourth receiving portion 24D does not protrude outward in the first direction from the second flange portion 12R.

[0046] Furthermore, similar to the first metal terminal 20A described above, a center line C4 of the fourth receiving portion 24D in the fourth metal terminal 20D and an imaginary straight line L4 intersecting the center line C4 are drawn out. Additionally, the angle between the center line C4 and the imaginary straight line L4, specifically the angle at the second end of the first direction and the top end Q of the fourth receiving portion 24D, is defined as the terminal angle α4. In this embodiment, the direction in which the fourth receiving portion 24D extends is specified, such that the terminal angle α4 is approximately 5 degrees. Furthermore, in this embodiment, the direction in which the fixing portion 23, including the fourth receiving portion 24D, extends as a whole is specified, such that the terminal angle α4 is approximately 5 degrees.

[0047] Next, the angles at which the first wire 30 and the second wire 40 extend on the receiving part 24 will be explained.

[0048] like Figure 3 As shown, the first wire 30 is bent at the boundary between the connecting portion 22 and the fixing portion 23 of the first flange portion 12L, i.e., at the bending portion R, so that its tip faces the direction of the central axis. Furthermore, the first wire 30 extends in a straight line on the first receiving portion 24A of the first metal terminal 20A. Here, the angle between the first end of the first direction and the tip Q of the first receiving portion 24A, formed by the angle between the extending direction of the first wire 30 and the imaginary straight line L1, is defined as the wire angle β1. In this embodiment, the fixed position of the first wire 30 relative to the first receiving portion 24A is defined such that the wire angle β1 is approximately 15 degrees.

[0049] like Figure 2 As shown, the second wire 40 is bent at the boundary between the connecting portion 22 and the fixing portion 23 of the first flange portion 12L, i.e., at the bending portion R, so that its tip faces the direction of the central axis. Furthermore, the second wire 40 extends in a straight line on the second receiving portion 24B of the second metal terminal 20B. Here, the angle between the second end of the first direction and the tip Q of the second receiving portion 24B, formed by the angle between the extension direction of the second wire 40 and the imaginary straight line L2, is defined as wire angle β2. In this embodiment, the fixed position of the second wire 40 relative to the second receiving portion 24B is defined such that wire angle β2 is approximately 25 degrees.

[0050] The first wire 30 is bent at the boundary between the connecting portion 22 and the fixing portion 23 of the second flange portion 12R, i.e., at the bending portion R, forming a second end side with its tip facing the direction of the central axis. Furthermore, the first wire 30 extends in a straight line on the third receiving portion 24C of the third metal terminal 20C. Here, the angle between the first end side of the first direction of the angle formed by the extension direction of the first wire 30 and the imaginary straight line L3, and the angle between the tip Q side of the third receiving portion 24C, is defined as wire angle β3. In this embodiment, the fixed position of the first wire 30 relative to the third receiving portion 24C is defined such that the wire angle β3 is approximately 15 degrees.

[0051] The second wire 40 is bent at the boundary between the connecting portion 22 and the fixing portion 23 of the second flange portion 12R, i.e., at the bending portion R, forming a second end side with its tip facing the direction of the central axis. Furthermore, the second wire 40 extends in a straight line on the fourth receiving portion 24D of the fourth metal terminal 20D. Here, the angle between the second end side of the first direction of the angle formed by the extension direction of the second wire 40 and the imaginary straight line L4, and the angle between the tip Q side of the fourth receiving portion 24D, is defined as wire angle β4. In this embodiment, the fixed position of the second wire 40 relative to the fourth receiving portion 24D is defined such that the wire angle β4 is approximately 10 degrees.

[0052] Next, the function of this embodiment will be explained.

[0053] The stresses on the wires 30 and 40 on the receiving portion 24 of the metal terminal 20 will be explained. The end of the first wire 30 wound on the core portion 11 is fixed to the metal terminal 20. The metal terminal 20 is mounted on the flange portion 12 extending outward in the first direction, so the end of the first wire 30 is subjected to a force that wants to move outward in the direction of the central axis.

[0054] Specifically, near the first flange portion 12L, the end of the first wire 30 is bent at the bend portion R as the bend point, so that the top end of the first wire 30 faces the first end side in the direction of the central axis. Therefore, on the first wire 30 fixed to the first receiving portion 24A, there is a force that aims to eliminate the bending force at the bend portion R as the bend point, that is, a force that aims to make one end of the first wire 30 face outward in the first direction. Similarly, on the first wire 30 and the second wire 40 fixed to the other metal terminals 20, there is a force that aims to make the ends of each wire 30, 40 face outward in the first direction.

[0055] On the other hand, when comparing the forces that each wire 30 and 40 wants to exert on the outside of the first direction, the second wire 40 in the second metal terminal 20B has the greatest force on the outside of the first direction.

[0056] This is because, near the first flange portion 12L, the second wire 40 bends at the ridge of the core portion 11 furthest from the first metal terminal 20A. Before bending at this ridge, the second wire 40 extends along the first direction. Therefore, when the second wire 40 is fixed to the second receiving portion 24B, a spring force is applied to eliminate the bending at this ridge, that is, a force is applied to cause one end of the second wire 40 to move outward in the first direction. In other words, the spring force aimed at eliminating the bending at the bending portion R is added to the spring force aimed at eliminating the bending at the ridge of the core portion 11 furthest from the first metal terminal 20A, increasing the force that causes one end of the second wire 40 to move outward in the first direction.

[0057] However, similar to the case where the end of the second wire 40 near the second metal terminal 20B experiences relatively large stress towards the outside in the first direction, the end of the first wire 30 near the third metal terminal 20C also experiences relatively large stress towards the outside in the first direction.

[0058] However, as Figure 4 As shown, when viewed from the central axis direction, the first wire 30 is wound around the core portion 11 at a position closer to the center axis than the second wire 40. Therefore, at the ridge line of the core portion 11 from which the first wire 30 extends toward the third metal terminal 20C, i.e., at the ridge line of the core portion 11 furthest from the fourth metal terminal 20D, the first wire 30 is pressed by the second wire 40. Therefore, the stress acting on the end of the first wire 30 near the third metal terminal 20C, towards the outer side in the first direction, is not as great as the stress acting on the end of the second wire 40 near the second metal terminal 20B, towards the outer side in the first direction.

[0059] Next, the effects of this implementation method will be explained.

[0060] (1) In this embodiment, the receiving portion 24 of each metal terminal 20 extends such that its tip is away from the central axis. Specifically, the receiving portion 24 of each metal terminal 20 extends such that the tip Q side is farther from the central axis than the base P side. When the receiving portion 24 extends as described above, compared to the case where the receiving portion 24 extends parallel to the central axis, each wire 30, 40 and each receiving portion 24 can be positioned further outward in the first direction. Therefore, when each wire 30, 40 is fixed to each receiving portion 24, compared to the case where the receiving portion 24 extends parallel to the central axis, the force required for each wire 30, 40 to move outward in the first direction is reduced. As a result, misalignment of each wire 30, 40 relative to each metal terminal 20 can be suppressed.

[0061] (2) In this embodiment, the terminal angle α1 is approximately 10 degrees, the terminal angle α2 is approximately 20 degrees, the terminal angle α3 is 10 degrees, and the terminal angle α4 is 5 degrees. The larger the terminal angle of each metal terminal 20, the more effectively the wires 30 and 40 can be fixed to the receiving portion 24 further outward in the first direction. Therefore, misalignment of each wire 30 and 40 relative to the metal terminal 20 can be effectively suppressed. On the other hand, if the terminal angle is too large, the outer diameter in the first direction of the coil component 10 will increase. As described above, the terminal angles α1 to α4 in this embodiment are all less than 45 degrees, so it is preferable to suppress the expansion of the size of the coil component 10 while suppressing the misalignment of each wire 30 and 40 relative to the metal terminal 20.

[0062] (3) In this embodiment, the tip Q of each receiving portion 24 is located closer to the central axis than the end of each flange portion 12 in the first direction. In this way, the tip Q of the receiving portion 24 does not protrude outward in the first direction from the flange portion 12, thus suppressing the expansion of the coil component 10 in the first direction.

[0063] (4) In this embodiment, the wire angle β1 at the first metal terminal 20A is approximately 15 degrees, which is greater than the terminal angle α1. Similarly, the wire angle β2 at the second metal terminal 20B is approximately 25 degrees, which is greater than the terminal angle α2. The wire angle β3 at the third metal terminal 20C is approximately 15 degrees, which is greater than the terminal angle α3. The wire angle β4 at the fourth metal terminal 20D is approximately 10 degrees, which is greater than the terminal angle α4.

[0064] The larger the wire angle, the better the force that would cause the wires 30 and 40 to move outward in the first direction can be suppressed when each wire is fixed by the receiving part 24. Therefore, in this embodiment, the wire angle is set to be greater than the terminal angle, thereby suppressing misalignment of each wire 30 and 40 relative to each metal terminal 20. In addition, the wire angle being greater than the terminal angle allows for a stable connection between the wires and the receiving parts.

[0065] (5) In this embodiment, the terminal angle α2 of the second metal terminal 20B is greater than the terminal angle α1 of the first metal terminal 20A. As described above, the force that the end of the second wire 40 on the side of the second metal terminal 20B wants to move outward in the first direction is greater than the force that the end of the first wire 30 on the side of the first metal terminal 20A wants to move outward in the first direction. In this way, the terminal angles α1 and α2 are set in accordance with the magnitude of the force that the ends of each wire 30 and 40 want to move outward, thereby suppressing wire misalignment while preventing the terminal angles α1 and α2 from becoming too large.

[0066] (6) In this embodiment, the terminal angle α2 of the second metal terminal 20B is greater than the terminal angle α3 of the third metal terminal 20C. As described above, the force that the end of the second wire 40 near the second metal terminal 20B wants to move outward in the first direction is greater than the force that the end of the first wire 30 near the third metal terminal 20C wants to move outward in the first direction. Thus, by setting the terminal angles α2 and α3 in accordance with the magnitude of the force that the ends of each wire 30 and 40 want to move outward, wire misalignment is suppressed while the terminal angles α2 and α3 do not become too large.

[0067] (8) In this embodiment, the first wire 30 and the second wire 40 are fixed to the respective receiving portions 24 by laser welding. Fixing the wires 30 and 40 to the receiving portions 24 by laser welding achieves a more stable fixation. However, when the receiving portions 24 are melted by laser welding, the wires 30 and 40 may sometimes be released from their temporary fixed state, causing them to tend to move outward in the first direction. In this embodiment, the receiving portion 24 of each metal terminal 20 is extended such that the tip Q side is further away from the central axis than the base P side, thus reducing the force that causes the wires 30 and 40 to tend to move outward in the first direction. Therefore, during laser welding, misalignment of the wires from the metal terminals can also be effectively suppressed.

[0068] This embodiment can be implemented in the following modified ways. This embodiment and the following modifications can be combined and implemented together within the scope of technical inconsistencies.

[0069] In the above embodiments, the structure of the coil component 10 is not limited. For example, the coil component 10 may also have a top plate of a magnetic material connected to both the first flange 12L and the second flange 12R at its second end side in the second direction. The coil component 10 with the top plate forms a closed magnetic circuit, thus improving the inductance.

[0070] In the above embodiment, the core portion 11 may not be a rectangular column. For example, it may be cylindrical. Even assuming the core portion 11 is cylindrical, in a structure where the flange portion 12 extends outward in the first direction from the core portion 11, the tip Q of the receiving portion 24 is further away from the central axis than the base end P, thereby suppressing misalignment of the wires 30, 40 relative to the receiving portion 24. Furthermore, when the cross-section of the core portion 11 is not rectangular, the direction orthogonal to the central axis and parallel to the surface opposite the substrate during mounting is designated as the first direction, and the direction orthogonal to both the central axis and the first direction is designated as the second direction.

[0071] In the above embodiments, the metal terminal 20 may also be a component with metal plated on the surface of an insulator. If a metal layer exists on the surface and thus has conductivity, it can be called a metal terminal.

[0072] • In the above embodiment, the wire may also be a single strand. For example, if there is only one strand of wire, a metal terminal 20 may be provided on each flange portion 12. In this case, the metal terminal 20 is located in the first direction at a position extending outward from the core portion 11.

[0073] • In the above embodiments, the shape of the metal terminal 20 is not limited to the examples of the above embodiments. For example, the first notch 25 or the second notch 26 may not be provided. However, in the absence of the first notch 25, the non-bent surface near where the receiving part 24 and each wire 30, 40 are fixed is used as the receiving part 24.

[0074] In the above embodiment, the receiving portion 24 may be square when viewed from the second direction, or it may be rectangular with its shorter side pointing towards the central axis. Regardless of the shape, if the side closer to the core portion 11 in the central axis direction is designated as the base end P, and the side farther from the core portion 11 is designated as the top end Q, the receiving portion 24 extends such that the top end Q is farther from the central axis than the base end P. Furthermore, regardless of the shape of the receiving portion 24, the direction in which the receiving portion 24 extends is defined as a straight line orthogonal to the top end of the fixing portion 23. Additionally, when the width direction is defined as orthogonal to the direction in which the receiving portion 24 extends and parallel to the mounting surface opposite the substrate during mounting, the center line of the receiving portion 24 is the straight line passing through the center of the position where the width of the receiving portion 24 is at its maximum.

[0075] In the above embodiment, the direction in which the long side of the fixing part 23 extends (excluding the receiving part 24) may not be the same as the direction in which the long side of the receiving part 24 extends. For example, the fixing part 23 may extend parallel to the central axis (excluding the receiving part 24), while only the receiving part 24 may be bent as described in the above embodiment. Alternatively, the receiving part 24 and the fixing part 23 may be the same.

[0076] In the above embodiment, the top end Q of each receiving portion 24 may also be located on the outer side of the two ends in the first direction of the flange portion 12.

[0077] • In the above embodiments, the fixing method between each receiving part 24 and each wire 30, 40 may not be laser welding. Each receiving part 24 and each wire 30, 40 may also be fixed by heat pressing or other methods.

[0078] In the above embodiment, when viewed from the central axis direction, the first wire 30 may also be wound around the core portion 11 from the outer side of the central axis than the second wire 40. In this case, the pressure on the second wire 40 disappears, and therefore the force required for the first wire 30 on the third receiving portion 24C to move outward in the first direction increases. Therefore, it is possible to increase the terminal angle α3 and the wire angle β3 at the third metal terminal 20C.

[0079] In the above embodiments, the wires 30 and 40 may not extend in a straight line along the receiving portion 24. For example, the first wire 30 may be bent or curved along the first receiving portion 24A. In this case, the extending direction of the first wire 30 is the orientation of a straight line connecting the point where the first wire 30 intersects with the base P of the first receiving portion 24A and the point where the first wire 30 intersects with the top Q of the first receiving portion 24A.

[0080] In the above embodiments, the specific angle of the terminal is not limited to the examples of the above embodiments. For example, the terminal angle α1 can be 1 degree or 60 degrees. However, as explained in the above embodiments, the terminal angle is preferably greater than 0 degrees and less than 45 degrees.

[0081] In the above embodiments, the relationship between the terminal angles of each metal terminal 20 is not limited. For example, the terminal angle α1 at the first metal terminal 20A may be greater than the terminal angle α2 at the second metal terminal 20B. However, considering that the force at the second metal terminal 20B that the second wire 40 wants to move outward in the first direction is the greatest, it is preferable to make the terminal angle α2 at the second metal terminal 20B as large as possible.

[0082] In the above embodiment, corresponding to winding each wire 30, 40 from the first flange portion 12L side or from the second flange portion 12R side, it is preferable that the terminal angles of each metal terminal 20 are different. For example, when the second wire 40 is wound from the second flange portion 12R side, winding errors occur on the second wire 40 as it is continuously wound towards the first flange portion 12L side. Therefore, the stress on the second wire 40 increases as it moves towards the first flange portion 12L side, making it easier to detach from the second metal terminal 20B. From this viewpoint, it is preferable that the terminal angle of the metal terminal 20 on the winding end side of the second wire 40 is greater than the terminal angle of the metal terminal 20 on the winding start side of the second wire 40. This is also the same for the first wire 30.

[0083] • The wire angle is not limited to the example of the above embodiment. The ends of each wire 30 and 40 are located at the top end Q of each receiving part 24, so that each receiving part 24 and each wire 30 and 40 can be fixed.

[0084] In the above embodiments, the wire angle can be the same as the terminal angle or smaller than the terminal angle. Preferably, as in the above embodiments, the wire angle is larger than the terminal angle, but if the terminal angle is relatively large, even if the wire angle is smaller than the terminal angle, the effect on misalignment is sufficient.

Claims

1. A coil component, wherein, have: The core has a columnar core portion and a first end and a second end disposed in the direction of the central axis of the core portion and a pair of flange portions extending outward from the core portion in a first direction orthogonal to the central axis. A wire wound around the core portion; and Metal terminals, which are mounted on the flange portion, The metal terminal has a plate-shaped receiving portion that extends in the direction of the central axis toward a side away from the core portion and for fixing the end of the wire. In the receiving portion, if the side closest to the core portion is designated as the base end and the top end away from the core portion is designated as the top end, then the receiving portion extends such that the top end is farther away from the central axis than the base end.

2. The coil component according to claim 1, wherein, When the direction of the receiving portion extending orthogonal to and parallel to the mounting surface that faces the substrate during installation is defined as the width direction, When the angle formed by the centerline passing through the center of the width direction of the receiving portion and an imaginary straight line extending along the central axis direction and intersecting the centerline of the receiving portion at the base end of the receiving portion, the angle outside the first direction and the angle of the receiving portion near the top end is defined as the terminal angle. The terminal angle is greater than 0 degrees and less than 45 degrees.

3. The coil component according to claim 1 or 2, wherein, The top end of the receiving portion is closer to the central axis side of the core portion than both ends of the flange portion in the first direction.

4. The coil component according to claim 1 or 2, wherein, When the direction orthogonal to both the central axis and the first direction is defined as the second direction, The wire is fixed to the receiving part on the side away from the central axis in the second direction. In the angle formed by the centerline of the receiving portion and an imaginary straight line extending along the central axis and intersecting the centerline of the receiving portion at the base end of the receiving portion, the angle outside the first direction and the angle at the top end of the receiving portion is defined as the terminal angle. When the angle between the extension direction of the wire on the receiving part and the imaginary straight line is defined as the angle of the outer side of the first direction and the top end side of the receiving part, the wire angle is considered. The angle of the wire is greater than the angle of the terminal.

5. The coil component according to claim 1 or 2, wherein, The core portion is a quadrangular prism. The system includes a first wire and a second wire as the wire. A first metal terminal is provided at one end of the flange portion in the first direction as the metal terminal. At the other end of the flange portion in the first direction, a second metal terminal is provided as the metal terminal. The first wire extends from the first metal terminal towards the core portion along the ridge line closest to the second metal terminal among the four ridge lines and is wound around the core portion. The second wire extends from the fourth ridge furthest from the first metal terminal among the four ridges facing the core portion and is wound around the core portion. When the angle between the centerline of the receiving portion and an imaginary straight line extending along the central axis and intersecting the centerline of the receiving portion at the base end of the receiving portion is defined as the terminal angle, the angle outside the first direction and the top end side of the receiving portion is taken as the terminal angle. The terminal angle of the second metal terminal is greater than the terminal angle of the first metal terminal.

6. The coil component according to claim 1 or 2, wherein, The core portion is a quadrangular prism. The system includes a first wire and a second wire as the wire. A first metal terminal is provided at one end of the flange portion on the first end side in the first direction to serve as the metal terminal. At the other end of the flange portion on the first end side in the first direction, a second metal terminal is provided as the metal terminal. At the end of the flange portion on the second end side, on the side where the first metal terminal is provided in the first direction, a third metal terminal is provided as the metal terminal. At the end of the flange portion on the second end side, on the side where the second metal terminal is provided in the first direction, a fourth metal terminal is provided as the metal terminal. The first wire extends from the first metal terminal towards the core portion, specifically from the ridge closest to the second metal terminal among the four ridges, and is wound around the core portion. Furthermore, it extends towards the third metal terminal from the ridge furthest from the fourth metal terminal among the four ridges of the core portion. The second wire extends from the fourth metal terminal, from the ridge furthest from the first metal terminal among the four ridges of the second metal terminal toward the core portion, and is wound around the core portion in the same direction as the first wire. Furthermore, it extends from the ridge closest to the third metal terminal among the four ridges of the core portion toward the fourth metal terminal. The second wire is wound around the core portion from a position axially outer of the first wire. When the angle between the centerline of the receiving portion and an imaginary straight line extending along the central axis and intersecting the centerline of the receiving portion at the base end of the receiving portion is defined as the terminal angle, the angle outside the first direction and the top end side of the receiving portion is taken as the terminal angle. The terminal angle of the second metal terminal is greater than the terminal angle of the third metal terminal.

7. A method for manufacturing a coil component, the coil component comprising: The core has a columnar core portion and a first end and a second end disposed in the direction of the central axis of the core portion and a pair of flange portions extending outward from the core portion in a first direction orthogonal to the central axis. A wire wound around the core portion; and A metal terminal is mounted on the flange portion and is used to secure the end of the wire. The metal terminal has a receiving portion that extends in the direction of the central axis toward the side away from the core portion and for securing the end of the wire. The receiving portion extends such that the top end on the side away from the core portion is further away from the central axis than the base end on the side closer to the core portion. In the manufacturing method of the coil component, The receiving portion of the metal terminal and the wire are fixed by laser welding.

Images