Coil component

Abstract

The present invention relates to a coil component. A protrusion (21) is provided on a lower main surface (15) of a top plate (14), and a recess (22) that houses the protrusion (21) is provided on a top surface (9) of a flange portion (5) provided in a core (2). The protrusion (21) is, for example, a conical frustum, and a cavity formed by the recess (22) has a conical inner peripheral surface. An outer surface of the protrusion (21) and a wall surface that defines the recess (22) provide guide surfaces that guide the protrusion (21) into the recess (22), and a first abutting portion (25) and a second abutting portion (26) that abut against each other in a state in which the recess (22) houses the protrusion (21) are provided. The mutual abutment of the first abutting portion (25) and the second abutting portion (26) defines a terminal end of insertion of the protrusion (21) into the recess (22) in a state in which a gap (GP) is formed between the lower main surface (15) of the top plate (14) and the top surface (9) of the flange portion (5), and alignment of the top plate (14) with respect to the core (2) is achieved.

Description

Technical Field

[0001] The present invention relates to a coil component comprising: a core having a core portion on which wire is wound and a first flange portion and a second flange portion disposed at each end of the core portion; and a top plate fixed to the core in a manner spanning between the first flange portion and the second flange portion, particularly relating to the construction of the joint portion of the core and the top plate. Background Technology

[0002] For example, Japanese Patent Application Publication No. 2011-96815 (Patent Document 1) describes a coil component comprising: a core having a core portion on which wire is wound and a first flange portion and a second flange portion disposed at each end of the core portion; and a top plate being bonded and fixed to the core in a state spanning between the first flange portion and the second flange portion.

[0003] The first flange portion and the second flange portion each have a bottom surface facing the mounting substrate side during installation, a top surface opposite the bottom surface, and an outer end surface connecting the bottom surface and the top surface and located opposite the core portion. The top plate is fixed to the core with its lower main surface facing the top surfaces of the first flange portion and the second flange portion respectively, by means of an adhesive.

[0004] At least one terminal electrode is provided in both the first flange portion and the second flange portion. The terminal electrode is configured to extend integrally from the bottom surface of each of the first flange portion and the second flange portion through the outer end face to the top surface.

[0005] Each end of the wire wound around the core is connected to a terminal electrode, but the connection portion between the wire end and the terminal electrode is located on the top surface of the first flange and the second flange, respectively. Therefore, the top plate is positioned at a predetermined distance from the top surfaces of the first and second flanges, thus creating a magnetic gap between the flanges and the top plate. This magnetic gap makes magnetic saturation less likely to occur, contributing to improved DC superposition characteristics.

[0006] Patent Document 1: Japanese Patent Application Publication No. 2011-96815

[0007] In recent years, the requirements for high current and high inductance have increased in coil components. Therefore, it is necessary to obtain high inductance and improve DC superposition characteristics.

[0008] Patent document 1 describes a structure that improves DC superposition characteristics by setting a gap between the top plate and the core.

[0009] On the other hand, as described in Patent Document 1, in a coil assembly comprising a top plate and a core, the top plate and the core are positioned opposite each other in a predetermined relationship, thereby obtaining the desired inductance value and DC superposition characteristics. In other words, the positional relationship between the top plate and the core is crucial to obtaining the desired characteristics. Therefore, during the manufacturing stage of the coil assembly, it is necessary to assemble the top plate and the core in a stable positional relationship. However, while Patent Document 1 describes the gap, it does not describe the positional control of the top plate and the core at points other than the gap. Summary of the Invention

[0010] Therefore, the object of the present invention is to provide a structure for a coil component that can form a gap between the top plate and the core and achieve a stable positional relationship.

[0011] The present invention relates to a coil component comprising: a core having a core portion, a first flange portion, and a second flange portion extending along an axial direction, the first flange portion and the second flange portion being respectively disposed at a first end and a second end of the core portion opposite to each other in the axial direction; a top plate having a lower main surface and an upper main surface facing opposite directions; at least one wire wound around the core portion; and a first terminal electrode and a second terminal electrode being electrically connected to each end of the wire and respectively disposed at the first flange portion and the second flange portion.

[0012] The first flange portion and the second flange portion each have a bottom surface facing the mounting substrate side during installation and a top surface opposite the bottom surface. The top plate is fixed to the core by adhesive with its lower main surface facing the respective top surfaces of the first flange portion and the second flange portion.

[0013] The present invention is intended to solve the above-mentioned technical problems, and is characterized by having the following structure.

[0014] When one of the top surface and the lower main surface of at least one of the first flange portion and the second flange portion is used as the first surface and the other is used as the second surface, a protrusion is provided on the first surface and a recess for receiving the protrusion is provided on the second surface.

[0015] At least one of the outer surface of the protrusion and the wall surface defining the recess is provided with a guide surface capable of guiding the protrusion into the recess.

[0016] The outer surface of the protrusion and the wall surface defining the recess are respectively provided with a first abutting portion and a second abutting portion that abut against each other when the recess accommodates the protrusion. The abutting of these first abutting portions and second abutting portions is defined as the insertion terminal of the protrusion into the recess with a gap formed between the first surface and the second surface, thereby achieving positioning in the insertion direction and enabling alignment of the top plate relative to the core in at least one of the directions along the first surface and the second surface.

[0017] According to the present invention, due to the presence of the aforementioned guide surface, the protrusion is smoothly guided into the recess, resulting in the first abutment portion and the second abutment portion abutting against each other, thereby forming a gap between the top plate and the core, and achieving positioning of the top plate and the core in a predetermined direction. Therefore, during the manufacturing stage of the coil component, a gap can be formed between the top plate and the core, and a stable positional relationship can be achieved. Attached Figure Description

[0018] Figure 1 The following diagram shows the appearance of the coil component 1 according to the first embodiment of the present invention: (A) is a front view, and (B) is a left side view.

[0019] Figure 2 They represent Figure 1 The coil component 1 shown has a top plate 14 and a core 2. (A) is a bottom view of the top plate 14 and (B) is a top view of the core 2.

[0020] Figure 3 It is a schematic representation of what will Figure 2 The top plate 14 and the core 2 are fixed together by adhesive 17, along... Figure 2 An enlarged sectional view of line CC.

[0021] Figure 4 This is a diagram illustrating the second embodiment of the present invention, schematically showing the state in which the top plate 14 and the core 2 are fixed by adhesive 17, equivalent to... Figure 3 The image.

[0022] Figure 5 This diagram illustrates the third embodiment of the present invention, schematically showing the state in which the top plate 14 and the core 2 are fixed by adhesive 17, equivalent to... Figure 3 The image.

[0023] Figure 6 This diagram illustrates the fourth embodiment of the present invention, schematically showing the state in which the top plate 14 and the core 2 are fixed by adhesive 17, equivalent to... Figure 3 The image.

[0024] Figure 7 This diagram illustrates the fifth embodiment of the present invention, schematically showing the state in which the top plate 14 and the core 2 are fixed by adhesive 17, equivalent to... Figure 3 The image.

[0025] Figure 8 This is a diagram illustrating the sixth embodiment of the present invention, schematically showing the state in which the top plate 14 and the core 2 are fixed by adhesive 17, equivalent to... Figure 3 The image.

[0026] Figure 9 This diagram illustrates the seventh embodiment of the present invention, schematically showing the state in which the top plate 14 and the core 2 are fixed by adhesive 17, equivalent to... Figure 3 The image.

[0027] Figure 10 This is a diagram illustrating the eighth embodiment of the present invention, showing the top plate 14 and the core 2 respectively, corresponding to... Figure 2 The image.

[0028] Figure 11 This is a diagram illustrating the ninth embodiment of the present invention, showing the top plate 14 and the core 2 respectively, corresponding to... Figure 2 The image.

[0029] Figure 12 This is a diagram illustrating the tenth embodiment of the present invention, showing the top plate 14 and the core 2 respectively, corresponding to... Figure 2 The image.

[0030] Figure 13 This is a diagram illustrating the eleventh embodiment of the present invention, showing the top plate 14 and the core 2 respectively, corresponding to... Figure 2 The image.

[0031] Figure 14 This is a diagram illustrating the twelfth embodiment of the present invention, showing the top plate 14 and the core 2 respectively, corresponding to... Figure 2 The image.

[0032] Figure 15 This is a diagram illustrating the thirteenth embodiment of the present invention, showing the top plate 14 and the core 2 respectively, corresponding to... Figure 2 The image.

[0033] Figure 16 This is a diagram illustrating the fourteenth embodiment of the present invention, showing the top plate 14 and the core 2 respectively, corresponding to... Figure 2 The image.

[0034] Figure 17 This is a diagram illustrating the fifteenth embodiment of the present invention, showing the top plate 14 and the core 2 respectively, corresponding to... Figure 2 The image.

[0035] Figure 18 It is a schematic representation of what will Figure 17 The top plate 14 and the core 2 are fixed together by adhesive 17, along... Figure 17 An enlarged sectional view of line DD.

[0036] Explanation of reference numerals in the attached figures

[0037] 1…coil component; 2…core; 3…winding core; 5, 6…flange; 7, 8…bottom surface; 9, 10…top surface; 11, 12…terminal electrode; 13…wire; 14…top plate; 15…lower main surface; 16…upper main surface; 17…adhesive; 21…protrusion; 22…recess; 23…inward slope surface; 24…outward slope surface; 25…first abutment; 26…second abutment; 31…second protrusion; AX…axial direction; GP…gap. Detailed Implementation

[0038] Reference Figure 1 The outline of the coil component 1 according to the first embodiment of the present invention will be described.

[0039] like Figure 1 As shown, the coil component 1 includes a core 2 made of ferrite such as Ni-Zn ferrite, alumina, or resin containing metallic magnetic powder. The core 2 has a winding core portion 3 extending along the axial direction AX, and a first flange portion 5 and a second flange portion 6 respectively provided at a first end and a second end opposite to each other in the axial direction AX of the winding core portion 3. The cross-sectional shape of the winding core portion 3 is, for example, a quadrilateral shape, but it can also be a polygonal shape such as a hexagonal shape, a circular shape, an elliptical shape, or a shape obtained by combining them.

[0040] The first flange portion 5 and the second flange portion 6 each have a bottom surface 7 and 8 facing the mounting substrate (not shown) during installation, and a top surface 9 and 10 on the opposite side of each of the bottom surfaces 7 and 8.

[0041] A first terminal electrode 11 is provided on the bottom surface 7 of the first flange portion, and a second terminal electrode 12 is provided on the bottom surface 8 of the second flange portion 6. The terminal electrodes 11 and 12 are formed, for example, by impregnating or printing a conductive paste containing conductive metal powder such as Ag powder, then sintering them, and subsequently performing Cu, Ni, and Sn plating in sequence. Alternatively, the terminal electrodes 11 and 12 can also be provided by mounting terminal components made of conductive metal plates to the first flange portion 5 and the second flange portion 6.

[0042] At least one wire 13 is wound in the core portion 3. The wire 13 may have a center wire made of a highly conductive metal such as copper, silver, or gold, and an insulating film covering the center wire made of an electrically insulating resin such as polyamide-imide, polyurethane, or polyesterimide. The center wire has a diameter of, for example, 60 μm or more and 160 μm or less. One end of the wire 13 is connected to the first terminal electrode 11 on the bottom surface 7 side of the first flange portion 5, and the other end is similarly connected to the second terminal electrode 12 on the bottom surface 8 side of the second flange portion 6. The connection between the terminal electrodes 11 and 12 and the wire 13 is achieved, for example, by thermoforming, ultrasonic welding, or laser welding. The number of turns of the wire 13 on the core portion 3 can be arbitrarily selected according to the desired characteristics. The wire 13 may also be wound in multiple layers as needed.

[0043] The coil component 1 includes a top plate 14 spanning between the first flange portion 5 and the second flange portion 6. The top plate 14 has a lower main surface 15 and an upper main surface 16 facing opposite directions. The top plate 14 is made of, for example, ferrite, alumina, or resin containing metallic magnetic powder. Furthermore, when both the core 2 and the top plate 14 are made of magnetic materials, the top plate 14 and the core 2 cooperate to form a closed magnetic circuit.

[0044] The top plate 14 is fixed to the core 2 with its lower main surface 15 facing the top surface 9 of the first flange portion 5 and the top surface 10 of the second flange portion 6 through the adhesive 17. The adhesive 17 includes, for example, a thermosetting resin such as an epoxy resin. To improve thermal shock resistance, inorganic fillers such as silica fillers may be added to the adhesive 17.

[0045] Taking coil component 1 as an example, its length (axial direction AX) is 2.0 mm, its width (direction perpendicular to axial direction AX and parallel to the mounting surface) is 1.2 mm, and its height (direction perpendicular to both axial direction AX and width) is 1.6 mm. Further miniaturization is possible, such that the length is 1.6 mm, the width is 0.8 mm, and the height is 1.3 mm. Due to the precision requirements of the assembly equipment, the smaller the coil component 1, the better the effect of the invention. Furthermore, the planar dimensions of the top plate 14 are generally equal to the planar dimensions of the core 2. Figure 1 and Figure 2 The diagram also illustrates this, but the planar dimensions of the top plate 14 can also be larger than those of the core 2. When the planar dimensions of the top plate 14 are larger than those of the core 2, magnetic flux can reliably pass through the top plate 14 even if their positions are slightly offset.

[0046] The coil component 1 is preferably manufactured as follows, for example.

[0047] First, core 2 and top plate 14 are prepared separately. To manufacture these core 2 and top plate 14 separately, ferrite powder is stamped using a mold, and the resulting molded body is fired to obtain a sintered body that should become core 2 and top plate 14. Then, burrs are removed by tumbling the sintered body that corresponds to core 2 and top plate 14, respectively, to obtain core 2 and top plate 14. Although in Figure 1 The diagram is omitted, but the edges of the core 2 and the top plate 14 are chamfered and have small rounded corners.

[0048] Next, in order to provide terminal electrodes 11 and 12 on the core 2, conductive paste containing Ag is applied to the bottom surfaces 7 and 8 of the first flange portion 5 and the second flange portion 6, and sintered. Then, Cu, Ni and Sn are plated sequentially by electrolytic barrel plating.

[0049] Next, for example, the wire 13 is wound onto the core portion 3 of the core 2 through a nozzle, and one end of the wire 13 is connected to the first terminal electrode 11 and the second terminal electrode 12, respectively. Here, the connection between the wire 13 and the terminal electrodes 11 and 12 is achieved, for example, by thermoforming based on a heating element. The excess portion of the wire 13 connected to the terminal electrodes 11 and 12 is cut off by a cutter.

[0050] Next, the top plate 14 is disposed on the core 2 via adhesive 17, and the top plate 14 and the core 2 are fixed to each other.

[0051] As described above, complete coil component 1.

[0052] The coil component 1 has the following features. (Refer to...) Figure 2 and Figure 3 Please provide an explanation.

[0053] A protrusion 21 is provided on the main surface 15 below the top plate 14. On the other hand, a recess 22 for receiving the protrusion 21 is provided on the first top surface 9 of the first flange portion 5 and the second top surface 10 of the second flange portion 6 of the core body 2. Figure 2 (A) indicates top plate 14. Figure 2 (B) represents core 2, but when the top plate 14 and core 2 are combined, the top plate 14... Figure 2 The surface and core 2 shown in (A) Figure 2 The surfaces shown in (B) are arranged to be opposite each other. In the combined state of the top plate 14 and the core 2, Figure 2 (A) shows the top plate 14 around Figure 2 The rotation axis extending 180 degrees along the left-right direction is configured in a posture. Figure 2 On core 2 as shown in (B).

[0054] In this embodiment, protrusions 21 are distributed in a dotted pattern at multiple locations on the lower main surface 15 of the top plate 14, and recesses 22 are distributed in a dotted pattern at multiple locations on the first top surface 9 of the first flange portion 5 and the second top surface 10 of the second flange portion 6. More specifically, on each of the first top surface 9 of the first flange portion 5 and the second top surface 10 of the second flange portion 6 of the core 2, two recesses 22 are arranged side by side along the width direction, and on each of the regions on the lower main surface 15 of the top plate 14 that are opposite to the first top surface 9 of the first flange portion 5 and opposite to the second top surface 10 of the second flange portion 6, two protrusions 21 are arranged side by side along the width direction.

[0055] The protrusion 21 has an outer peripheral surface that forms at least a portion of a cone, and the recess 22 has a conical inner peripheral surface. Preferably, the end of the protrusion 21 is chamfered to form a frustum shape. This makes it less likely that a notch will be formed at the end of the protrusion 21 during the manufacturing of the coil component 1. For example, the height H of the frustum-shaped protrusion 21 is 25 μm or more and 65 μm or less.

[0056] The outer surface of the protrusion 21 and the wall surface of the recess 22 function as guide surfaces that can guide the protrusion 21 into the recess 22. For example, in Figure 3 When viewed in the cross-section shown, the protrusion 21 has an end portion smaller than the opening of the recess 22 in dimensions measured along the lower main surface 15 of the top plate 14. On the other hand, the recess 22 has an inwardly sloped surface 23 that decreases in size as it approaches the bottom from the opening in dimensions measured along the top surfaces 9 and 10 of the flange portions 5 and 6. This inwardly sloped surface 23 provides the aforementioned guiding surface. Additionally, for example in… Figure 3 When viewed in the cross-section shown, the protrusion 21 has an outwardly sloping surface 24 that, in dimensions measured along the lower main surface 15 of the top plate 14, becomes larger as it approaches the base, the portion that contacts the lower main surface 15. This outwardly sloping surface 24 provides the aforementioned guiding surface.

[0057] The outer surface of the protrusion 21 and the wall surface of the recess 22 are respectively provided with a first abutting portion 25 and a second abutting portion 26 that abut against each other when the recess 22 accommodates the protrusion 21. More specifically, the first abutting portion 25 is provided at the ridge where the chamfered end face of the protrusion 21 intersects with the outer peripheral surface, and a portion of the inward slope surface 23 of the recess 22 provides the second abutting portion 26.

[0058] exist Figure 3When viewed in the cross-section shown, the angle of the outward slope surface 24 of the outer peripheral surface of the protrusion 21 relative to the extending direction of the lower main surface 15 of the top plate 14 is larger than the angle of the inward slope surface 23 of the inner peripheral surface of the recess 22 relative to the extending direction of the lower main surface 15 of the top plate 14. With this structure, the inner peripheral surface (inward slope surface 23) of the recess 22 can be positioned within a relatively large range, and the positioning effect is easily achieved even if the positions of the protrusion 21 and the recess 22 are significantly offset.

[0059] The mutual contact of these first abutting portions 25 and second abutting portions 26 is defined such that a gap GP is formed between the lower main surface 15 of the top plate 14 and the top surfaces 9 and 10 of the first flange portion 5 and the second flange portion 6 of the core body 2, and the insertion terminal of the protrusion 21 into the recess 22 is achieved, thereby realizing the positioning in the insertion direction and enabling the alignment of the top plate 14 relative to the core body 2 in at least one of the directions along the lower main surface 15 and the top surfaces 9 and 10.

[0060] More specifically, even if the opposing positions of the protrusion 21 and the recess 22 are offset, since at least one of the outer surface of the protrusion 21 and the wall surface of the recess 22 is provided with a guide surface that can guide the protrusion 21 into the recess 22, the opposing positions of the protrusion 21 and the recess 22 can be aligned by using the guide surface.

[0061] As described above, the direction for positioning or alignment is at least one of the directions along the lower main surface 15 and the top surfaces 9 and 10, but preferably the length direction (axial direction AX) or width direction of the coil component 1. Figure 1 (B) Positioning in the left-right direction is preferred, but positioning in the length direction is even more desirable. This is because, since the length direction is also the direction of the magnetic flux in the coil component 1, the inductance value changes significantly when the core 2 and the top plate 14 are offset in the length direction. Furthermore, in the case of the protrusion 21 and the recess 22 shown in the figure, positioning of the top plate 14 relative to the core 2 in all directions along the lower main surface 15 and the top surfaces 9 and 10 is possible.

[0062] In at least a portion of the aforementioned gap GP, adhesive 17 is preferably applied over the entire area, thereby fixing the top plate 14 and the core 2 via adhesive 17.

[0063] In addition, Figure 3In the configuration shown, the first abutment portion 25 and the second abutment portion 26 are provided by the end of the protrusion 21 and the inner peripheral surface of the recess 22, so the end of the protrusion 21 does not contact the bottom surface of the recess 22. That is, only the edge portion of the periphery of the end of the protrusion 21 contacts the inner peripheral surface of the recess 22, so the resin that will become the adhesive 17 can be injected between the protrusion 21 and the recess 22, thereby improving the connection strength between the core 2 and the top plate 14.

[0064] In short, the following structure is achieved by making the protrusion 21 and the recess 22 into the shapes described above.

[0065] At least one of the outer surface of the protrusion 21 and the wall surface of the recess 22 is provided with a guide surface capable of guiding the protrusion 21 into the recess 22. The outer surface of the protrusion 21 and the wall surface of the recess 22 are respectively provided with a first abutting portion 25 and a second abutting portion 26 that abut against each other when the recess 22 accommodates the protrusion 21. The abutting between the first abutting portion 25 and the second abutting portion 26 is defined as the insertion terminal of the protrusion 21 into the recess 22 when a gap GP is formed between the lower main surface 15 of the top plate 14 and the top surfaces 9 and 10 of the flanges 5 and 6, thereby achieving positioning in the insertion direction and enabling alignment in at least one of the directions of the lower main surface 15 of the top plate 14 and the top surfaces 9 and 10 of the flanges 5 and 6.

[0066] Next, refer to Figure 4 The following figures will describe other embodiments of the invention. Figure 4 In the accompanying diagrams, regarding... Figure 2 or Figure 3 Elements shown that correspond to each other are labeled with the same reference numerals, and repeated descriptions are omitted. Descriptions of other embodiments will only be related to... Figure 2 and Figure 3 The parts or features that are substantially different from those in the illustrated implementation are taken as objects.

[0067] Reference Figure 4 In the second embodiment, the recess 22 has a conical inner circumferential surface, but the cavity formed by the recess 22 is frustoconical. This makes it less likely for the mold forming the recess 22 to develop gaps.

[0068] exist Figure 5 In the third embodiment shown, with Figure 4 The structure shown is the same, with the cavity formed by the recess 22 being frustoconical. On the other hand, the protrusion 21 is also frustoconical, but the inclination of its outer circumferential surface is equal to the inclination of the inner circumferential surface of the recess 22. According to this structure, the stability of the bonding state between the top plate 14 and the core 2 can be improved.

[0069] exist Figure 6In the fourth embodiment shown, the cavity formed by the recess 22 is frustum-shaped. On the other hand, the protrusion 21 has a cylindrical portion 27 and a frustum-shaped portion 28, with the cylindrical portion 27 located on the base side and the frustum-shaped portion 28 located on the end side. The inclination of the outer peripheral surface of the frustum-shaped portion 28 of the protrusion 21 is equal to the inclination of the inner peripheral surface of the recess 22.

[0070] exist Figure 7 In the fifth embodiment shown, the protrusion 21 is frustoconical. On the other hand, the cavity formed by the recess 22 is cylindrical. In one of the cross-sections that serves as the direction for achieving positioning, for example along... Figure 7 When viewed in cross-section, the protrusion 21 has an outwardly sloping surface 24 that increases in size from the end toward the base in dimensions measured along the lower main surface 15 of the top plate 14. This outwardly sloping surface 24 provides a guide surface that can guide the protrusion 21 into the recess 22. In addition, in the state where the recess 22 receives the protrusion 21, the first abutting portion 25 and the second abutting portion 26 abut against each other are provided by the outwardly sloping surface 24 of the protrusion 21, and the second abutting portion 26 is provided by the edge portion defining the opening of the recess 22.

[0071] according to Figure 7 The structure shown expands the space between the protrusion 21 and the core 2, thus allowing sufficient application of the adhesive 17, thereby enabling a firm bond between the core 2 and the top plate 14.

[0072] In addition, as Figure 7 In a variation of the fifth embodiment shown, the protrusion 21 may be conical and the recess 22 may be deeper so that the end of the protrusion 21 does not contact the bottom of the recess 22.

[0073] Figure 8 The sixth embodiment shown is the same as Figure 7 Compared to the structure shown, the shape of the recess 22 is different. Figure 8 In this recess 22, the edge of the opening is chamfered to form an inwardly sloped surface 23. The inwardly sloped surface 23, together with the outwardly sloped surface 24 provided by the outer peripheral surface of the protrusion 21, provides a guiding surface that guides the protrusion 21 into the recess 22. Furthermore, in the state where the recess 22 accommodates the protrusion 21, the first abutting portion 25 and the second abutting portion 26 abut against each other are provided by the outwardly sloped surface 24 of the protrusion 21, and by the inwardly sloped surface 23 along the edge of the opening of the recess 22. In this case, the first abutting portion 25 and the second abutting portion 26 contact each other with a relatively large contact area.

[0074] exist Figure 9 In the seventh embodiment shown, in one of the cross sections that serves as the direction for achieving positioning, for example along... Figure 9When viewed in cross-section, the recess 22 has a concave bottom surface 29, and the protrusion 21 abuts against the concave bottom surface 29 only at its end. In the state where the recess 22 accommodates the protrusion 21, the first abutting portion 25 and the second abutting portion 26 abut against each other are provided by the end of the protrusion 21 and the second abutting portion 26 by the concave bottom surface 29. Furthermore, the outer surface of the protrusion 21 and the wall surface defining the recess 22 provide guide surfaces that can guide the protrusion 21 into the recess 22.

[0075] exist Figure 9 In the structure shown, a magnetic circuit is formed through the contact between the core 2 and the top plate 14, which affects the DC superposition characteristics. Therefore, according to Figure 9 In the seventh embodiment shown, by changing the shape of the concave bottom surface 29, the contact area between the core 2 and the top plate 14 can be adjusted, thus making it easy to adjust the influence on the DC superposition characteristics.

[0076] Figure 10 These respectively represent the top plate 14 and the core 2 used in the eighth embodiment, equivalent to Figure 2 The image.

[0077] exist Figure 10 In the eighth embodiment shown, the protrusion 21 provided on the lower main surface 15 of the top plate 14 has a pyramidal outer peripheral surface, and the recess 22 provided on the top surfaces 9 and 10 of the flange portions 5 and 6 and receiving the protrusion 21 has a pyramidal inner peripheral surface. Preferably, the end of the protrusion 21 is chamfered to form a frustum shape. This makes it less likely that a notch will be formed at the end of the protrusion 21 during the manufacturing of the coil component 1.

[0078] Figure 10 The eighth embodiment shown has the following significance: the planar shape of the dotted protrusions 21 and recesses 22 can be deformed in various ways.

[0079] Figure 11 These respectively represent the top plate 14 and the core 2 used in the ninth embodiment, equivalent to Figure 2 The image.

[0080] exist Figure 11 In the ninth embodiment shown, protrusions 21 are provided on the top surfaces 9 and 10 of the flange portions 5 and 6 of the core 2, and recesses 22 are provided on the lower main surface 15 of the top plate 14. Figure 11 The structure shown indicates that the positional relationship between the protrusion 21 and the recess 22 can also be reversed.

[0081] Furthermore, considering the ease of manufacturing the core 2 and the top plate 14, and more specifically, the ease of molding and the simplification of the mold shape, it is preferable to provide a protrusion 21 on the side of the top plate 14, which has a simpler shape. However, as Figure 11As shown, when a recess 22 is provided on the top plate 14 side, when the top plate 14 is combined with the core 2, the adhesive can be further retained on the top plate 14 side with the recess 22, so that the adhesive is less likely to adhere to the wire along the core 2.

[0082] As Figure 11 In a variation of the ninth embodiment shown, some of the protrusions 21 may be disposed on the top plate 14 side, and the remainder on the core 2 side, with the recesses 22 disposed separately on the core 2 side and the top plate 14 side to correspond to these protrusions 21.

[0083] exist Figure 12 In the tenth embodiment shown, the protrusion 21 extends linearly on the lower main surface 15 of the top plate 14, and the recess 22 accommodating the protrusion 21 extends linearly on the top surfaces 9 and 10 of the flanges 5 and 6 of the core 2. The protrusion 21 and the recess 22 extend along the width direction of the coil component. The cross-sectional shapes of the protrusion 21 and the recess 22 are not shown, but they can be similar to those described above. Figures 3 to 9 The cross-sectional shapes shown are the same.

[0084] exist Figure 13 In the eleventh embodiment shown, with Figure 12 The situation is similar in the embodiment shown. The protrusion 21 extends linearly on the main surface 15 below the top plate 14, and the recess 22 that accommodates the protrusion 21 extends linearly on the top surfaces 9 and 10 of the flange portions 5 and 6 of the core, but the protrusion 21 and the recess 22 extend along the length direction of the coil component. Figure 13 The cross-sectional shapes of the protrusion 21 and the recess 22 are not shown in the figure, but they can be made using the same methods as described above. Figures 3 to 9 The cross-sectional shapes shown are the same.

[0085] exist Figure 14 In the twelfth embodiment shown, the following are combined Figure 12 The embodiments shown and Figure 13 The eleventh embodiment shown. Specifically, on the lower main surface 15 of the top plate 14, there are protrusions 21a extending linearly in the width direction of the coil component and protrusions 21b extending linearly in the length direction of the coil component. On the top surfaces 9 and 10 of the flange portions 5 and 6 of the core body 2, there are recesses 22a extending linearly in the width direction of the coil component and recesses 22b extending linearly in the length direction of the coil component, corresponding to these protrusions 21a and 21b respectively. Figure 14 The cross-sectional shapes of the protrusion 21 and the recess 22 are not shown in the figure, but they can be made using the same methods as described above. Figures 3 to 9 The cross-sectional shapes shown are the same.

[0086] exist Figure 15 In the thirteenth embodiment shown, the top plate 14 side adopts... Figure 2 (A) shows the shape of the top plate 14 side, and the core 2 side adopts Figure 12 (B) shows the shape of the core on two sides. This embodiment is significant in that, in order to achieve the positioning function, and more specifically, to provide the guide surface and the first and second abutments, a combination of dot-shaped protrusions 21 and straight recesses 22 can be used.

[0087] Figure 16 The fourteenth embodiment shown can solve the problem in Figure 12 The problems that may be encountered in the illustrated implementation are as follows. Figure 12 As shown in the embodiment, when the protrusion 21 reaches the periphery of the lower main surface 15 of the top plate 14, and the recess 22 reaches the periphery of the respective top surfaces 9 and 10 of the flange portions 5 and 6, adhesive 17 is filled (see Figure 17). Figure 3 The space (etc.) has a relatively large opening on the outer surface of the coil component. Therefore, it is possible for a relatively large amount of adhesive 17 to overflow.

[0088] To address the aforementioned issues, Figure 16 In the fourteenth embodiment shown, the protrusion 21 is located at the periphery of the lower main surface 15 of the top plate 14, and the recess 22 is located at the periphery of the top surfaces 9 and 10 of the flanges 5 and 6, respectively.

[0089] In reference Figures 1 to 11 In the first to ninth embodiments described, each of the protrusions 21 and recesses 22 has multiple sets, more specifically two sets, existing in the region opposite the top surface 9 of the first flange portion 5 on the lower main surface 15 of the top plate 14, and in the region opposite the top surface 10 of the second flange portion 6 on the lower main surface 15 of the top plate 14. Furthermore, the multiple sets of protrusions 21 and recesses 22 are arranged symmetrically with respect to the surface containing the central axis of the core portion 3 and orthogonal to the lower main surface 15 of the top plate 14. Additionally, the multiple sets of protrusions 21 and recesses 22 are arranged symmetrically with respect to the surface orthogonal to the central axis of the core portion 3 and passing through the midpoint of the axial direction AX of the core portion 3.

[0090] According to the above structure, it has the advantage of being able to stably maintain the posture of the top plate 14 relative to the core 2. However, in this invention, the selection of the number and arrangement of the protrusions 21 and the recesses 22 should not be conditional on bringing such advantages.

[0091] In addition, in order to stably maintain the posture of the top plate 14 relative to the core 2, it is also possible to... Figure 17 and Figure 18 As shown in the fifteenth embodiment, the structure other than the group of protrusions 21 and recesses 22 is combined with the structure of the group of protrusions 21 and recesses 22.

[0092] exist Figure 17 and Figure 18 In the fifteenth embodiment shown, in addition to the structure of the protrusion 21 and the recess 22, a second protrusion 31 is provided opposite to the portion of the top surface 9 and 10 of the flange portions 5 and 6 that does not have a recess. The second protrusion 31 abuts against the top surface 9 and 10 of the flange portions 5 and 6 when a gap GP is formed between the lower main surface 15 of the top plate 14 and the top surface 9 and 10 of the flange portions 5 and 6.

[0093] In the above embodiment, the combination of protrusion 21 and recess 22 enables the top plate 14 to be positioned relative to the core 2 in the direction along the lower main surface 15 of the top plate 14 and the top surfaces 9 and 10 of the flanges 5 and 6. Furthermore, the combination of protrusion 21 and recess 22, along with the second protrusion 31, enables a gap to be formed between the lower main surface 15 of the top plate 14 and the top surfaces 9 and 10 of the flanges 5 and 6.

[0094] In the embodiments described above, such as Figure 1 As shown and as described above, one end of the wire 13 is connected to the first terminal electrode 11 on the bottom surface 7 side of the first flange portion 5, and the other end is similarly connected to the second terminal electrode 12 on the bottom surface 8 side of the second flange portion 6. With this structure, it is not necessary to place the end of the wire 13 at the junction of the core 2 and the top plate 14, so the positions of the protrusion 21 and the recess 22 can be freely selected.

[0095] The present invention has been described above in connection with the illustrated embodiments, but various other modifications are possible within the scope of the present invention.

[0096] For example, in addition to being a single coil as shown in the illustrated embodiment, the coil component involved in this invention can also be configured as a common-mode choke coil, a transformer, or a balun. Therefore, the number of wires can be varied depending on the function of the coil component, and correspondingly, the number of terminal electrodes provided on each flange can also be varied.

[0097] Furthermore, when constructing the coil component involved in this invention, partial substitutions or combinations of structures can be made between the different embodiments described in this specification.

Claims

1. A coil component, wherein, have: The core has a core portion, a first flange portion, and a second flange portion extending along the axial direction, wherein the first flange portion and the second flange portion are respectively disposed at a first end and a second end of the core portion opposite to each other in the axial direction; The top panel has a lower main surface and an upper main surface facing opposite directions to each other; At least one wire is wound around the core portion; as well as The first terminal electrode and the second terminal electrode are respectively provided for electrical connection to each end of the wire, and are respectively disposed on the first flange portion and the second flange portion. The first flange portion and the second flange portion each have a bottom surface facing the mounting substrate during installation, and a top surface on the opposite side of the bottom surface. The top plate is fixed to the core with its lower main surface facing the top surfaces of the first flange and the second flange, respectively, via adhesive. When one of the top surface and the lower main surface of at least one of the first flange portion and the second flange portion is designated as the first surface, and the other is designated as the second surface, a protrusion is provided on the first surface, and a recess is provided on the second surface to accommodate the protrusion. At least one of the outer surface of the protrusion and the wall surface defining the recess is provided with a guide surface capable of guiding the protrusion into the recess. The outer surface of the protrusion and the wall surface of the recess are respectively provided as a first abutting part and a second abutting part that abut against each other when the recess accommodates the protrusion. The mutual contact between the first abutting part and the second abutting part is defined such that, with a gap formed between the first surface and the second surface, the end of the protrusion is inserted into the recess to achieve positioning in the insertion direction, and to enable alignment of the top plate relative to the core in at least one direction along the first surface and the second surface.

2. The coil component according to claim 1, wherein, When viewed in a cross section along the direction in which the positioning is achieved, the protrusion has an end portion smaller than the opening of the recess in dimensions measured along the first surface, the recess having an inwardly sloping surface that becomes smaller in dimensions measured along the second surface as it approaches the bottom from the opening, the inwardly sloping surface providing the guide surface.

3. The coil component according to claim 2, wherein, The protrusion's end portion provides the first abutment, and the recess's inwardly sloping surface provides the second abutment.

4. The coil component according to claim 2 or 3, wherein, When viewed in a cross section along the direction in which the positioning is achieved, the protrusion has an outwardly sloping surface that becomes larger in size along the first surface as it moves from the end portion toward the portion that contacts the lower main surface, i.e., the base, and the outwardly sloping surface provides the guiding surface.

5. The coil component according to claim 2, wherein, When viewed in a cross-section along the direction in which the positioning is achieved, the protrusion has an outwardly sloping surface that increases in size as it approaches the base from the end portion, as measured along the first surface; this outwardly sloping surface provides the guiding surface. The outwardly sloping surface of the protrusion provides the first abutment portion, and the edge portion of the opening of the recess provides the second abutment portion.

6. The coil component according to claim 2, wherein, When viewed in a cross section along the direction in which the positioning is achieved, the recess has a concave bottom surface, the protrusion abuts against the concave bottom surface only at its end, the end of the protrusion providing the first abutment portion, and the concave bottom surface providing the second abutment portion.

7. The coil component according to any one of claims 1 to 3, wherein, The protrusions and recesses are respectively distributed in a dotted pattern at multiple locations on the first and second surfaces.

8. The coil component according to claim 7, wherein, The protrusion has an outer peripheral surface that forms at least a portion of a cone, and the recess has a conical inner peripheral surface.

9. The coil component according to claim 8, wherein, The protrusion is truncated cone-shaped.

10. The coil component according to claim 7, wherein, The protrusion has a pyramidal outer peripheral surface, and the recess has a pyramidal inner peripheral surface.

11. The coil component according to claim 10, wherein, The protrusion is shaped like a frustum.

12. The coil component according to claim 7, wherein, The protrusions and the recesses each have multiple sets, existing in the region where the lower main surface faces the top face of the first flange and the region where the lower main surface faces the top face of the second flange.

13. The coil component according to claim 12, wherein, The multiple sets of protrusions and recesses are arranged symmetrically with respect to the central axis containing the core portion and orthogonal to the lower main surface.

14. The coil component according to claim 12, wherein, The multiple sets of protrusions and recesses are arranged symmetrically with respect to the surface that is orthogonal to the central axis of the core portion and passes through the midpoint of the core portion in the axial direction.

15. The coil component according to any one of claims 1 to 3, wherein, The protrusion and the recess extend in a straight line on the first surface and the second surface, respectively.

16. The coil component according to any one of claims 1 to 3, wherein, The protrusion and the recess are located at positions that do not reach the periphery of the first surface and the periphery of the second surface, respectively.

17. The coil component according to any one of claims 1 to 3, wherein, The coil component further includes a second protrusion disposed on at least one of the first surface and the second surface, wherein the second protrusion abuts against the first surface or the second surface when the gap is formed between the first surface and the second surface.

18. The coil component according to any one of claims 1 to 3, wherein, The first surface is the lower main surface, and the second surface is the top surface of at least one of the first flange portion and the second flange portion.

19. The coil component according to any one of claims 1 to 3, wherein, The connection portion of one end of the wire to the first terminal electrode and the connection portion of the other end of the wire to the second terminal electrode are located on the bottom surface side of the first flange and the second flange, respectively.

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