Coil component and method for manufacturing coil component

Abstract

The present application provides a coil component and a manufacturing method of the coil component. In a case where the coil component is mounted on a circuit substrate using solder, even if a flux component included in the solder is transferred on a wire, the flux component is able to be suppressed from reaching a winding core portion. A first wire (31) of the coil component has a winding portion (31a) wound around a winding core portion (21) of a core body (20), a first end portion (31b) electrically connected to a terminal electrode (12a) provided to a first flange portion (22), and a first lead-out portion (31d) linking the winding portion and the first end portion. In a first direction (Z3), the first end portion is located at a first side of a center axis (F) of the winding core portion, and a boundary portion between the first lead-out portion and the winding portion, that is, a first boundary portion (311), is located at a second side of the center axis. A corner (C1) of the winding core portion is located between the first boundary portion and the first end portion in a circumferential direction (Z2). A gap (SP1) is interposed between the first lead-out portion and the corner.

Description

Technical Field

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

[0002] As described in Patent Document 1, coil components comprising a core and a core portion wound around the core are known. A first end of the core portion is connected to a first flange, and a second end of the core portion is connected to a second flange. A first terminal electrode and a second terminal electrode are provided on the first flange. A third terminal electrode and a fourth terminal electrode are provided on the second flange. A first wire and a second wire are wound around the core portion. Furthermore, a first end of the first wire is electrically connected to the first terminal electrode, and a second end of the first wire is electrically connected to the third terminal electrode. Similarly, a first end of the second wire is electrically connected to the second terminal electrode, and a second end of the second wire is electrically connected to the fourth terminal electrode.

[0003] Patent Document 1: Japanese Patent Application Publication No. 2017-11288

[0004] In the coil components described above, a coated conductor is used as the wire. For example, the wire has a linear central conductor and a coating formed of resin. Moreover, such a wire is wound around a core portion.

[0005] When mounting such coil components onto a circuit board using solder, the flux component contained in the solder sometimes travels from the terminal electrodes along the wire and reaches the core. The concern is that if the flux component reaches the portion of the wire wound around the core, i.e., the winding portion, it may have some impact on the performance of the coil component. Summary of the Invention

[0006] The methods used to solve the above problems and their effects are recorded.

[0007] One embodiment of the coil component includes: a core having a prism-shaped core portion, a first flange portion connected to a first end of the core portion extending in the axial direction of the core portion's central axis, and a second flange portion connected to a second end of the core portion in the axial direction; a first terminal electrode disposed on the first flange portion; a second terminal electrode disposed on the second flange portion; and a wire having a winding portion wound around the core portion, a first end portion electrically connected to the first terminal electrode, a second end portion electrically connected to the second terminal electrode, a first lead-out portion connecting the winding portion to the first end portion, and a second lead-out portion connecting the winding portion to the second end portion. In a direction orthogonal to the axial direction, i.e., a first predetermined direction, the first end portion is disposed on a first side closer to the central axis, and the boundary portion between the first lead-out portion and the winding portion, i.e., a first boundary portion, is disposed on a second side closer to the central axis. The first predetermined corner, which is the corner closest to the first end point in the circumferential direction centered on the central axis among a plurality of corners of the core portion located on the second side of the first predetermined direction, is located between the first boundary portion and the first end point in the circumferential direction. A gap is provided between the first lead-out portion and the first predetermined corner.

[0008] According to the above structure, a gap is provided between the first corner of the core portion and the first lead-out portion. Therefore, when the coil component is mounted on the circuit board using solder, even if the flux component contained in the solder is transferred along the wire, the flux component does not easily reach the core portion.

[0009] One method for manufacturing a coil component relates to a method for manufacturing a coil component comprising a core and a wire. The core has a prism-shaped core portion, a first flange portion connected to a first end of the core portion extending in the axial direction of the core portion's central axis, and a second flange portion connected to a second end of the core portion in the axial direction. The wire has a winding portion wound around the core portion, a first end portion electrically connected to a terminal electrode provided on the first flange portion, a second end portion electrically connected to a terminal electrode provided on the second flange portion, a first lead-out portion connecting the winding portion to the first end portion, and a second lead-out portion connecting the winding portion to the second end portion. The manufacturing method includes: a step of forming the winding portion by winding the wire around the core portion; and a step of, in a low-tension state during the step of forming the winding portion by adjusting the wire tension, leading the wire from the core portion to the terminal electrode provided on the second flange portion and fixing the second end portion of the wire to the terminal electrode.

[0010] By manufacturing the coil component using the above-described manufacturing method, a gap can be easily formed between the first lead-out portion of the wire and the first corner of the winding core portion. In other words, the coil component manufactured using this method achieves the same effect as the coil component described above.

[0011] According to this disclosure, when a coil component is mounted on a circuit board using solder, even if the flux component contained in the solder is transferred on the wire, the flux component can be prevented from reaching the core portion. Attached Figure Description

[0012] Figure 1 This is a perspective view schematically illustrating one embodiment of the coil component.

[0013] Figure 2 This is a cross-sectional view of the coil component.

[0014] Figure 3 This is a cross-sectional view of the coil component.

[0015] Figure 4 This is a cross-sectional view of the coil component.

[0016] Figure 5 This is a cross-sectional view of the coil component.

[0017] Figure 6 This is a flowchart illustrating the manufacturing process of the coil component.

[0018] Figure 7 This is a cross-sectional view of the coil component in the modified example.

[0019] Explanation of reference numerals in the attached figures:

[0020] 10…coil component; 12a~12d, 12a1, 12b1…terminal electrodes; 20…core; 21…core portion; 211~214…side surface; 22…first flange portion; 23…second flange portion; 31…first wire; 31a…winding portion; 31b…first end; 31c…second end; 31d…first lead-out portion; 31e…second lead-out portion; 311…first boundary portion; 312…second boundary portion; 41…second wire; 41a…winding portion; 41b…third end; 41c…fourth end; 41d…third lead-out portion; 41e…fourth lead-out portion; 411…third boundary portion; 412…fourth boundary portion; C1~C4…corner; F…central axis; SP1~SP4…gap. Detailed Implementation

[0021] The following is based on Figures 1-6An embodiment of the coil component and its manufacturing method is described. Furthermore, structural elements are sometimes shown enlarged for ease of understanding in the accompanying drawings. The dimensional ratios of the structural elements may sometimes differ from those in actual figures or other drawings. Additionally, shading lines are used in sectional views, but sometimes the shading lines for some structural elements are omitted for ease of understanding.

[0022] like Figure 1 As shown, the coil component 10 includes a core 20 and a plurality of wires 31, 41 wound around the core 20. The coil component 10 is, for example, a common-mode choke coil.

[0023] The core 20 may contain, for example, an electrically insulating material. Specifically, the core 20 may contain a non-magnetic material such as alumina or resin, a magnetic material such as ferrite or resin containing magnetic powder. Preferably, the core 20 is composed of a sintered body such as alumina or ferrite.

[0024] The core 20 has a polygonal core portion 21, a first flange portion 22 connected to a first end of the core portion 21 in the axial direction Z1, and a second flange portion 23 connected to a second end of the core portion 21 in the axial direction Z1. That is, the core portion 21 extending along the axial direction Z1 is disposed between a pair of flange portions 22 and 23 arranged in the axial direction Z1. The axial direction Z1 is... Figure 2 The direction of extension of the central axis F of the core portion 21 shown.

[0025] exist Figure 2 The diagram illustrates a cross-section of the core portion 21, the first flange portion 22, and a portion of the first wire 31 when the core portion 21 is cut in a direction orthogonal to the axial direction Z1. In this embodiment, as... Figure 2 As shown, the core portion 21 is a quadrangular prism. Of course, the core portion 21 can be any prism shape, or it does not have to be a quadrangular prism. Moreover, there are two corners on the first side of the direction orthogonal to the axial direction Z1, which is closer to the central axis F. In addition, there are two corners on the second side of the direction orthogonal to the axial direction Z1, which is closer to the central axis F.

[0026] When the core portion 21 is a quadrangular prism, it has four sides 211, 212, 213, and 214. Along the circumferential direction Z2 centered on the central axis F of the core portion 21, the first end of side 211 is connected to the second end of side 212 via corner C1. The second end of side 211 is connected to the first end of side 213 via corner C2. The first end of side 212 is connected to the second end of side 214 via corner C3. The second end of side 213 is connected to the first end of side 214 via corner C4. Here, "the first end of the side" refers to... Figure 2The end in the counterclockwise direction of the circumferential Z2 centered on the central axis F of the core portion 21. Additionally, the "second end on the side" is... Figure 2 The end of the circumferential direction Z2 in the clockwise direction.

[0027] The core portion 21 has a rectangular cross-section. In this cross-section, the length of side 211 is greater than the lengths of side 212 and side 213. The length of side 214 is greater than the lengths of side 212 and side 213. Figure 2 In the cross-section shown, the extension direction of side 211 is referred to as "first direction Z3", and the extension direction of side 212 is referred to as "second direction Z4". First direction Z3 and second direction Z4 are directions orthogonal to the axial direction Z1.

[0028] The first flange portion 22 and the second flange portion 23 extend outward in the first direction Z3, respectively, beyond the core portion 21. Furthermore, the first flange portion 22 and the second flange portion 23 extend outward in the second direction Z4, beyond the core portion 21.

[0029] like Figure 1 As shown, the side of the first flange portion 22 that corresponds to the circuit board when the coil component 10 is mounted on the circuit board is called the first mounting surface 221. The side of the second flange portion 23 that corresponds to the circuit board when the coil component 10 is mounted on the circuit board is called the second mounting surface 231.

[0030] In this embodiment, such as Figure 1 and Figure 2 As shown, a terminal electrode 12a for a first wire 31 and a terminal electrode 12b for a second wire 41 are provided on the first mounting surface 221. That is, the terminal electrode 12b is positioned at the same location as the terminal electrode 12a in the axial direction Z1. In addition, the terminal electrode 12b is located on the opposite side of the terminal electrode 12a in the first direction Z3, separated by the central axis F of the core portion 21.

[0031] exist Figure 4 The diagram illustrates a cross-section of the core portion 21, the second flange portion 23, and a portion of the first wire 31 when the core portion 21 is cut in a direction orthogonal to the axial direction Z1. In this embodiment, as... Figure 1 and Figure 4 As shown, a terminal electrode 12c for the first wire 31 and a terminal electrode 12d for the second wire 41 are provided on the second mounting surface 231. That is, the terminal electrode 12d is positioned at the same location as the terminal electrode 12c in the axial direction Z1. In addition, in the first direction Z3, the terminal electrode 12d is located on the opposite side of the terminal electrode 12c, separated by the central axis F.

[0032] As the first wire 31 and the second wire 41, a coated conductor is used. The coated conductor includes a linear center conductor and a coating formed of resin. That is, wires 31 and 41 are components that cover the center conductor with a coating. Furthermore, the resin forming the coating is an insulating resin.

[0033] The first wire 31 and the second wire 41 are wound around the core portion 21 of the core body 20. In this embodiment, the first wire 31 and the second wire 41 are wound around the core portion 21 by a lap winding method. That is, the first wire 31 is directly wound around the core portion 21, and the second wire 41 is wound around the core portion 21 starting from the first wire 31. Moreover, the number of turns of the first wire 31 around the core portion 21 is substantially the same as the number of turns of the second wire 41 around the core portion 21.

[0034] Furthermore, the method of winding the first wire 31 and the second wire 41 onto the core portion 21 does not have to be a double-winding method. For example, the first wire 31 and the second wire 41 can also be wound onto the core portion 21 by double-winding, and it is also possible to form both a region where the first wire 31 and the second wire 41 are wound onto the core portion 21 by double-winding and a region where the first wire 31 and the second wire 41 are wound onto the core portion 21 by double-winding.

[0035] like Figure 1 , Figure 2 as well as Figure 4 As shown, the first wire 31 has a first winding portion 31a, a first end portion 31b, a second end portion 31c, a first lead-out portion 31d, and a second lead-out portion 31e. The first winding portion 31a is the portion of the first wire 31 wound around the core portion 21. In the first winding portion 31a, the first wire 31 contacts each corner C1 to C4 until the first wire 31 is wound one turn on the core portion 21. The first end portion 31b is the portion of the first wire 31 that is electrically connected to the terminal electrode 12a. The second end portion 31c is the portion of the first wire 31 that is electrically connected to the terminal electrode 12c. That is, when the terminal electrode provided on the first flange portion 22 is defined as the "first terminal electrode" and the terminal electrode provided on the second flange portion 23 is defined as the "second terminal electrode", the terminal electrode 12a corresponds to the first terminal electrode and the terminal electrode 12c corresponds to the second terminal electrode.

[0036] The first lead-out portion 31d is the portion of the first wire 31 that connects the first winding portion 31a to the first end portion 31b. The second lead-out portion 31e is the portion of the first wire 31 that connects the first winding portion 31a to the second end portion 31c. In this embodiment, the first end portion 31b and the second end portion 31c of the first wire 31 are electrically connected to the terminal electrode of the plurality of terminal electrodes 12a~12d located on the first side of the first direction Z3, which is closer to the first side of the first direction than the central axis F.

[0037] The tension of the first lead-out portion 31d is less than the tension of the first winding portion 31a. Furthermore, as... Figure 2 As shown, a gap SP1 is provided between the corner C1 of the core portion 21 and the first lead-out portion 31d. Specifically, a gap SP1 is provided between the curved portion of the first lead-out portion 31d (described later) and the corner C1. In this example, a gap is also provided between the first lead-out portion 31d and the side surface 212 of the core portion 21.

[0038] The boundary portion between the first lead-out portion 31d and the first winding portion 31a in the first wire 31 is defined as the first boundary portion 311. In the first direction Z3, the first boundary portion 311 is located on the opposite side of the first end portion 31b, separated by the central axis F. As described above, the first end portion 31b is located on a first side of the first direction Z3, which is closer to the central axis F. Therefore, the first boundary portion 311 is located on a second side of the first direction Z3, which is closer to the central axis F.

[0039] The direction orthogonal to the axial direction Z1, i.e., the first direction Z3, is defined as the first predetermined direction. Furthermore, among the multiple corners C1 and C3 of the core portion 21 located on the first predetermined direction Z3, which is a second side of the first direction closer to the central axis F, the corner C1 located closest to the first end 31b in the circumferential direction Z2 is designated as the "first predetermined corner," and the corner C3 located second closest to the first end 31b in the circumferential direction Z2 is designated as the "second predetermined corner." In this case, the corner C1, as the first predetermined corner, is located between the first end 31b and the first boundary portion 311 in the circumferential direction Z2. Moreover, the first boundary portion 311 is located at the same position as the corner C3, which is the second predetermined corner, in the circumferential direction Z2. That is, the first boundary portion 311 is in contact with the corner C3.

[0040] Furthermore, the first lead-out portion 31d is formed in a shape that runs along the side of the core portion 21. That is, the first lead-out portion 31d includes a straight portion that mimics the side surface 212 and a curved portion that mimics the corner C1.

[0041] The tension of the second lead-out section 31e is less than the tension of the first winding section 31a. Furthermore, as... Figure 4 As shown, a gap SP2 is provided between the corner C4 of the core portion 21 and the second lead-out portion 31e. Specifically, a gap SP2 is provided between the curved portion of the second lead-out portion 31e (described later) and the corner C4. In this example, a gap is also provided between the second lead-out portion 31e and the side surface 214 of the core portion 21.

[0042] The boundary portion between the second lead-out portion 31e and the first winding portion 31a in the first wire 31 is designated as the second boundary portion 312. In the second direction Z4, the second boundary portion 312 is located on the opposite side of the second end portion 31c, separated by the central axis F. The second end portion 31c is located on a first side of the second direction, closer to the central axis F, in the second direction Z4. Therefore, the second boundary portion 312 is located on a second side of the second direction, closer to the central axis F (lower side in the figure), in the second direction Z4.

[0043] The direction orthogonal to the axial direction Z1, i.e., the second direction Z4, is defined as the second predetermined direction. Furthermore, among the multiple corners C3 and C4 of the core portion 21 located on the second direction Z4 (defined as the second predetermined direction) and on the second side of the second direction closer to the central axis F, the corner C4 located closest to the second end 31c in the circumferential direction Z2 is designated as the "fourth predetermined corner," and the corner C3 located second closest to the second end 31c in the circumferential direction Z2 is designated as the "second predetermined corner." In this case, the corner C4, as the fourth predetermined corner, is located between the second end 31c and the second boundary portion 312 in the circumferential direction Z2. Moreover, the second boundary portion 312 is located at the same position as the corner C3, which is the second predetermined corner, in the circumferential direction Z2. That is, the second boundary portion 312 is in contact with corner C3.

[0044] Furthermore, the second lead-out portion 31e is formed in a shape that runs along the side of the core portion 21. That is, the second lead-out portion 31e includes a straight portion that mimics the side surface 214 and a curved portion that mimics the corner C4.

[0045] exist Figure 3 The figures show a cross-section of the core portion 21, the first flange portion 22, and a portion of the second wire 41 when the core portion 21 is cut in a direction orthogonal to the axial direction Z1. Figure 5 The figures show a cross section of the core portion 21, the second flange portion 23, and a portion of the second wire 41 when the core portion 21 is cut in a direction orthogonal to the axial direction Z1.

[0046] like Figure 1 , Figure 3 as well as Figure 5 As shown, the second wire 41 has a second winding portion 41a, a third end portion 41b, a fourth end portion 41c, a third lead-out portion 41d, and a fourth lead-out portion 41e. The second winding portion 41a corresponds to the first winding portion 31a of the first wire 31. The third end portion 41b corresponds to the first end portion 31b of the first wire 31, and the fourth end portion 41c corresponds to the second end portion 31c of the first wire 31. The third lead-out portion 41d corresponds to the first lead-out portion 31d of the first wire 31, and the fourth lead-out portion 41e corresponds to the second lead-out portion 31e of the first wire 31.

[0047] The second winding portion 41a is the portion of the second wire 41 wound around the core portion 21. The third end portion 41b is the portion of the second wire 41 electrically connected to the terminal electrode 12b. The fourth end portion 41c is the portion of the second wire 41 electrically connected to the terminal electrode 12d. That is, when the terminal electrode provided on the first flange portion 22 is defined as the "first terminal electrode" and the terminal electrode provided on the second flange portion 23 is defined as the "second terminal electrode", terminal electrode 12b corresponds to the first terminal electrode and terminal electrode 12d corresponds to the second terminal electrode.

[0048] The third lead-out portion 41d is the portion of the second wire 41 that connects the second winding portion 41a to the third end portion 41b. The fourth lead-out portion 41e is the portion of the second wire 41 that connects the second winding portion 41a to the fourth end portion 41c. In this embodiment, the third end portion 41b and the fourth end portion 41c of the second wire 41 are electrically connected to the terminal electrode of the plurality of terminal electrodes 12a~12d located on the second side of the central axis F in the first direction Z3.

[0049] The tension of the third lead-out section 41d is less than the tension of the second winding section 41a. Furthermore, as... Figure 3 As shown, a gap SP3 is provided between the corner C3 of the core portion 21 and the third lead-out portion 41d. Specifically, a gap SP3 is provided between the curved portion of the third lead-out portion 41d (described later) and the corner C3. In this example, a gap is also provided between the third lead-out portion 41d and the side surface 214 of the core portion 21.

[0050] The boundary portion between the third lead-out portion 41d of the second wire 41 and the second winding portion 41a is designated as the third boundary portion 411. In the second direction Z4, the third boundary portion 411 is located on the opposite side of the third end portion 41b, separated by the central axis F. As described above, the third end portion 41b is located on a first side of the second direction in the second direction Z4, which is closer to the central axis F. Therefore, the third boundary portion 411 is located on a second side of the second direction in the second direction Z4, which is closer to the central axis F.

[0051] The direction orthogonal to the axial direction Z1, i.e., the second direction Z4, is defined as the third defined direction. In this case, the corner C3 is located between the third end 41b and the third boundary portion 411 in the circumferential direction Z2. Moreover, the third boundary portion 411 is located at the same position as the corner C4 in the circumferential direction Z2. That is, the third boundary portion 411 is in contact with the corner C4.

[0052] Furthermore, the third lead-out portion 41d is formed in a shape that runs along the side of the core portion 21. That is, the third lead-out portion 41d includes a straight portion that mimics the side surface 214 and a curved portion that mimics the corner C3.

[0053] The tension of the fourth lead-out section 41e is less than the tension of the second winding section 41a. Furthermore, as... Figure 5 As shown, a gap SP4 is provided between the corner C2 of the core portion 21 and the fourth lead-out portion 41e. Specifically, a gap SP4 is provided between the curved portion of the fourth lead-out portion 41e (described later) and the corner C2. In this example, a gap is also provided between the fourth lead-out portion 41e and the side surface 213 of the core portion 21.

[0054] The boundary portion between the fourth lead-out portion 41e and the second winding portion 41a in the second wire 41 is designated as the fourth boundary portion 412. In the first direction Z3, the fourth boundary portion 412 is located on the opposite side of the fourth end portion 41c, separated by the central axis F. The fourth end portion 41c is located on a second side of the first direction than the central axis F in the first direction Z3, therefore the fourth boundary portion 412 is located on a first side of the first direction than the central axis F in the first direction Z3.

[0055] The direction orthogonal to the axial direction Z1, i.e., the first direction Z3, is defined as the fourth predetermined direction. Furthermore, among the multiple corners C2 and C4 of the core portion 21 located on the first side of the first direction (defined as the fourth predetermined direction) closer to the first direction than the central axis F, the corner C2 located closest to the fourth end 41c in the circumferential direction Z2 is designated as the "third predetermined corner," and the corner C4 located second closest to the fourth end 41c in the circumferential direction Z2 is designated as the "fourth predetermined corner." In this case, the corner C2, as the third predetermined corner, is located between the fourth end 41c and the fourth boundary portion 412 in the circumferential direction Z2. Moreover, the fourth boundary portion 412 is located at the same position as the corner C4, which is the fourth predetermined corner, in the circumferential direction Z2. That is, the fourth boundary portion 412 is in contact with the corner C4.

[0056] Furthermore, the fourth lead-out portion 41e is formed in a shape that runs along the side of the core portion 21. That is, the fourth lead-out portion 41e includes a straight portion that mimics the side surface 213 and a curved portion that mimics the corner C2.

[0057] The function of this embodiment will be explained.

[0058] In the coil component 10, coated wires are used as wires 31 and 41. Moreover, the two coated wires are wound together in an adjacent state on the core portion 21. When this coil component 10 is mounted on a circuit board using solder, the flux component contained in the solder is sometimes transferred from the terminal electrodes 12a to 12d on the wires 31 and 41 to the core portion 21.

[0059] In this respect, in coil component 10, such as Figure 2As shown, a gap SP1 is provided between the first lead-out portion 31d and the corner C1. In this case, the length of the first lead-out portion 31d is longer than that of a coil component without a gap between the first lead-out portion and the first predetermined corner. That is, the distance of the first wire 31 from the first boundary portion 311 that contacts the core portion 21 to the first end portion 31b that connects to the terminal electrode 12a is longer. Therefore, even if flux components contained in the solder are transferred along the first wire 31, the flux components can be suppressed from reaching the core portion 21. As a result, short circuits and insulation defects in the coil component 10 can be suppressed, thereby improving the reliability of the coil component 10.

[0060] In this embodiment, the following effects can also be achieved.

[0061] (1-1) In this embodiment, as Figure 4 As shown, a gap SP2 is provided between the second lead-out portion 31e and the corner C4 of the core portion 21. Therefore, by achieving the same effect as described above, even if flux components are transferred along the first wire 31, the flux components can be prevented from reaching the core portion 21.

[0062] (1-2) In this embodiment, as Figure 3 As shown, a gap SP3 is provided between the third lead-out portion 41d and the corner C3 of the core portion 21. Therefore, by achieving the same effect as described above, even if flux components are transferred along the second wire 41, the flux components reaching the core portion 21 can be suppressed.

[0063] (1-3) In this embodiment, as Figure 5 As shown, a gap SP4 is provided between the fourth lead-out portion 41e and the corner C2 of the core portion 21. Therefore, by achieving the same effect as described above, even if flux components are transferred along the second wire 41, the flux components can be prevented from reaching the core portion 21.

[0064] (1-4) In this embodiment, as Figure 2 As shown, the first boundary portion 311 of the first wire 31 contacts the corner C3. This reduces the tension of the first lead-out portion 31d while suppressing winding irregularities in the first wire 31 that forms the first winding portion 31a.

[0065] (1-5) In this embodiment, as Figure 4 As shown, the second boundary portion 312 of the first wire 31 contacts the corner C3. This reduces the tension of the second lead-out portion 31e while suppressing the winding disorder of the first wire 31 that forms the first winding portion 31a.

[0066] (1-6) In this embodiment, as Figure 3 As shown, the third boundary portion 411 of the second wire 41 contacts the corner C4. This reduces the tension of the third lead-out portion 41d while suppressing winding irregularities in the second wire 41 that forms the second winding portion 41a.

[0067] (1-7) In this embodiment, as Figure 5 As shown, the fourth boundary portion 412 of the second wire 41 contacts the corner C4. This reduces tension in the fourth lead-out portion 41e while suppressing the disorder of the second wire 41 that forms the second winding portion 41a.

[0068] Next, refer to Figure 6 An example of a method for manufacturing a coil component will be described. Here, the case where the first wire 31 of the first wire 31 and the second wire 41 is wound onto the core 20 will be described. The method of winding the second wire 41 onto the core 20 is largely the same as the method of winding the first wire 31 onto the core 20, and will be omitted here.

[0069] First, in the first temporary fixing process of step S11, the initially wound end of the first wire 31, i.e., the first end 31b, is temporarily fixed to the terminal electrode 12a of the first flange portion 22. As long as the first end 31b can remain stationary until the winding of the first wire 31 into the core 20 is completed, any method can be used for this temporary fixing. For example, the first end 31b can be temporarily fixed to the terminal electrode 12a by heat pressing.

[0070] In the next step S13, the first tension adjustment process forms the first lead-out portion 31d of the first wire 31. For example, the tension when the first wire 31 is wound around the core portion 21, i.e., the tension when the first winding portion 31a is formed, is set as the reference tension Pb. In the first tension adjustment process, for example, the first wire 31 is wound around the core portion 21 with the reference tension Pb applied to it. In this case, the first wire 31 contacts the corner C1. Furthermore, the first wire 31 also contacts the side 212 connected to the corner C1. Moreover, if the first wire 31 contacts the corner C3, the tension applied to the first wire 31 is less than the reference tension Pb. As a method to reduce tension, for example, a method of feeding the first wire 31 toward the corner C1 in the circumferential direction Z2, or a method of rotating the core 20 in the direction in which the first wire 31 is wound around the core portion 21 in the circumferential direction Z2. In this way, a portion of the first wire 31 is separated from the core portion 21. This forms the first lead-out portion 31d. Specifically, the first lead-out portion 31d can be formed in a shape that runs along the side of the core portion 21.

[0071] Furthermore, in the winding process of step S15, a first winding portion 31a of the first wire 31 is formed. That is, the first wire 31 is wound around the core portion 21 while the tension applied to the first wire 31 is restored to the reference tension Pb. The winding process ends when the formation of the first winding portion 31a is completed.

[0072] In the next step S17, the second tension adjustment process, a second lead-out portion 31e of the first wire 31 is formed. For example, in the second tension adjustment process, the first wire 31 is brought to the terminal electrode 12c while a reference tension Pb is applied to it. In this state, the portion of the first wire 31 that constitutes the second lead-out portion 31e contacts the corner C3, the side surface 214, and the corner C4. Then, the tension applied to the first wire 31 is reduced to a level lower than the reference tension Pb. This tension can, for example, be the same as the tension during the first tension adjustment process. As a result, the second lead-out portion 31e of the first wire 31 separates from the core portion 21. That is, a second lead-out portion 31e is formed that does not contact the side surface 214 and the corner C4. In this case, the second lead-out portion 31e can be formed in a shape that runs along the side surface of the core portion 21.

[0073] Furthermore, in the second temporary fixing process of step S19, the end of the first wire 31 at the end of its winding, i.e., the second end 31c, is temporarily fixed to the terminal electrode 12c of the second flange portion 23. This temporary fixing can be achieved using any method. For example, the second end 31c can be temporarily fixed to the terminal electrode 12c by heat pressing.

[0074] In the next step S21, the wire is cut. That is, the first wire 31 wound on the core 20 is cut off from the wire held by the manufacturing device.

[0075] Furthermore, in this fixing process of step S23, the first end 31b is electrically connected to the terminal electrode 12a, for example, by thermal welding. Similarly, the second end 31c is electrically connected to the terminal electrode 12c.

[0076] That is, in Figure 6In the manufacturing method shown, steps S11 and S13 are steps prior to forming the first winding portion 31a, respectively corresponding to the steps of temporarily fixing the first end 31b of the first wire 31 to the terminal electrode 12a and drawing the first wire 31 from the terminal electrode 12a to the core portion 21 while reducing the tension of the first wire 31 to a level lower than that in the process of forming the first winding portion 31a. Step S15 corresponds to the step of forming the first winding portion 31a by winding the first wire 31 to the core portion 21. Steps S17 and S19 correspond to the steps of drawing the first wire 31 from the core portion 21 to the terminal electrode 12c while reducing the tension of the first wire 31 to a level lower than that in the process of forming the first winding portion 31a, and fixing the second end 31c of the first wire 31 to the terminal electrode 12c.

[0077] According to the manufacturing method of this embodiment, the following effects can be obtained.

[0078] (1-8) A gap SP1 can be easily provided between the first lead-out portion 31d of the first wire 31 and the corner C1 of the winding portion 31a. In addition, a gap SP2 can be easily provided between the second lead-out portion 31e of the first wire 31 and the corner C4 of the winding portion 31a. That is, it is easy to manufacture the coil component 10.

[0079] The above-described embodiments can be modified as follows. The above-described embodiments and the following modifications can be combined with each other to the extent that they do not contradict each other technically.

[0080] Terminal electrodes can also be made of, for example Figure 7 It is constructed of metal plates as shown. Furthermore, in Figure 7 In the example shown, a terminal electrode 12a1 for electrically connecting the first end 31b of the first wire 31 is disposed on the first flange portion 22, and a terminal electrode 12b1 for electrically connecting the third end 41b of the second wire 41 is disposed on the first flange portion 22.

[0081] If the second lead-out portion 31e separates from the core portion 21, the second boundary portion 312 may also not contact the corner C3.

[0082] If the fourth lead-out portion 41e separates from the core portion 21, then the fourth boundary portion 412 may also not contact the corner C4.

[0083] If the first lead-out portion 31d separates from the core portion 21, the first boundary portion 311 may also not contact the corner C3.

[0084] If the third lead-out portion 41d separates from the core portion 21, then the third boundary portion 411 may also not contact the corner C4.

[0085] The tension of the second lead-out section 31e can also be the same as the tension of the first winding section 31a.

[0086] The tension of the fourth lead-out section 41e can also be the same as the tension of the second winding section 41a.

[0087] The tension of the first lead-out section 31d can also be the same as the tension of the first winding section 31a.

[0088] The tension of the third lead-out section 41d can also be the same as the tension of the second winding section 41a.

[0089] If the second lead-out portion 31e is separated from the core portion 21, the shape of the second lead-out portion 31e does not necessarily have to be the shape along the side of the core portion 21.

[0090] If the fourth lead-out portion 41e is separated from the core portion 21, the shape of the fourth lead-out portion 41e does not necessarily have to be the shape along the side of the core portion 21.

[0091] If the first lead-out portion 31d is separated from the core portion 21, the shape of the first lead-out portion 31d does not necessarily have to be the shape along the side of the core portion 21.

[0092] If the third lead-out portion 41d is separated from the core portion 21, the shape of the third lead-out portion 41d does not necessarily have to be the shape along the side of the core portion 21.

[0093] Regarding the first wire 31, if the first lead-out portion 31d separates from the corner C1, then the second lead-out portion 31e does not necessarily need to separate from the corner C4. In this case, Figure 6 In the manufacturing method shown, the second tension adjustment process in step S17 can also be omitted.

[0094] If the first lead-out portion 31d of the first wire 31 is separated from the corner C1, then the third lead-out portion 41d of the second wire 41 does not necessarily have to be separated from the corner C3.

[0095] If the first lead-out portion 31d of the first wire 31 separates from the corner C1, then the fourth lead-out portion 41e of the second wire 41 does not necessarily have to separate from the corner C2.

[0096] The first specified direction may not be the first direction Z3. That is, if the first end 31b of the first wire 31 is arranged on the first side of the first specified direction, which is closer to the central axis F than the central axis F, and the first boundary portion 311 is arranged on the second side of the first specified direction, which is closer to the central axis F than the central axis F, then the first specified direction may be a direction different from the first direction Z3.

[0097] The second specified direction may not be the second direction Z4. That is, if the second end 31c of the first wire 31 is arranged on the first side of the second specified direction, which is closer to the central axis F than the central axis F, and the second boundary portion 312 is arranged on the second side of the second specified direction, which is closer to the central axis F than the central axis F, then the second specified direction may be a direction different from the second direction Z4. For example, the second specified direction may not be a direction orthogonal to the first specified direction.

[0098] The third specified direction may not be the second direction Z4. That is, if in the third specified direction, the third end 41b of the second wire 41 is arranged on the first side of the third specified direction, which is closer to the central axis F than the central axis F, and the third boundary portion 411 is arranged on the second side of the third specified direction, which is closer to the central axis F than the central axis F, then the third specified direction may be a direction different from the second direction Z4.

[0099] The fourth specified direction may not be the first direction Z3. That is, if in the fourth specified direction, the fourth end 41c of the second wire 41 is arranged on the first side of the fourth specified direction, which is closer to the central axis F than the central axis F, and the fourth boundary portion 412 is arranged on the second side of the fourth specified direction, which is closer to the central axis F than the central axis F, then the fourth specified direction may be a direction different from the first direction Z3.

[0100] In the above embodiment, the cross-section of the core portion 21 when cut in a direction orthogonal to the axial direction Z1 is rectangular, but it is not limited to this. For example, the core portion 21 may also be a core portion with a square cross-section when cut.

[0101] If the core portion 21 is formed into a prism shape, it does not have to be a tetragonal prism. For example, the core portion can be a triangular prism or a hexagonal prism.

[0102] In the above embodiment, the core portion 21 is configured such that when it is cut in a direction orthogonal to the axial direction Z1, the shapes of each side surface 211 to 214 are straight, but it is not limited to this. That is, the cross-section of the core portion 21 when it is cut in a direction orthogonal to the axial direction Z1 can have ridge lines.

[0103] The coil component can also consist of only one wire wound around the core.

[0104] The coil component may not be a common-mode choke coil.

Claims

1. A coil component, wherein, have: The core has a prism-shaped core portion, a first flange portion connected to a first end of the core portion in the direction of extension of the central axis of the core portion, i.e., in the axial direction, and a second flange portion connected to a second end of the core portion in the axial direction. A first terminal electrode is disposed on the first flange portion; The second terminal electrode is disposed on the second flange portion; and The first wire has a winding portion wound around the core portion, a first end electrically connected to the first terminal electrode, a second end electrically connected to the second terminal electrode, a first lead-out portion connecting the winding portion to the first end, and a second lead-out portion connecting the winding portion to the second end. In a first predetermined direction orthogonal to the central axis, the first end portion is positioned on a first side closer to the central axis in the first predetermined direction, and the boundary portion between the first lead-out portion and the winding portion, i.e., the first boundary portion, is positioned on a second side closer to the central axis in the first predetermined direction. The first predetermined corner, which is the corner closest to the first end point in the circumferential direction of the core portion located on a second side of the first predetermined direction, closer to the central axis than the central axis, is located in the circumferential direction between the first boundary portion and the first end point. A gap is provided between the first lead-out portion and the first designated corner.

2. The coil component according to claim 1, wherein, The first boundary portion contacts the second defined corner, which is located on the second side of the plurality of corners in the first defined direction, closer to the first end in the circumferential direction.

3. The coil component according to claim 1, wherein, In a second predetermined direction orthogonal to both the axial direction and the first predetermined direction, the second end is positioned on a first side closer to the central axis, and the boundary portion between the second lead-out portion and the winding portion, i.e., the second boundary portion, is positioned on a second side closer to the second predetermined direction than the central axis. The fourth defined corner, which is the corner located closest to the second end in the circumferential direction of the core portion, on a second side of the second defined direction relative to the central axis, is located between the second boundary portion and the second end in the circumferential direction, centered on the central axis. A gap is provided between the second lead-out portion and the fourth specified corner.

4. The coil component according to claim 3, wherein, The second boundary portion contacts the second defined corner, which is located on the second side of the second defined direction, in the second defined direction, closer to the second end in the circumferential direction than the central axis.

5. The coil component according to any one of claims 1 to 4, wherein, The first lead-out portion is formed in a shape along the side of the core portion.

6. The coil component according to any one of claims 1 to 4, wherein, The second lead-out portion is formed in a shape along the side of the core portion.

7. The coil component according to any one of claims 1 to 4, wherein, It also has a second wire. The second wire has a second winding portion, a third end portion, a fourth end portion, a third lead-out portion, and a fourth lead-out portion.

8. A method for manufacturing a coil component, wherein, The coil component comprises a core and wire. The core has a prism-shaped core portion, a first flange portion connected to a first end of the core portion extending along the central axis of the core portion (i.e., in the axial direction), and a second flange portion connected to a second end of the core portion in the axial direction. The wire has a winding portion wound around the core portion, a first end electrically connected to a terminal electrode provided on the first flange portion, a second end electrically connected to a terminal electrode provided on the second flange portion, a first lead-out portion connecting the winding portion to the first end portion, and a second lead-out portion connecting the winding portion to the second end portion. The method for manufacturing the coil component includes: The process of forming the winding portion by winding the wire around the core portion; and In a state where the tension of the wire is smaller than that in the process of forming the winding portion, the wire is led out from the core portion to the terminal electrode provided on the second flange portion, and the second end of the wire is fixed to the terminal electrode.

9. The method for manufacturing a coil component according to claim 8, wherein, It also includes a process prior to the process of forming the winding portion, and a process of drawing the wire from the terminal electrode provided on the first flange portion to the core portion while keeping the tension of the wire smaller than when forming the winding portion.

Images