Coil component

Abstract

This invention relates to coil components. The objective of this invention is to easily withstand a load applied to the top plate, thus preventing breakage. In the coil component, a first flange is connected to a first end of the core in a first positive direction. A second flange is connected to a second end of the core in a first negative direction. The top plate extends longer than the core along its central axis and is connected to the first and second flanges via an adhesive. The adhesive does not contact the core. The area on the surface of the top plate where the adhesive is present is defined as a first presence range. The area combining a second range where the adhesive is present on the surface of the first flange and a fourth range where the adhesive is present on the surface of the second flange is defined as a second presence range. In this case, the first presence range is larger than the second presence range.

Description

Technical Field

[0001] This invention relates to coil components. Background Technology

[0002] Patent Document 1 describes a coil component comprising a core having a core portion having a central axis, a first flange portion, a second flange portion, and a top plate. The core portion is prism-shaped. The first flange portion is connected to a first end of the core portion. The first flange portion protrudes radially outward from the circumference of the core portion about the central axis. The second flange portion is connected to a second end of the core portion. The second flange portion protrudes radially outward more than the circumference of the core portion about the central axis. Furthermore, the top plate extends longer than the core portion in the direction along the central axis. The top plate is connected to the first flange portion and the second flange portion via an adhesive.

[0003] Patent Document 1: Japanese Patent No. 6477622

[0004] In the coil component described in Patent Document 1, a load is sometimes applied to the top plate. Specifically, for example, when mounting the coil component onto the substrate, the top plate is sometimes pressed towards the substrate. Thus, when a load is applied to the top plate, there is a concern that the top plate may not be able to withstand the load and may break. Summary of the Invention

[0005] To address the aforementioned issues, one aspect of this disclosure is to provide a coil component comprising: a core; a wire having a portion extending spirally on the circumferential surface of the core portion about a central axis of rotation; and a top plate extending longer than the core portion in the direction along the central axis and connected to a first flange portion and a second flange portion via an adhesive. The core includes: the core portion having the central axis; and the first flange portion connected to a first end of the core portion in the direction along the central axis, and extending further radially from the circumferential surface of the core portion towards the central axis. The outer side protrudes; and the second flange portion is connected to the second end of the core portion on the opposite side of the first end, and protrudes radially outward from the circumference of the core portion about the central axis. The adhesive does not contact the core portion. When the range on the surface of the top plate where the adhesive exists is defined as the first range, and the range combining the range on the surface of the first flange portion and the range on the surface of the second flange portion is defined as the second range, the first range is larger than the second range.

[0006] According to the above structure, the portion of the adhesive that extends onto the surface of the top plate functions as a protective layer for the top plate. Furthermore, the adhesive extends across the surface of the top plate beyond the area required for fixing the top plate to each flange. Thus, the adhesive is present over a large area on the surface of the top plate, thereby increasing the mechanical strength of the whole unit that binds the top plate and the adhesive together. As a result, even when a load is applied to the top plate, damage to the top plate can be suppressed.

[0007] When a load is applied to the top plate, it can easily withstand the load and suppress the damage to the top plate. Attached Figure Description

[0008] Figure 1 This is a side view of the coil component.

[0009] Figure 2 yes Figure 1 A bottom view of the coil component.

[0010] Figure 3 It is along Figure 2 A sectional view along line 3-3 in the diagram.

[0011] Figure 4 It is along Figure 3 The sectional view along line 4-4.

[0012] Figure 5 This is a bottom view of the top panel.

[0013] Figure 6 This is an explanatory diagram used to illustrate the thickness of the first film.

[0014] Figure 7 This is an explanatory diagram used to illustrate the first thin film portion.

[0015] Figure 8 This is an explanatory diagram illustrating the manufacturing method of the coil component.

[0016] Explanation of reference numerals in the attached figures

[0017] 10…coil component; 10C…core; 11…winding core; 11F…peripheral surface; 12…first flange; 13…second flange; 21…first terminal electrode; 22…second terminal electrode; 30…wire; 40…top plate; 50…adhesive; A1…first area of ​​existence; A2…second area of ​​existence; CA…central axis; S10…core preparation process; S11…wire winding process; S12…top plate preparation process; S13…coating process; S14…configuration process; S15…curing process. Detailed Implementation

[0018] <An embodiment of the coil component>

[0019] The following describes one embodiment of the coil component. Furthermore, the components are sometimes shown enlarged for ease of understanding in the accompanying drawings. The dimensional ratios of the components may differ from the actual dimensional ratios or those in other drawings. Additionally, while shading lines are indicated in sectional views, some shading lines for certain components are sometimes omitted for clarity.

[0020] (Overall structure)

[0021] like Figure 1 As shown, the coil component 10 includes a core 10C. The core 10C includes a winding core portion 11. The winding core portion 11 is a quadrangular prism. Therefore, the winding core portion 11 has a central axis CA and extends in the direction along the central axis CA. In addition, the winding core portion 11 has a circumferential surface 11F surrounding the central axis CA.

[0022] Furthermore, in the following description, the axis extending along the direction of the central axis CA will be designated as the first axis X. Additionally, as... Figure 2 As shown, in the cross-section of the core portion 11 orthogonal to the central axis CA, the axis extending parallel to any one of the four sides constituting the quadrilateral is designated as the second axis Y. Furthermore, as... Figure 1 As shown, the axis orthogonal to the first axis X and the second axis Y is designated as the third axis Z. That is, the third axis Z is an orthogonal axis orthogonal to the central axis CA. Furthermore, one direction along the first axis X is designated as the first positive direction X1, and the other direction along the first axis X is designated as the first negative direction X2. Moreover, as... Figure 2 As shown, one direction along the second axis Y is designated as the second positive direction Y1, and the other direction along the second axis Y is designated as the second negative direction Y2. Additionally, as... Figure 1 As shown, one direction along the third axis Z is designated as the third positive direction Z1, and the other direction along the third axis Z is designated as the third negative direction Z2. That is, the opposite direction of the third positive direction Z1 is the third negative direction Z2.

[0023] like Figure 1 As shown, the core 10C also includes a first flange portion 12 and a second flange portion 13. The first flange portion 12 is connected to the end portion of the winding core portion 11 in the first positive direction X1, i.e., the first end. The first flange portion 12 protrudes radially outward from the circumferential surface 11F of the winding core portion 11, centered on the central axis CA. Figure 2 As shown, the amount of protrusion from the circumferential surface 11F of the core portion 11 is the same in both the second positive direction Y1 and the second negative direction Y2. On the other hand, as... Figure 1As shown, the amount of protrusion from the circumferential surface 11F of the core portion 11 in the third negative direction Z2 is greater than the amount of protrusion from the circumferential surface 11F of the core portion 11 in the third positive direction Z1. In other words, the center of the first flange portion 12 in the direction along the third axis Z is offset in the third negative direction Z2 than the central axis CA of the core portion 11.

[0024] The second flange portion 13 is connected to the end of the core portion 11 in the first negative direction X2, i.e., the second end. The second flange portion 13 has a shape that is symmetrical with the first flange portion 12 in the direction along the first axis X, with the core portion 11 as a boundary. The cross sections of the first flange portion 12 and the second flange portion 13 that are orthogonal to the central axis CA of the core portion 11 are quadrilaterals.

[0025] The core 10C is made of a non-conductive material. Materials for the core 10C include, for example, aluminum oxide, nickel-zinc ferrite, resin, or mixtures thereof.

[0026] The coil component 10 has a first terminal electrode 21 and a second terminal electrode 22.

[0027] like Figure 3 As shown, the first terminal electrode 21 is located on the surface of the first flange portion 12. Specifically, it is located on the surface of the end of the first flange portion 12 in the third negative direction Z2.

[0028] The second terminal electrode 22 is located on the surface of the second flange portion 13. Specifically, it is located on the surface of the end of the second flange portion 13 in the third negative direction Z2.

[0029] The first terminal electrode 21 and the second terminal electrode 22 are composed of a silver metal layer and a copper, nickel, and tin plating layer applied to the surface of the metal layer. In this embodiment, in the coil component 10, the surface of the first terminal electrode 21 and the second terminal electrode 22, that is, the surface facing the third negative direction Z2, is the surface that faces the substrate when the coil component 10 is mounted on the substrate.

[0030] like Figure 1 As shown, the coil component 10 includes a wire 30. A first end of the wire 30 is connected to a first terminal electrode 21. A second end of the wire 30 is connected to a second terminal electrode 22. The wire 30 has a portion that extends spirally on the circumferential surface 11F of the core portion 11 about a central axis CA. Specifically, the central portions of the first and second ends of the wire 30 extend spirally on the circumferential surface 11F. On the other hand, a portion of the wire 30 starting from the first end separates from the circumferential surface 11F and extends spirally about the central axis CA. Similarly, a portion of the wire 30 starting from the second end separates from the circumferential surface 11F and extends spirally about the central axis CA.

[0031] The coil component 10 includes a top plate 40. The top plate 40 is a rectangular plate that is longer along the first axis X than along the second axis Y. The top plate 40 is connected to the end of the core 10C in the third positive direction Z1. That is, the top plate 40 is connected to the end of the core 10C opposite to the end where the first terminal electrode 21 and the second terminal electrode 22 are disposed. The top plate 40 is connected to the core 10C such that it is mounted on the end face of the first flange portion 12 in the third positive direction Z1 and the end face of the second flange portion 13 in the third positive direction Z1. Therefore, the dimension of the top plate 40 along the first axis X is larger than the dimension of the winding core portion 11 along the first axis X. In other words, the top plate 40 extends longer than the winding core portion 11 in the direction along the central axis CA. Furthermore, as... Figure 2 As shown, the dimensions of the top plate 40 along the second axis Y are approximately the same as the dimensions of the first flange portion 12 and the second flange portion 13 along the second axis Y.

[0032] Here, the surface roughness of the core 10C and the surface roughness of the top plate 40 will be explained. The following values ​​are obtained by measuring the surface of the top plate 40 facing the third negative direction Z2 and the surface of the first flange portion 12 facing the third positive direction Z1, respectively.

[0033] Regarding the surface roughness of core 10C, the unfolded area ratio Sdr of the core 10C surface is 0.08. The arithmetic mean Spc of the peak vertices TP of the core 10C surface is 2160. The arithmetic mean height Sa of the core 10C surface is 0.40. These values ​​were measured non-contactly according to the standard specified in ISO 25178.

[0034] On the other hand, regarding the surface roughness of the top plate 40, the unfolded area ratio Sdr of the surface of the top plate 40 is 0.19. The arithmetic mean Spc of the peaks TP of the surface of the top plate 40 is 2860. The arithmetic mean height Sa of the surface of the top plate 40 is 0.28. Therefore, the unfolded area ratio Sdr of the surface of the top plate 40 is greater than 0.15 and less than 0.50. In addition, the unfolded area ratio Sdr of the surface of the top plate 40 is greater than the unfolded area ratio Sdr of the surface of the core 10C.

[0035] Thus, both the core 10C and the top plate 40 have a certain degree of roughness. Moreover, the surface roughness of the top plate 40 is greater than that of the core 10C.

[0036] like Figure 1As shown, the top plate 40 is connected to the first flange portion 12 and the second flange portion 13 via adhesive 50. On the other hand, the adhesive 50 does not contact the core portion 11. The adhesive 50 is divided into a first adhesive portion 51 that connects the top plate 40 to the first flange portion 12, and a second adhesive portion 52 that connects the top plate 40 to the second flange portion 13. The adhesive 50 is a thermosetting adhesive, for example, made of epoxy resin.

[0037] like Figure 4 As shown, the first adhesive portion 51 connects the first flange portion 12 to the top plate 40. Additionally, as... Figure 5 As shown, the first adhesive portion 51 is located on the surface of the top plate 40 facing the third negative direction Z2, at a position closer to the first positive direction X1 than the center along the first axis X.

[0038] Moreover, such as Figure 3 and Figure 4 As shown, the first adhesive portion 51 wets and expands within a first region A11 of the surface of the top plate 40 facing the third negative direction Z2. (As shown) Figure 5 As shown, in the first range A11, the first adhesive portion 51 has a first film thickness portion 51A and a first film thin portion 51B.

[0039] like Figure 6 As shown, the first film thickness portion 51A is a portion of the surface of the roughened top plate 40 that has a thickness extending from the surface to a position farther from the surface than the peak TP. The first film thickness portion 51A is located in the surface of the top plate 40 facing the third negative direction Z2, at a position closer to the first positive direction X1 than the center of the top plate 40 along the first axis X.

[0040] On the other hand, the first thin film portion 51B is the portion of the surface of the roughened top plate 40 that does not have a thickness up to the peak TP. That is, as... Figure 7 As shown, although the first film thin portion 51B wets and spreads on the surface of the roughened top plate 40 in the valley between peaks TP, the peaks TP of the top plate 40 are not covered. Additionally, as... Figure 5 As shown, when viewed from the direction along the third axis Z, the first thin film portion 51B surrounds the first thick film portion 51A. Moreover, the end of the first thin film portion 51B in the first negative direction X2 does not reach the center of the top plate 40 in the direction along the first axis X.

[0041] like Figure 4 As shown, the surface of the first flange portion 12 facing the third positive direction Z1 is opposite to a portion of the first film thin portion 51B of the first adhesive portion 51. Furthermore, as... Figure 3 and Figure 4As shown, the first flange portion 12 is connected to the top plate 40 via a portion of the first film thickness portion 51A in the first adhesive portion 51. Therefore, as Figure 5 As shown, the area on the surface of the first flange portion 12 where the adhesive 50 exists, i.e., the second area A21, is smaller than the area in the first adhesive portion 51 where the first film thickness portion 51A exists. Therefore, the first area A11 is larger than the second area A21.

[0042] In addition, such as Figure 3 As shown, the second adhesive portion 52 wets and expands in the third region A12 of the surface of the top plate 40 facing the third negative direction Z2. Figure 5 As shown, within the third range A12, the second adhesive portion 52 has a second film thickness portion 52A and a second film thin portion 52B.

[0043] When viewed from the direction along the third axis Z, the second adhesive portion 52 is symmetrical to the first adhesive portion 51 about an axis parallel to the second axis Y, passing through the center of the top plate 40 along the first axis X. Therefore, the second film thickness portion 52A, like the first film thickness portion 51A, is a portion on the surface of the roughened top plate 40 that has a thickness extending from the surface to a position farther from the surface than the peak TP. The second film thickness portion 52A is located in the middle of the surface of the top plate 40 facing the third negative direction Z2, at an end closer to the first negative direction X2 than the center of the top plate 40 along the first axis X.

[0044] On the other hand, the second film thin portion 52B, like the first film thin portion 51B, is a portion of the surface of the roughened top plate 40 that does not have a thickness up to the peak TP. That is, although the second film thin portion 52B wets and extends on the surface of the roughened top plate 40 in the valley between the peaks TP, the peak TP of the top plate 40 is not covered. In addition, when viewed from the direction along the third axis Z, the second film thin portion 52B surrounds the second film thick portion 52A. Moreover, the end of the second film thin portion 52B in the first positive direction X1 does not reach the center of the top plate 40 in the direction along the first axis X. Therefore, the second film thin portion 52B does not contact the first film thin portion 51B. That is, the first range A11 and the third range A12 are separated. Furthermore, when the range in which the adhesive 50 exists on the surface of the top plate 40 is defined as the first existence range A1, the first existence range A1 is the range that combines the first range A11 and the third range A12.

[0045] like Figure 4 As shown, the surface of the second flange portion 13 facing the third positive direction Z1 is opposite to a portion of the second film thin portion 52B of the second adhesive portion 52. Furthermore, as... Figure 3 As shown, the second flange portion 13 is connected to the top plate 40 via a portion of the second film thickness portion 52A in the second adhesive portion 52. Therefore, as Figure 5 As shown, the area on the surface of the second flange portion 13 where the adhesive 50 exists, i.e., the fourth area A22, is smaller than the area in the second adhesive portion 52 where the second film thickness portion 52A exists. Therefore, the third area A12 is larger than the fourth area A22.

[0046] The combined range of the second range A21 and the fourth range A22 is defined as the second existence range A2. The first existence range A1 is larger than the second existence range A2. Specifically, the first existence range A1 is more than 1.1 times the size of the second existence range A2.

[0047] Furthermore, when viewed from the direction along the third axis Z, the surface of the core portion 11 opposite to the top plate 40 overlaps with a portion of the first range A11 and a portion of the third range A12. That is, a portion of the first existence range A1 is opposite to the core portion 11. The portion of the first existence range A1 opposite to the core portion 11 includes a first film thin portion 51B and a second film thin portion 52B.

[0048] (Manufacturing method)

[0049] Next, the manufacturing method of the coil component 10 will be described.

[0050] like Figure 8 As shown, the manufacturing method of the coil component 10 includes a core preparation process S10, a wire winding process S11, a top plate preparation process S12, a coating process S13, a configuration process S14, and a curing process S15.

[0051] In the core preparation step S10, firstly, a core 10C is prepared. For example, a molded body obtained by stamping ferrite powder using a mold is fired. Flash is removed by performing a flash removal process after firing. As a result, a core 10C having a rolled core portion 11, a first flange portion 12, and a second flange portion 13 is formed.

[0052] Next, in the core 10C, a first terminal electrode 21 is formed on the surface of the first flange portion 12, and a second terminal electrode 22 is formed on the surface of the second flange portion 13. For example, each terminal electrode is formed by plating or the like.

[0053] Next, the wire winding process S11 is performed. In the wire winding process S11, the wire 30 is wound around the core portion 11. In the wire 30, approximately one turn at each end is wound separately from the circumferential surface 11F of the core portion 11 in the direction along the first axis X. Then, the first end of the wire 30 is pressed onto the first terminal electrode 21. Then, the second end of the wire 30 is pressed onto the second terminal electrode 22. Thus, a core 10C with the wire 30 wound on it is prepared.

[0054] Next, the top plate preparation step S12 is performed. In the top plate preparation step S12, a top plate 40 with a specified surface roughness is prepared. Specifically, as described above, a top plate 40 with an unfolded area ratio Sdr of 0.15 or more and 0.50 or less is prepared. In the top plate preparation step S12, similar to the core preparation step S10, the molded body obtained by stamping ferrite powder using a mold is fired and deburred, thereby forming the top plate 40.

[0055] Next, the coating process S13 is performed. In the coating process S13, firstly, adhesive 50 is applied to two points at both ends of the surface of the top plate 40 opposite to the core 10C, along the direction of the first axis X. Specifically, a predetermined amount of adhesive 50 is dispensed using a dispenser. At this time, the adhesive 50 placed on the top plate 40 has a corresponding thickness due to surface tension. Then, a predetermined time is allowed. An example of the predetermined time is a few seconds to tens of seconds, which is the time during which the fluidity of the adhesive 50 is not lost. As a result, when viewed from the direction along the third axis Z, the adhesive 50 gradually wets and spreads around the surface of the rough top plate 40. Therefore, the thickness of the adhesive 50 gradually decreases, and the coating range expands when viewed from the direction along the third axis Z. More specifically, the central portion of the wetted and spread adhesive 50 on the surface of the rough top plate 40 has a thickness from the surface to a position farther from the surface than the peak TP. On the other hand, the edge portion of the wetting and spreading adhesive 50 does not have a thickness up to the peak TP on the surface of the roughened top plate 40. Furthermore, one of the two adhesive 50 portions becomes the first adhesive portion 51, and the other becomes the second adhesive portion 52.

[0056] Next, the configuration step S14 is performed. In configuration step S14, the first flange portion 12 and the second flange portion 13 of the core 10C are configured such that their surfaces face the surfaces of the top plate 40 coated with adhesive 50. Thus, a portion of the adhesive 50 applied to the two locations on the top plate 40, having a thickness extending from the surface to a position farther from the surface than the peak TP, contacts the first flange portion 12 and the second flange portion 13. That is, the area of ​​adhesive 50 applied to the surface of the top plate 40 in the coating step S13 is larger than the combined area of ​​the adhesive 50 contacting the first flange portion 12 and the second flange portion 13 in the configuration step S14.

[0057] Furthermore, the portion of the wire 30 that extends separately from the peripheral surface 11F also contacts the area of ​​the top plate 40 coated with adhesive 50. On the other hand, the first flange portion 12 and the second flange portion 13 are brought into contact with the adhesive 50 so that the adhesive 50 does not contact the core portion 11. More specifically, the thickness of the wetted and spread adhesive 50 is smaller than the amount of protrusion from the peripheral surface 11F of the core portion 11 in the third positive direction Z1. In addition, the edge portion of the wetted and spread adhesive 50 that does not have a thickness up to the peak TP on the surface of the roughened top plate 40 does not contact the core 10C.

[0058] Next, a curing process S15 is performed. In the curing process S15, the core 10C and the top plate 40, which are configured via adhesive 50, are subjected to heat treatment. As a result, adhesive 50 is cured. Consequently, the top plate 40 is connected to the core 10C via adhesive 50. Specifically, a first bonding portion 51 located on the top plate 40 at a position closer to the center along the first axis X and towards the first positive direction X1, and a second bonding portion 52 located on the top plate 40 at a position closer to the center along the first axis X and towards the first negative direction X2, are cured. In the first bonding portion 51, the first range A11 on the surface of the top plate 40 where adhesive 50 is present is larger than the second range A21 on the surface of the first flange portion 12. In the second bonding portion 52, the third range A12 on the surface of the top plate 40 where adhesive 50 is present is larger than the fourth range A22 on the surface of the second flange portion 13. That is, the first existence range A1 is larger than the second existence range A2. Thus, the coil component 10 is completed.

[0059] (The role of the implementation method)

[0060] When the coil component 10 is mounted on the substrate, the surface of the top plate 40 in the third positive direction Z1 is held by a retainer and mounted on the substrate. At this time, a load in the third negative direction Z2 is applied to the top plate 40. When such a load is applied, assuming that the top plate 40 is relatively thin, there is a concern that the top plate 40 alone may not be able to withstand the load and may break.

[0061] According to the above embodiment, the range that combines the first range A11 and the third range A12, i.e., the first existence range A1, is larger than the second existence range A2 that combines the second range A21 and the fourth range A22. Therefore, the portion of the adhesive 50 in the first existence range A1 that is opposite to the second existence range A2 serves to fix the first flange portion 12 and the second flange portion 13 to the top plate 40. On the other hand, in the range of the first existence range A1 that is not opposite to the second existence range A2, the adhesive 50 wets and spreads on the surface of the top plate 40 more than in the second existence range A2, thus creating a range of adhesive 50 that exists in addition to the thickness of the top plate 40.

[0062] (Effects of the implementation method)

[0063] (1) According to the above embodiment, the portion of the adhesive 50 that wets and spreads on the surface of the top plate 40 functions as a protective layer for the top plate 40. Furthermore, the first presence range A1 of the adhesive 50 on the surface of the top plate 40 is larger than the second presence range A2, which combines the range of the adhesive 50 on the surface of the first flange 12 and the range of the adhesive 50 on the surface of the second flange 13. Therefore, the adhesive 50 extends on the surface of the top plate 40 beyond the range required for fixing the first flange 12 and the second flange 13 to the top plate 40. Thus, the large area of ​​adhesive 50 on the surface of the top plate 40 allows it to easily withstand loads relative to the top plate 40 along the third axis Z, corresponding to the amount of adhesive 50 present. As a result, even when a load is applied to the top plate 40, breakage can be suppressed.

[0064] Furthermore, the adhesive 50 does not contact the core portion 11. If the adhesive 50 were to reach the core portion 11, there would be a concern that a large portion of the wire 30 would be in contact with the adhesive 50, leading to deterioration of the coating on the wire 30. Therefore, short circuits between adjacent wires due to such deterioration can be avoided. Additionally, the amount of adhesive 50 is not excessive compared to the minimum amount required to bond the first flange portion 12 and the second flange portion 13 to the top plate 40.

[0065] (2) According to the above embodiment, when viewed from the direction along the third axis Z, the surface of the core portion 11 opposite to the top plate 40 overlaps with a portion of the first range A11 and a portion of the third range A12. That is, a portion of the first range A1 is opposite to the core portion 11. The core portion 11 is located at the center of the coil member 10 in the direction along the second axis Y. Therefore, by reinforcing the top plate 40 with the adhesive 50, the top plate 40 can withstand the load even when a load is applied to the top plate 40 when the coil member 10 is mounted on the substrate.

[0066] (3) According to the above embodiment, the size of the first existence range A1 is 1.1 times or more the size of the second existence range A2. If it is 1.1 times or more, then the area of ​​the first existence range A1 is sufficient to strengthen the area of ​​the top plate 40.

[0067] (4) According to the above embodiment, the unfolded area ratio Sdr of the surface of the top plate 40 is 0.15 or more and 0.50 or less. Therefore, when the adhesive 50 is applied to the surface of the top plate 40, the adhesive 50 can easily wet and spread between the fine protrusions and depressions of the top plate 40. Therefore, even without using a special method as the application method of the adhesive 50, it is possible to apply the adhesive 50 to a large area of ​​the surface of the top plate 40.

[0068] (5) According to the above embodiment, the unfolded area ratio Sdr of the surface of the top plate 40 is greater than the unfolded area ratio Sdr of the surfaces of the first flange portion 12 and the second flange portion 13. Therefore, the adhesive 50 is more easily wetted and spread on the surface of the top plate 40 than on the surfaces of the first flange portion 12 and the second flange portion 13. As a result, the range of wetting and spreading of the adhesive 50 on the surface of the top plate 40 is larger than the range of wetting and spreading of the adhesive 50 on the surfaces of the first flange portion 12 and the second flange portion 13.

[0069] <Other Implementation Methods>

[0070] The above-described embodiments can be modified as follows. The above-described embodiments and the following modifications can be combined and implemented within the scope of technical inconsistency.

[0071] • In the above embodiments, the shape of the core portion 11 is not limited to the examples of the above embodiments. For example, it may be cylindrical or a polygonal prism other than a tetrahedral prism.

[0072] In the above embodiment, multiple wires 30 may also be wound around the core portion 11. Furthermore, the number of terminal electrodes can be appropriately adjusted to match the number of wires 30.

[0073] • In the above embodiments, a portion of the wire 30 may not be in contact with the adhesive 50.

[0074] • In the above embodiments, the shape of the top plate 40 is not limited to the examples of the above embodiments. As long as it is at least mounted on the first flange portion 12 and the second flange portion 13, for example, a protrusion may be provided on the surface of the top plate 40 in the third negative direction Z2.

[0075] • In the above embodiment, the first existence range A1 may not exist in the portion opposite to the core portion 11. For example, the first range A11 may exist only in the portion opposite to the first flange portion 12, and the second range A21 may exist only in a portion of the surface of the first flange portion 12 facing the third positive direction Z1.

[0076] In the above embodiment, the first range A11 and the third range A12 are separate, but they can also be in contact, forming a first existing range A1. Alternatively, the first existing range A1 can also be composed of three or more ranges.

[0077] In the above embodiment, the adhesive 50 may also consist entirely of the film thickness portion. For example, the entire film thickness portion may be formed by applying a corresponding amount of adhesive 50 to the entire surface of the top plate 40 facing the third negative direction Z2. Even in this case, the adhesive 50 only needs not to contact the core portion 11.

[0078] In the above embodiments, the unfolded area ratio Sdr of the top plate 40 and the unfolded area ratio Sdr of the core 10C are not limited to the examples of the above embodiments. The unfolded area ratio Sdr of the top plate 40 may be less than 0.15 or greater than 0.50. In addition, the unfolded area ratio Sdr of the top plate 40 may be less than or equal to the unfolded area ratio Sdr of the core 10C. In this case, in order to widely wet and spread the adhesive 50 on the surface of the top plate 40 facing the third negative direction Z2, it is sufficient to first apply the adhesive 50 to the top plate 40. Alternatively, after placing the adhesive 50 on the top plate 40, the adhesive 50 may be applied using a jig or by spin coating or other methods.

[0079] In the above embodiment, the size of the first existence range A1 may also be less than 1.1 times the size of the second existence range A2. In the coating process S13, as long as deviation is not likely to occur in the coating range of the adhesive 50, it is highly likely that the size of the first existence range A1 is greater than the size of the second existence range A2, even if the size of the first existence range A1 is less than 1.1 times the size of the second existence range A2.

[0080] In the above embodiment, the adhesive 50 is a thermosetting adhesive 50, but the type of adhesive 50 can be appropriately changed. The adhesive 50 may also be composed solely of resin, or an inorganic filler such as a silica filler may be added to the resin. Furthermore, when the adhesive 50 contains an inorganic filler, the inorganic filler is likely to exist only in the film thickness portion.

[0081] • In the coating step S13 of the above-described manufacturing method, the adhesive 50 is not applied to the first flange portion 12 and the second flange portion 13, but the adhesive 50 may also be applied to the surfaces of the first flange portion 12 and the second flange portion 13.

[0082] In addition, in the coating process S13, in order to wet and spread the adhesive 50 on the surface of the top plate 40, in addition to waiting for a specified time to pass, a material with better wettability can be used as the material of the top plate 40, or a highly viscous adhesive 50 can be used.

Claims

1. A coil component, wherein, have: The core has a core portion, a first flange portion, and a second flange portion. The core portion has a central axis. The first flange portion is connected to a first end of the core portion along the central axis and protrudes from the circumference of the core portion radially outward about the central axis. The second flange portion is connected to a second end of the core portion on the opposite side of the first end and protrudes further radially outward about the central axis than the circumference of the core portion. The wire has a portion that extends in a spiral shape on the circumferential surface of the core portion about the central axis as the axis of rotation; as well as The top plate extends longer than the core in the direction along the central axis and is connected to the first flange and the second flange via adhesive. The adhesive does not come into contact with the core portion. When the area on the surface of the top plate where the adhesive is present is defined as the first presence range, and the area combining the area on the surface of the first flange and the area on the surface of the second flange is defined as the second presence range,... The first existence range is larger than the second existence range. A portion of the first existing range is opposite to the core portion. Within the first range of presence, the adhesive has a thick portion and a thin portion. On the surface of the top plate, peaks and valleys are formed due to surface roughness. The film thickness portion is the portion on the surface of the top plate that has a thickness extending from the surface to a position farther from the surface than the peak. The thin film portion is the part on the surface of the top plate that spreads out due to wetting by the adhesive and therefore does not have a thickness up to the peak. The thin portion of the film is opposite to the core portion.

2. The coil component according to claim 1, wherein, The size of the first existence range is more than 1.1 times the size of the second existence range.

3. The coil component according to claim 1 or 2, wherein, The unfolded area ratio of the surface of the top plate is greater than 0.15 and less than 0.

50.

4. The coil component according to claim 1 or 2, wherein, The unfolded area ratio of the surface of the top plate is greater than the unfolded area ratio of the surfaces of the first flange and the second flange.

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